Article list
Increase productivity with Human Interface Mate (HIM)
HIM is an innovative system that transforms workstations into a digital and interactive environment. It reduces the qualitative and productivity variations in the manual processes by guiding the operator, thus being a poka-yoke system, ie a process in which mistakes due to the human factor can be prevented.Transforming workstations into a digital environment is done by:
Operator guidance with augmented reality instructions
Validation of operations by built-in smart sensors
Integrating...
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FlexSim - software for analysis and 3D modeling of processes and systems
FlexSim is software that helps you turn your existing factory data into accurate predictions for your organization in order to analyze a current or future scenario.The 3D simulations created with FlexSim help you mimic the look of the real system, so it is easier to understand and evaluate based on data happening in current processes or designed for optimization.This allows you to identify potential bottlenecks in the process or system and the optimal location options to eliminate them.FlexSim...Read this article...
Who is responsible for PFMEA?
Responsibilities within the organizationWhen an organization decides to use the PFMEA methodology one of the first questions that arise is about responsibility for the process… and usually after this time the organization gets stuck in a long series of negotiations in the management team, usually between the engineering and quality departments.The ambiguity arises from a poor understanding of what this responsibility means or because of the behavior of that organization in terms of (non)...Read this article...
IATF - remote audits during COVID-19
The spread of the COVID-19 pandemic affected all branches of industry, with automotive production being one of the hardest hit.In addition to the existing problems in 2019 with the availability of labor and the decrease of orders, there was also a less known and discussed issue, the conduct of audits in pandemic conditions.Due to the pandemic, many organizations were forced to discontinue their activities for a shorter or longer period, which in many cases led to the expiry of the IATF...Read this article...
Setting the objectives; SMART
Companies that want to achieve performance need to develop an organizational culture based on goals. And of course these related to performance evaluation for both top and middle management and for individual employees.Starting from the CEO's vision and strategy, the long-term objectives of the company are defined and they are later broken down at the level of the organization's structures and finally at the individual level.The power of goals lies in how they create both an action plan for the...Read this article...
Prioritization; Make the most of opportunities
During the improvement process, after defining the problem, collecting the data and analyzing them, decisions must be made regarding the choice of optimal solutions to be implemented.After finding the root causes, the project team can generate several improvement ideas, only a few of which need to be selected based on an objective assessment.Prioritization is a decision-making, rational process that is achieved through criteria. Most of the times, when the team members find the best criteria,...Read this article...
How much do we plan and how much do we leave (planned) "at random" ?
n our "Production Planning" courses, when we get to the capacity calculation of production capacity and especially how much we choose to fill capacity, many participants have the same frustration: WE KNOW (it is 100% sure) that we will have variations in customer orders , that there are problems with machines and equipment (it does not work at 100% capacity), that we do not have enough operators sufficiently prepared, but we insist on planning at theoretical capacity (maximum). "We know" and...Read this article...
Sampling
Data must be collected to perform analyzes, studies, graphs, or to demonstrate improvements after a project.
Collecting (measuring) a lot of data can sometimes be very expensive, it would require a lot of time and resources. For this reason, we are working with sampling.The sample is a significantly smaller extract of the population used to make a deduction and relate back to the population. Usually the most common deductions are average and standard...
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DOE - What it is, and purpose
The study of processes is essential for their improvement. We can observe events as they occur without influencing them. If we are lucky, an interesting event for our process can take place during the observations.If not, then we need to proactively manipulate the input variables so that their effect on the output variables can be studied.DOE (Design Of Experiment) is a scientific method by which, in a systematic and planned way, experiments are performed that allow the evaluation of the effect...Read this article...
COPQ: Non-Quality and Six Sigma Costs
As it is known, Six Sigma is a problem-solving methodology, which improves the quality of products and, consequently, increases customer satisfaction.COPQ means the costs of Poor Quality.Knowledge of COPQ allows an organization to determine the extent to which its resources are wasted.Having such information allows an organization to determine the potential savings that can be achieved by implementing process improvements.There are four categories of quality costs to consider in the COPQ. These...Read this article...
