As a follow up to our 9-part “Ready for Change” article series, our next step down the “Lean” path is to introduce other tools and methods to reduce waste and time. The first in this new bi-monthly series focuses on SMED, Single Minute Exchange of Die, and how this...

For many years, I have been beating the drum that board footage (BF) is an imperfect unit measurement that our industry should abandon. The better alternative is the proven method of time estimations which uses man-minutes (MM). Man-minutes are derived from time-in-motion practices that have...

I read a book recently that discussed the term “benchmark” and its origins as relates to business. Surprisingly, the term originates within the history of guns and ammunition. In fact, with the same aim we use it today—comparison and improved performance. The book talked...

As a follow up to our last article, How the DMAIC Process Helps Sustain Achievements and Drive Continuous Improvements, below is another example and case study based on the need to reduce design cycle time. After setting the parameters, I will outline the DMAIC Lean method and demonstrate how...

As an industry, there are many times I believe we have been behind the curve in adopting/taking on new technology or hardware in our operations. Over the past 15 years or so, we have seen incredible growth in the use of automation, software, etc., but other industries have far exceeded the...

Most people have a mistaken belief that my services are all about making component manufacturing more efficient. Actually, more than half my time during a consultation is taken up reviewing things like management practices and the sales process. Fact is, sales—correction, healthy...

As companies grow and change, we should ask ourselves—what are the essential pillars of support that help companies succeed? While making changes that will transform their businesses, successful companies will rely on core pillars that form the foundation of who they will be in the future....

Most think lack of time is their biggest barrier to achieving their goals, but they are mistaken. “Culture eats strategy for breakfast.” This quote by Peter Drucker is one of my favorites. While providing consulting services for over one hundred companies, I have witnessed and...

As the next and final step in the DMAIC process, the Control phase is perhaps the most critical! You have identified and Defined the scope of a challenge. Collected data and statistically Measured the baseline of the current process and/or output. Analyzed the current procedures and...

We’ve all seen the predictions: Component manufacturing is going to grow ever bigger as labor remains tight and big builders get more efficient. And with component manufacturing gross margins being higher than what you get for selling commodities, it’s a good time to ask:...