“Good players do not always make good coaches.”

January 29, 2008 at 1:35 pm | In Business, Six Sigma, quality, training | Leave a Comment
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“Good players do not always make good coaches.”

We usually hear these words in conjunction with sports. When I hear the phrase, I always think of Ted Williams, who may have been the greatest hitter who ever played the game, but failed completely when he managed the Washington Senators/Texas Rangers. Or I might think of Michael Jordan, arguably the greatest player to ever lace up basketball shoes, but whose tenure as general manager of the Washington Wizards was less than successful.

But today I heard the message from a young Asian-American woman who was discussing on-the-job training. As part of our efforts to improve the infrastructure of our facility, we’re holding round-robin discussions with four groups of employees who have been on the job for less than six months. We want to know what went right in their training…and what went wrong.

So we’re holding four sessions (across our four shifts–clever, huh!?) with our new employees, and a couple of sessions with their trainers. We’re hoping to pull the best practices together.

The quote above came about halfway through the first session, when one young woman noted that even though her trainer had been with the company for over 20 years, she really was not successful in explaining the job, in mentoring her trainee. Just because she knew how to do the job well, that didn’t mean she knew how to demonstrate it well.

Among the other comments gleaned from this first session:

  • The trainer needs to level-set the training to the needs of the trainee. One young man had been with the company in earlier years, was returning to his old job, with the same supervisor, but was made to again undergo training for something in which he was already proficient, while another new employee was bombarded with  acronyms and terminology for which she was not ready.
  • One operator who has been with the company for over four months still isn’t sure what her job is…she knows how to push the buttons, but has no idea what the machine actually does, or where her process fits in the overall scheme of the manufacturing activity.
  • The folks in our meeting had been hoping for an opportunity to discuss their training experience. Had we not invited them to do so, they would have (corerctly) assumend we didn’t care.

So over the next several weeks we’ll continue these sessions — six in all.

I’ll keep you posted.

One up on the competition

January 26, 2008 at 1:34 pm | In Business, quality | Leave a Comment
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Yesterday, I attended my first “business improvement competition” at my new employer. I watched seven teams give twenty-minute presentations on projects that they had conducted over the past year to improve some part of the business at our facility. One team had completely overhauled the manufacturing documentation system. Another had almost completely eliminated a harmful chemical from use in the company. Yet another had re-engineered a product to reduce the leading cause of failure at our customer’s site.

In all, nearly 70 team members were involved in the presentations–nearly a tenth of the employees at the facility. The teams used innovative and imaginative means to get their message across: my favorite was the team that used the Wizard of Oz concept to describe their road to improvement.

The three teams that won our local competition will move on to Charleston, South Carolina, to take on their counterparts from our other North American sites. The winners there will head to Beijing for the corporate finals.

For years we in the quality world have talked about empowering our people to make improvements. What this company has done is to create a world-wide environment where the impetus for such activity involves the pride of creation, the pleasure of presentation, and the recognition not only of their peers, but also of  the whole company. This drives engaging and innovative projects that are good for the bottom line and support corporate growth. If that’s not the essence of quality, I don’t know what is.

Some folks are already  starting to look to next year’s competition!

The Mercy of Quality is not strained…

January 25, 2008 at 10:16 am | In Business | Leave a Comment
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Back in the dark ages (25 years ago), a quality guru named Philip Crosby wrote a book called “Quality Is Free.” At the time, the established wisdom held that you achieved quality through inspection, using the results of the inspection or test to look for ways to improve your product. Conventional wisdom held that there was such a thing as an “acceptable quality level (AQL)”, implying that it was okay to expect to ship a certain level of defective product. Crosby suggested that the goal should be perfection: the best defect is the one that never happens, that is prevented before it occurs. His book challenged the notion that it cost extra to have high quality; rather, he insisted, if we can identify and eliminate the causes of defective material, thereby avoiding rework and scrap costs, better quality in all aspects of the organization will provide savings rather than incurring costs.

This was a revolutionary concept, at a time when quality organizations were considered to be of no added value to the organization.

 Today, we look to our quality organizations to be the leaders in coordinating internal changes and improvements that can lower cost and improve product reliability. We use terms such as “Zero Defect” and “Six Sigma” as an everyday part of the quality journey, without  remembering the days when “quality” was a bad word in the board room.

It’s a big change. And it’s been fun to be part of it!

So today we start…

January 24, 2008 at 3:55 pm | In Business, Uncategorized | Leave a Comment
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Hello, world!

Today we start a new blogging adventure, in which I will discuss the business, art and science of quality management.

A bit about me:

  • I am the quality manager for a large semiconductor wafer fabrication facility in the Hudson Valley of New York.
  • I have been in quality management, continuous improvement, ISO 9000, and lean manufacturing for over 20 years, in a variety of companies and locations.
  • I am passionate about continuous improvement.

In the next weeks and months we shall look at a variety of quality tools and applications, as well as discussing some of the challenges of being a quality professional in the real world.

I hope you will come along!

Bill

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