Choosing Six Sigma Projects: A Challenge
Six Sigma projects generally addresses to more complex problems, for which no solutions are known.Initially, when creating the methodology, the vast majority of projects started from VOC (Voice of Customer) and lately, especially in times of crisis, such as the one in 2009, the VOB (Voice of Business) approach was also observed - in fact a reduction in costs.Many projects are chosen from KPI (Key Process Indicators) to be improved.These could be: defect rate, preparation time, equipment...Read this article...
The purpose and advantages of an ANDON system
In Lean production, an ANDON refers to a tool that is used to inform and alert workers about problems in their production process.The term Andon comes from a Japanese word for the traditional paper lantern. An Andon is one of the most common forms of visual management that is used in Lean. It is an extremely effective tool, as it allows the operation to work without problems, without blockages. An ANDON is a system that helps the flow of information on the status of the production...
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Poka-Yoke concept and benefits
Poka Yoke is a commonly used method in Lean Manufacturing to ensure as few errors in a production process as possible. A "poka" is an "unintentional error" and "yokeru" is Japanese for "prevention", so Poka Yoke is a mechanism that prevents a mistake or makes the mistake obvious at first glance.Poka Yoke is used to prevent and resolve defects during the production process, eliminating the need for quality control after the process.Poka Yoke makes it practically very difficult or impossible to...Read this article...
Preventive maintenance. Important elements for its success
Preventive maintenance (PM) sums up the activities that are regularly performed on an equipment to reduce the likelihood of failure during operation. Basically we want the equipment to work perfectly until the next planned shutdown.Implementing preventive maintenance involves a few steps, namely:
1. Choice of equipment maintenance system
2. Preparation of spare parts lists
3. Supply of spare parts
4. Training of maintenance personnel for the performance of preventive maintenance...
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How do we balance workstations ?
Balancing workstations in a production line is used to improve technological flow by reducing worthless activities. The balancing of the line consists in distributing the work as evenly as possible between the stations.The reference time for balancing production operations is the tact time calculated based on the customer's order and available capacity.This type of project is carried out in two stages: evaluating the current situation and preparing & implementing the future situation.For...Read this article...
What is VSM / Value Flow Chart and what is it for?
Material and Information Flow Diagrams were originally developed by Taiichi Ohno and Toyota's Operations Management Consulting Division to help suppliers learn the Toyota Production System.Later, in 1999, Mike Rother and John Shook adapted the Toyota techniques and turned them into what we know as "Value Stream Mapping". Value Stream Map is a visual representation of the process flow and information.
VSM is used to locate where improvement is needed in a stream. Whether it is for...
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MUDA (Waste - identification and categories)
The activities are divided into two categories: activities with value (VA) and activities without value (NVA).Dumb / waste is defined as any activity that consumes resources without creating value for the customer.
Besides MUDA, there are also MURA and MURI, but both lead to MUDA.
The first means unevenness / imbalance between operations, in processes. MURI, refers to the overloading of equipment or operators.
Non-value added (NVA) activities can be divided into eight...
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5S - Performance indicator for the Production area
Organizations use multi-level KPIs or performance indicators to assess success in meeting targets.High-level KPIs can focus on overall business performance, while basic-level KPIs can focus on processes in departments such as sales, marketing, human resources, production, maintenance, and more.
In addition to the classic indicators for the Production area such as Efficiency, Productivity or OEE, we must also have 5S.
5S is composed of the following...
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Hypothesis Testing: Continuous Output vs. Attributive Input
Sometimes, in practice, we want to make sure we make the best decisions. For example, we want to choose for deliveries in the city, the fastest option between scooter and van.We will use hypothesis testing, a method of proving beyond any logical doubt that a statement is true or not.A number of statistical tools are used for data analysis, the application of which depends on the type of input and output data.We issue the null hypothesis (H0): The delivery time is the same for both means of...Read this article...
The link between FMEA & Control Plan
Common mistakes that impede performanceAre we conscientious users of the FMEA and the Control Plan and still have problems? Then we should be careful that:1. The FMEA should be aligned with the Control Plan process steps.The process steps must correspond to those defined in the Flowchart. Each line in the FMEA must have a corresponding line in the Control Plan, more precisely for each risk identified in the FMEA we must have a control for prevention or at least detection in the Control Plan.2....Read this article...
