World Class Mgt behaviours..

welcome to complexity made simple my name is paul allen and before we get into today's video well i'm just going to remind you the three books that are on sale drink tea and read the paper if you're a green belt in a black belt and you want simple instruction on how to apply your skill design of experiments for 21st century engineers and finally a statistical process control for small batch production they are all available from lulu.com and the links are in the video below welcome to complexity made simple my name is paul allen i'm the subject of today's video newsletter well we're going to answer a question that's been sent in by a viewer so frank w i said last week i would i would answer your question if whenever you watch any of my videos if there's a subject that i haven't covered or the more detailed question you would like to ask i am more than happy to answer those questions so please leave your comments in the area below or subscribe to see all the videos uh in the channel now frank's question is quite long if you wish to see the whole text you can see it on a comments page it's on a video called observed versus inferential statistics part two so if you want to take a look at the whole question please do but what i've done in order to help us out today i've paraphrased the questions there were three elements to it and here are the three elements let's take a look so here we go here's the three questions that frank has posed to me um so he he talks in his in his comments about senior managers and engineers not being on the same page so when an engineer is trying to fix a problem a senior manager is trying to cut cost and of course you can't fix the problem without extra cost and engineers just fight with senior management so they're not they're not being consistent so could we use some statistics in some way to help us to get senior managers and engineers on the same page how do we stop uh operators fiddling with process parameters and taking the process away from proper settings and could there be some automated way to compensate for noise in a process a little bit like noise cancelling software which works brilliantly by the way so three very good questions so i'm going to answer these questions one at the time so frank i'm going to do my best on this so here we go let's try and answer them one at a time so question one first of all we want to get engineers and senior management kind of working together not pulling in in opposite directions here so okay is there a way to do that now for me frank the answer here lies in design for six sigma so really the reason why engineers and senior managers pull in different directions is because they don't really understand what the customer wants and what the customer values and they haven't agreed what the customer wants and what the customer values because if they'd agreed that then they would understand that what they're doing has to be done so the thing in design for six sigma that helps to pull everything together is a prioritized voice of the customer and and this is the key thing the fact that it's prioritized not just a list of things that the customer wants so it needs to be prioritized and obviously one of the things that will be in that list undoubtedly will be the cost of the product so you know there'll be a list of is it safe is it reliable uh is it very strong can i drop it on the floor and it survive that type of thing does it cost me 30 quid or less so there'll be there'll be lots of things cost will be one of those things but if you've got a prioritized list then you understand how to make a proper decision otherwise you just fight one another and that's really what happens the engineer wants to solve the technical problem the manager wants to keep the cost down wants to make more money so if you've got a prioritized list and let's say um the strength of something so you know the um the customer has decided that the the product needs to be needs to be robust and therefore strength of a plastic molding is very important and that's because robustness to the customer is very high on the list and if it's higher than cost yes if they're saying well the fact that the product can be dropped on the floor and it just bounces is more important than what i pay for it and if you look at things i mean look at an iphone for instance we pay a thousand pound for an iphone it's just a bloody phone for christ's sake and yet we're prepared to pay the extra money why because he does other things that are worth a thousand pounds so we're prepared to pay so if you say the strength the robustness is important then when an engineer says well i need to make the the moldings i need to make the moldings thicker therefore of course i'm going to use more material and i'm going to add cost in order to do that well if that requirement is above cost in the prioritized list no decision to be made anybody can make the decision don't even need a senior manager to make that decision um and that's what's needed because customers don't buy it's rare that customers buy anything based on cost you know petrol we buy on cost we'll buy flour on cost you know things that are uh standard products we will buy on cost but if you think about a car i could easily knock a thousand pound off the price of a car it would be dead easy i could take all four doors off and people said well that's ridiculous no it's not because if you go back a hundred years cars didn't have