All entries for March 2009

March 29, 2009

RDD comes to an end

It was a very emotional day for me. I had mixed feeling.

It could be possible that I may not see some of my classmates again. This made me really upset. We got along so well like a family. I am going to miss each and every classmate.

I was happy because I now get a months break from the 9 to 5 classes but I really hope I do not procastinate.

I will miss Paul too. He has helped me further develop not only my learning skills but also develop my personality.


In RDD I really liked the fault tree analysis. The use of "And" and "Or" gates is really interesting. I do feel that fault tree analysis can get quite complicated sometimes. I felt so while working on the presentation.  I do feel its not a full proof way of getting all your problems solved. I thought benchmarking is imporant as you can always learn from other peoples success and failures




Knowledge Management—High turnover rate

As well all know by now that knowledge management is linked to intellectual capital. Intellectual capital not only encompases the empolyees knowledge but also the customers and vendors knowledge. It also includes things in the organisation when the employees go home such as databases, manuals, software and customer file.

I always used to wonder that if employee turnover is high then thats a lot of experience and information walking out of the door. But KM  makes it possible for us not to worry about that. If your company is organised in a way where there is exchange of knowledge and information easily available and recorded it is so much more easier. Each time something goes wrong we can record it in the database and also record how we solved the problem. So this will help us not worry about high turnover rate. But this doesnt mean that you should be happy with high turnover rate. Work to reduce it. High turn over rate means loss of time and money. Time and money taken to hire and train some one new is very expensive!!


March 15, 2009

Cell Manufacturing

I found the concept of working in small batches very interesting. I f one makes different types of products too, it important to alternate between the two products than just making product A in the morning and product B in the evening. This is called product levelling. It also involves producing goods at a fixed speed. There is standardization then. Its not the one day you produce more and the other day you produce less. By working in small batches one can detect defects more easily and reduce the lead time and changeover time. The WIP inventory is reduced.


Time Management

Well in our presentation we ran out of time and could not complete it. Well most of our team members were quite dissapointed, as this was the last presentation we would have and we all had worked very very hard on it. In the assesment we got from  team 1 was that we had good content in it. I tried to evaluate where we had gone wrong. Why did we not finish. May be because we spent too much time explaining definitions.

I have definately learnt how to be more careful and manage time more effectively by prioritizing whats more important. I think I came out a winner from this presentation and not a loser. I have learnt so much during the course of this presentation. We all discussed what we were talking about in the presentation, gave our inputs to each other. The team worked very efficiently. The portfolio was a good way to reflect on the ideas in the presentation.

It was very nice for a lot of class mates to say that they felt bad that we could not complete the presentation. This shows cooperation and unity and not competition. I think all groups did a really good job and as Paul said in class, that we all have come a long way from presentations we gave in CBE about 4 months back i think.


Lean and Six Sigma

I just turned in the pma a couple of hours back. It sure has been very interesting. It was interesting to see how lean and six sigma can be used together. Both have similar goals of minimizing defects, and are quite similar in many other ways.  One of the only difference I found was the lean also emphasises on compressing the process to reduce the lead time, which probably six sigma doesnt really work on. Both also use stastistical tools to solve problems and have a cylewhich helps them solve problem. What I found interesting was the use of hoshin kanri in lean. PDCA cycle is a huge part of lean culture which is a part of hoshin kanri too. Honshin kanri can be used in a lean company. The Catch ball method is a good way of brainstorming. Six sigma too talks a lot about brainstroming and having cross functional teams which would help improve the quality of brainstorming. It is very important to have a facilitator in a six sigma team who is a black belt, who will encourage comunication between members and try and create an environment of trust. There are so many other ways how these are similar. Its interesting to see so many companies such as Xerox, Ford adopting lean six sigma.


Health and Safety

During the presentation Billy talked about having the right uniform and job safety accessories such as helmet, gloves and so on. If such things are provided then people are bound to be safer. In India many a times I see that people dod not have the right accessories and get hurt. It is very essential to provide the workers with the right accessories. I know this is a very small blog but I hat to emphasise on the imporatnace of people having the right accessories and every life is important!!

I also wanted to talk about that keeping things such as toilets, kitchens, work place clean would help motivate the workers come to work apart from keeping a disease free environment..... One should try to abide by standards provided according to me. ....


Maintenance

In maintenance while researching, I thought having a maintenance technical library was a really good idea. You can store all your previous problems and solutions in it. So next time if something similar happens you have something to refer to. It will save so much time and cost of trying out something new. I thought benchmarking maintenace to the previous years maintenance cost is a really good idea too. Hopefully the trend should be downwards after applying different sort of maintenance like preventive, predictive or TPM.According to me preventive is based on Murphy's law which states that if anything can go wrong it will. Therefore take all the precaution. See that all the bolts in the machine are tight, the environment is clean, everything is in place

One of the groups talked about lean. I think its a good idea to stop te line wen you see a defect. Instead of of having a lot of rework which will increase cost, one can save a lot of money. This will definately help me to imporve the quality for the place I will work. Interesting idea.


March 13, 2009

Security and Facility Management

I think its important to have a facility which encourages communication. Having cubicles for workers would reduce interaction but eliminating the those walls would help a great deal. People working together would create a bond with more interaction. This will make the flow of  exachange of ideas and information easier. Having a social room could help. Some work places do have a social room life a cafeteria or a television room or a gym. Having a gym would promote a healthy lifestyle too among the workers

Having CCTV is important as one it would create a safer enviornment. Though personally I do not like the idea of having CCTV as I dont like to be watched all the time. The feeling of some one may be monitoring you is weird. Its like living in the Big Brother House. Also I would feel the company does not trust me. But for the greater good its important to have cctv to avoid any sort of theft. For information safety there should be some sort of software which prevents hackers from using your trade secrets and also  have password proteced documents so only the intended people can see the document.


Presentation

Today there were presentations in class. Everyone did a really good job. We all have come a long way. There was something new and unique in every presentation that took place. I really liked the idea of Lean IN ASSET MANAGEMENT. I think lean production would really help in maintenance, health and safety and facility management.. It said that it is important to stop production as and when the defect is found. It is one of the things lean teaches. This will save a lot of money in rework. In terms of health and safety, if your product is a boat it is important it is not defective as life of people are involved, so its important to stop the production as and when defect is found. In terms of resouse utilsation, JIT would ensure that there is no over producation and no additional place is needed to store things.

I also liked May's idea that innovation is necessary in exsiting products as well. I mean innovation keeps interest of the customers in existing products and also can increase the life cycle of the product.

In terms of knowledge management, I think its important to store ones mistakes and solution in the database and one can learn from their mistakes and its easily solution is easily availble if the same mistake is made again.



March 09, 2009

Craft Production and Six Sigma and Lean

Apart from mass production and lean production discussed in Louis's blog I came across this production method. Its is a higly flexible production method. It is basically a few skilled people working on a product and custom make it for the customer (For example make the car more decorative). It can be quite expensive and the out put less compared to lean and mass production. My professor in my previous school told me that mass production started in US. It was practised by General Motors. Lean started in Japan and is practised by Toyota. Craft Production originates from Europe. I really like the idea of Craft prodction. In India I do see some traces of Craft Prodution. Its practised by this person D. Chabaria. He customizes a car for the customer. He is highly successful in following craft production. I think  six sigma can be applied to craft production also. Some processes in craft production too might be standarised. In those processes six sigma can be applied. Six six sigma can be applied to mass production too. The DMAIC circle can be applied too. But I think its most effective with Lean.


March 2009

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