Graphical Analysis: Pareto and time chart
Graphic analysis is "the method of analysis that performs the graph by taking data from data tables." We learn from interpreting data about the nature of the process and where the sources of variation come from.The Pareto Chart, also called the 80/20 rule, which specifies an unequal relationship between effort and effect, helps us to prioritize actions. It was named after the Italian economist Vilfredo Pareto, who observed that 80% of Venice's wealth was owned by only 20% of the population....
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Why should we use Kanban ?
Kanban is a way of discovering problems related to processes and workflows, which allows them to be solved and the efficient delivery of products to the customer.These objectives are achieved by introducing constraints in the system to optimize value flows. The flow is the center of attention.The advantages would be: o Provides transportation information. o Provides production information. o Prevents overproduction and excessive transport. o Serves as a work order attached to the product. o...Read this article...
Why do we need a Quality Department?
One point of view: Why do we need a Quality Department?(or Why Production Can't Without Quality)
In society, fire prevention is generally considered to be everyone's responsibility - and yet it cannot be done without professional firefighters.
Similarly in an organization, no matter how Lean it is and everyone's dedication to maintaining quality, we will have problems reported by customers. Some of the immediate questions are:
To whom does the client address the complaint?
Who reacts...
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Speed, Quality, Cost - Meaning and use
The Speed-Quality-Cost Triangle is also known as the “Management Triangle” of the project (also called the triple constraint) which is a model of constraints in project management.What is essential is to balance all three, so that performance is targeted for each. There is no point in improving speed by increasing costs or reducing quality.
It is also known as the "Application Triangle" or "Quality Triangle" and shows the inherent trade-offs of any project.
In the normal...
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Point of view: Collaboration of the Production department with the support services (logistic perspective)
I suggest you do an imagination exercise: try to imagine a client, the most difficult client you have. Add to this customer the image of "very important" even if it is not, the image of "I need and I do not care how you do" even if it generates costs higher than the value it produces, a customer who has some indicators measurable defined for his activity and to achieve those indicators does not care about others around him. Any attempt to communicate to improve relations and, consequently, of...Read this article...
SigmaXL - among the most popular programs for statistical processing
Have you tried working with SigmaXL? If not, it's time to give it a try. It is a software that comes as an ‘Add-in tool’ to the well-known Microsoft Excel. So if you master Excel well then it means that you will get used to using SigmaXL very easily.Sigma XL comes with complete sets of graphical and statistical tools used in Six Sigma projects.As graphic tools I can mention: SPC Control Charts, Pareto Charts, EZ Pivot / Pivot Charts, Histograms, Dotplots, Boxplots, Normal...Read this article...
Hypothesis testing: Basic principles
During the problem-solving process, especially in Six Sigma projects, we are put in a position to statistically prove relationships between various process outputs and parameters that are suspected to influence them. The causal relationship is based in statistics on what is called hypothesis testing.For example: we want to improve the hardness of a metal part and the potential factor is the cooling rate.
Hypothesis testing is a formal procedure for investigating and proving the causal...
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Why use SMED ?
The SMED concept appeared in the late 1950s and early 1960s. It was developed by Shigeo Shingo together with Mazda, Mitsubishi, Toyota. The need to implement a fast and efficient method of change came after the analysis of the process of injection / pressing of automotive components. Through the implementation of SMED, the production concept has changed, offering them flexibility and reduced production costs.Single Minute Exchange of Die or in short S.M.E.D. : is one of the many methods of...
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Professional statistical programs: MINITAB
Minitab is a powerful data analysis and graphing software used worldwide.Minitab helps companies monitor process trends, easily apply automotive / aero (SPC, MSA) requirements and solve even the most complex problems.
Main uses:
Graphic analysis (Histogram, Boxplot, Dotplot, Bar Chart, Time Series Plot, Pareto Chart, Graphical Summary etc),
Testing normality and identifying the type of distribution
Statistical Process Control: Stability (I-MR control charts, Xbar-R, P chart, etc.) and...
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A3 problem solving
The A3 process is a problem-solving tool. Toyota has developed this system to encourage learning, collaboration and personal growth of employees. The term “A3” is derived from the special size of paper used to outline ideas, plans and objectives throughout the A3 process.Steps to achieve A3 improvement:
Identify the problem or need.