doors that that was something that initially they didn't want they just wanted the fact that it was a motorized carriage and they were perfectly happy with that but now the idea of saving money by taking doors off a car is ridiculous because we know the prioritized voice of the customer customer wouldn't buy it customer will pay 30 000 pound for chrissec for a car that in in 1900 they were paying 800 pounds for so times have changed enormously but part of it is there's an implicit understanding of the voice of the customer so that's the key thing you have to have a prioritized voice of the customer in the design process then all decisions can be easily made there is the answer to question one question two then what we got here how to stop the operator fiddling with process parameters now i think you also mentioned that if we've got engineers and senior managers on the right page and that they understand certain things on the machine is important in order to please the customer how do we make sure that the the operator doesn't go doesn't go fiddling with things okay so question two we want stop operator fiddling with parameters okay now there's a couple of things here uh there is a tool that you can use and you probably know which tool i'm going to mention but the first thing is this why don't you just define the operator's role and responsibility because this is one of the main ways to do this the first thing to say look what's the role and responsibility of management what's the role and responsibility of operators the role and responsibility of management is to set good rules whatever that means so that could be a cleaning routine it could be speeds feeds temperatures the way a machine is run maintenance routines we do these maintenance once a week once a month once a year purchasing uh purchasing policies we always buy from the best supplier we always buy from the cheapest supplier we always play suppliers off against one another whatever they happen to be the management their role is to set good rules all right and world-class companies would tell you what those good rules are then the role of the operator whoever they are by the way whether it's a purchasing somebody in the purchasing department somebody in the planning department somebody in the manufacturing department what is the operator's role and responsibility dead symbol follow the rules that's it this is what world-class companies do what world-class companies do is make great rules then they make sure everybody follows them end of story what we don't want is us to set no rules here and for the operator who we paid the cheapest salary to in the whole company for the operator to try and dig us out of the hole that's being created because the processes won't work properly why would you expect the cheapest paid least trained person to be able to save you money that's ridiculous they are just going to drive your process into the ground if you've set no rules but you set good rules and then the role and the responsibility is for the operator to follow them and by the way it's also for the management to follow them so if somebody says and comes to you and say what would you like me to do mr manager violate the rules or not get the job out on time you stick to the rules you always stick to the rules that's the end of it that's our senior manager's role and responsibility when i worked for sony one of the great things about working for saunee we had rules and the senior managers always stuck by the rules so that's job number one so that's you just set the policies and procedures set the roles and responsibilities properly but answer number two here so that's one answer number two is to give the operator some training and to train them in statistical process control because what statistical process control tells them to do of course it tells them when adjustment might be necessary because sometimes it is but without spc without understanding the difference between signal and noise in a process operators toast at this point what an operator will typically do they say without this tool an operator 90 of the time what do they do they will make your process worse because you cannot be bothered to give them a simple graph and a pencil and a piece of paper and teach them how to use it if you did that your operators could help you to run your processes better so the answer to number two how do you stop the operators fiddling get them on the same page as the engineers and the senior managers well clearly first of all if they've got prioritized voice the customer then the rules are made really well then you tell the operators that you got to follow it now all of this they all talk to one another that's the way this thing is supposed to work okay what's the last question could there be some automated way to compensate for noise in a process like noise cancelling software which is a fantastic idea um so question three noise cancelling some kind of automated noise cancelling system and what he's asking me is have i ever seen it do i know for a system and unfortunately frank i know that you work in the world of electronics i think where noise cancelling is possible i wish it was possible but it isn't and the reason it isn't is because in the world of electronics there's a couple of things going on with noise cancelling in an electronic system so you are listening to your mp3 player and you've got noise cancelling software on it the system knows that there is a line