Understand the current situation / state.
Develop the initial state - Develop the future state.
Perform root cause analysis.
Brainstorm /...
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8D Problem Solving? Procedure ?
It often happens that in the production process we have problems of quality, flow, cycle time, organization, supply, etc. In the literature have been developed several tools that define methodologies for solving more or less complex problems depending on their difficulty. Obviously, the ‘price paid’ for the application of these methodologies varies depending on the instrument chosen.Analyzing these problem-solving methodologies, we drew attention to the 8D method that helps solve...
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Do we really need the MSA procedure?
Today's production companies collect a large amount of data, through measurements and inspections, on the basis of which decisions will be made with an impact on processes and business in general.Inspections performed either automatically (more and more often) or by specialized personnel, can also generate erroneous decisions, with effects in artificially increasing defects or sending non-compliant products to customers. In both situations we lose money and even customers.
To prevent these...
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What should an SPC procedure contain?
Knowing that all production processes have some variation, about 100 years ago Walter Shewart discovered a way to distinguish between common causes and special causes of variation in a process. Shewart also understood the danger of "firefighting" actions to react and act depending on where individual values are located in relation to the tolerances of a process.This discovery of Walter Shewart, together with the methods developed later, is today called statistical analysis of a process...
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Efficiency of Warehouse Activities
Do we have enough resources? Correct answer: I don't know!Efficiency means the extent to which the effort or resources consumed generate value for a process.
How efficient are the activities defined in your warehouses? For the efficient measure in the logistic activities we must first of all have defined the processes and the activities in the warehouses - do we have them?
Are the responsible persons qualified for those activities? Are times defined for each activity (norms) and can...
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Dynamic Array – FILTER
To extract information from a table according to one or more criteria we can use Advanced Filter. It's a pretty good solution but it has a big problem: it doesn't update. Then we have to intervene with a macro, possibly a "filter" button.The Dynamic Array solution is much simpler and much more "dynamic": FILTER.Article dedicated only to Office 365 users.Here is the file used for example: http://bit.ly/384Lv59The problem is to extract information from a table into a form.In the Extras...Read this article...
Office process automation
These days, more than ever, we wanted some of the activities carried out even at home to be automated. Working from home is not easy, and the need for some of our office activities to be automated has become more acute.Even if we work from home, we still have a series of repetitive or time-consuming jobs (reading emails, extracting data from emails, responding to emails, obtaining approvals, preparing reports). Statistics say that a third of work time is spent on repetitive and time-consuming...
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Production Planning – Loss and Profit!
Product planning is the brain of a production unit, the product represents a strong resistance (bone and muscle) and logistics for circulatory care, if needed, food and cleaning the "body". It is very important to plan the production and the first information for a greater correction in time or time, then information on this matter is first planner, the finished product being a correct product planning.Proper product planning means predictable and high accuracy estimates over the medium and...Read this article...
Optimizing Warehouse Space Use - How to Get More Resources?
Both in Production and outside the production area one of the most expensive resources is space. When we enter the Logistics area and we talk about warehouses and warehouse service spaces (access roads, loading / unloading ramps, parking and waiting areas) the space seems more and more important and more expensive. If in the production areas we have dedicated departments and functions that deal with spaces (layout in production, spagetti diagram, VSM) to optimize the movements and obtain a...Read this article...
Production Planning - The Supreme Purpose !
In any production organization as well as those in the sphere of services, there are products that are made easier or harder or some with high loss rates (scrap and remedies). In general, it is considered that if we leave Production Planning (PP) to Production, we will only plan products that are easy to make with a small scrap, with a generally high productivity, but to the detriment of those for whom we have demand. On the other hand, PP switched to Logistics can decrease productivity but...Read this article...
Dynamic Array - Unique Sort
We start from the last article on XLOOKUP (https://bit.ly/39dN8yq) and try to solve the problem of extracting unique data and sorting them using the new dynamic array functions. Bonus, an optimization of data validation. This article is for Office 365 users only.Here is the file used for example:http://bit.ly/2UZAEGTProblem 1. Extract unique data. For example, the product list.We want to make a data extraction form (XLOOKUP) where we find out the quantity delivered for a particular product.In...Read this article...
Process Optimization Workshop
On March 12, our company organizes a workshop in Arad at the Continental Forum hotel with the theme "Process Optimization", where we will have as guests: InterMarium Company from Poland, Centro Software from Italy and company Arkite NV from Belgium. This workshop is intended for CEO's, Plant Manager, Operational Manager, Manager Engineering as well as other people who are responsible for improving processes in the factory.InterMarium company from Poland is an IT company that will present a...Read this article...
Dynamic Array – XLOOKUP
What we wanted in the last article (https://bit.ly/2sQCWvL), was done in mid-January: Microsoft has activated the Dynamic Array for all Office 365 users, not just for "Insiders". In the following articles we will describe these new functions. For today, XLOOKUP.As usual, we start from a problem and try to identify the elements to solve.Problem: Data table and extracting information in various situations.Access to the work file:Problem 1. We have a data form, where when choosing the product code...Read this article...
Analysis of Measurement Systems with Q-DAS or MINITAB ?
Measurement systems analysis (MSA) is meant to show us whether the data we use to analyze processes are reliable or not. MSA is a first step that should precede any decision, including the use of Statistical Process Control (stability and capability).There are several software used for statistical data processing. Often used today are MINITAB, Q-DAS but also Excel.Regardless of which software is used to achieve the MSA, all must comply with the standard required by the client, as the case may...Read this article...
Microsoft Power BI
For some time, the area of Business Intelligence has gone from predominantly IT to what we call self-service business intelligence. We need to process and analyze data much more often than we did before, on all levels, not just in the management area. We need to automate our processes and access information faster, in real time. Let's see how Microsoft Power BI can help us.From the beginning we must admit that the old BI solutions were the result of the collaboration between analysts and...Read this article...
Box Plot Chart
A Box Plot is a type of graph used to show quantitative data patterns. It provides information regarding the central tendency and the shape of the studied distribution.The elements of the Box Plot diagram are:Vmin - The minimum value named and is the smallest value observed in the string of values, excluding outliers;Q1 - The lower quartile delimits the lowest 25% of the observed values;Med - The median delimits 50% of the values (it is exactly halfway between the minimum and maximum...
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Teamwork
Teamwork is the collaborative effort of a group to achieve a common goal or to complete a task in the most efficient way.The team receives the goals, understands them and commits to achieving them. Team motivation is strengthened when the organization has clear expectations regarding its work, goals, responsibility and results.From the point of view of team building, they can be homogeneous or heterogeneous. By homogeneity, the team will be much faster aligned with the objectives and the way of...Read this article...
Materials Management Operations Guidelines/Logistics Evaluation V5
Initially defined to establish the requirements of the quality standard in the Automotive Industry for Logistics, MMOG / LE, or the Instructions for Materials Operations Management / Logistics Evaluation, it has become one of the most important tools for standardizing operations in the Automotive industry. The instrument has a multiple role:• Defining a common language throughout the automotive industry regarding otherwise differently perceived notions (eg stock level, recovery plan,...Read this article...
Risk Management
Risk management means identifying, evaluating and prioritizing risks (defined in ISO 31000 as an effect of uncertainty on objectives), followed by a coordinated and economical application of resources to minimize, monitor and control the probability / impact of unfortunate events or to maximize opportunities .The risk management standards have been developed by various institutions, including the Project Management Institute, the National Institute of Standards and Technology, and the ISO...Read this article...
VDA 6.3: 2016 - why do our customers "stress" us?
Life in a provider organization for the automotive industry is very ... alive. You just don't get bored. One of the special moments is when the customer announces that he is following a process audit according to VDA6.3, whether we are talking about a potential analysis or a process evaluation in series production.What and how do you continue? What is this and what does this VDA6.3 help us with?According to VDA6.3, process audit is a method of impartial analysis and evaluation of product...Read this article...
PPAP - Production part approval process
The Production Part Approval Process (PPAP) is designed to demonstrate that a supplier has developed its design and production process to meet customer requirements, minimizing the risk of failure through the efficient use of APQP. Therefore, the request for approval of the new product must be accepted in official PPAP format and with documented results.The latest PPAP edition, published by AIAG, has been completely restructured to describe the requirements regarding the approval of new or...Read this article...