coming in that carries the noise and there is a line that carries the signal so in other words the signal in an mp3 play of course is the music that you are listening to and it knows what the signal is anything else that's that's coming into that coming into that system it knows whether it's noise and of course it can listen for noise externally to the to the mp3 player so you've got the music and then you've got the external sounds and therefore the system knows what the noise is so that's one big difference now in a manufacturing process when i make this when i make this piece and i'm looking at the size of the piece the dimension that i get is made up of both the signal and the noise and i have no way of knowing which bits which can't measure it therefore i can't cancel the bit of noise out okay so that's the first that's the first problem but there's another problem and it's the speed at which the information is available electronic systems are reacting like that especially with extra processing power and the speed of processors and things like that so the response to the noise is is almost instantaneous well it has to be instantaneous with noise cancelling because the sine wave is obviously the opposite of the noise signal that's coming in so it's an instantaneous response to a known wave of noise number one we don't know the noise in manufacturing and number two the response is not instantaneous because this is what happens i make this one maybe this one took i'd say took 30 seconds in the molding machine to manufacture it i then measure it and by the way i don't know which bit signal and which bits noise at this point but then there's another 30 seconds till this one comes out where do you put the where'd you cancel the noise from where's the point where i have to inject some kind of electronic correction so that this one is okay the the response time is always different the cycle time for making these might be different to the cycle time for making this plastic body etc so it's so complex to try and put noise canceling you wouldn't know where to put it the response is so slow so it's a very discreet because it's a very discreet result a very discreet result so where'd you put the where'd you put the signal to cancel out the noise uh but also there is no way there is no way of understanding how much of what i've got there is signal and how much is noise and therefore you can't just offset it with some simple sine wave because we can't measure the sine wave so unfortunately it's a great idea i wish uh i know we sometimes talk in some of my workshops about i wish we had a dial on a machine that could adjust the noise down but we don't noise cancellation in processes just comes from this typically noise cancellation in processes comes from setting good rules and adhering to them because you get this it's very straightforward you get your money making process yeah so we're gonna make some money here i've got inputs coming in i've got an output maybe two outputs maybe three outputs coming out i'm trying to please the customer at this site how do you noise cancel in a manufacturing system well it's very simple you just cancel the bloody incoming noise so that's what the set of good rules do so if you have a temperature you make sure that the temperature is fixed to a hundred if you have a speed you might make sure that the speed is fixed to 32 if you have a pressure the pressure might be 131 psi and what you do is you make sure those are fixed fixed fixed fixed never move never adjusted you stop the operator putting unnecessary noise if you've got material how do you get rid of the noise in the material well you make sure that you buy from good suppliers in other words you're not buying on price if you just buy on price and you let that material come in and it's very noisy you just get noise coming out the other end and you violate the tolerances and you produce lots of scrap and cost yourself lots of money so noise cancelling in a manufacturing process comes from these and then these people adhere to those rules noise goes away and you don't need anything complicated you just need good rules that's what the best companies do so there are your three questions frank i hope i i've answered them as well as i possibly can if there's anything else if there's something i missed out or misunderstood please drop me a line if anybody else wants to ask me some questions and say hey how do you do this have you seen this has your experience ever found a solution to this please send me a message please leave some comments in the area below it helps with the channel please subscribe don't forget that you can get a copy of my ebook drink tea and read the paper if you'd like to get more thoughts on lots of different things in process improvements six sigma etc and if you drop me a line i hope to hear from you soon but guys come on get your processes under control get the noise out of your processes and if you do that what will your process do it will just make more money thanks for your questions frank good luck [Music] you

Channel: Paul Allen

Views: 281

Keywords: Six Sigma, Lean, World Class manufacturing, mSA, DOE, SPC, FMEA, TPM, 5s, TPS, Pull, Kanban, p value, Standard Deviation, Mean, Median, t test, Hypothesis test, Kaizen, https://youtu.be/QH984PnwRDE, https://youtu.be/AGJ1QYI2B4c, https://youtu.be/f_fjqCpd67Q, https://youtu.be/gsD8V2_eZ0A

Id: JWoNWT8juu0

Length: 21min 17sec (1277 seconds)

Published: Tue Sep 28 2021