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5S
This paper explains how a 5S program can improve a work environment to improve visibility, which in turn improves productivity, safety, cycle time, and quality. The paper provides a detailed description of each of five steps, the benefits of a 5S program, and how to implement a 5S program. The paper also provides an example for a crash cart in a clinic. The appendix presents a scorecard for a 5S audit.
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A3 Problem Solving
This paper reviews the standard Toyota Production System/lean methodology for creating a very short (2 page) project charter and project status reporting document. The paper describes the benefits of this important lean tool and provides examples and references.
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ABC Classification Analysis
A paper that presents a mathematical model for ABC classification analysis.
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Aggregate Production Planning Problem
This short paper develops the classical mathematical programming formulation for the aggregate production planning problem and then critiques the model.
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An Overview of Mapping Tools for Process Improvement
This paper overviews and compares a wide variety of mapping tools that can be used to understand and improve a process. The mapping tools included in this paper include relational mapping tools (mindmaps, work breakdown structures, and organizational charts), time mapping tools (process maps, value stream maps, and project networks), and causal mapping tools. These include causal maps, Ishikawa (Fishbone, Cause & Effect) diagrams, strategy maps, impact wheels, root cause trees, issue trees, and goal trees. Closely related papers include “Mind Mapping,” “Causal Mapping,” “Strategy Mapping,” “Process Mapping,” and “Value Stream Mapping.” These papers provide more detail on each of these mapping tools.
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An Overview of the Minto Pyramid Principle
This paper overviews the Minto Pyramid Principle, which is a structured approach to building a persuasive argument and presentation developed by Barbara Minto, a former McKinsey consultant (Minto 1987). The Minto Pyramid Principle has become the de facto standard for all major consulting firms worldwide. Minto’s approach can improve almost any presentation and almost any form of persuasive speech.
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Audit Sampling
A paper that presents a hypergeometric probability distribution approach for audit sampling. The paper presents the methodology for setting up a stop and go sampling plan for an audit based on the hypergeometric distribution. This distribution is the most precise approach for auditing and results in the lowest recommended sample size. The companion Excel workbook “audit sampling.xls” implements the sampling model developed in this paper
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Benchmarking, Best Practices, and Leading Practices
A paper that provides a complete framework for understanding benchmarking, best practices, and leading practices and also how organizations can apply these principles to improve processes.
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Brainstorming with the Nominal Group Technique
A paper that explains how to conduct a brainstorming session with the nominal group technique. The recommended steps include: prepare, kickoff, generate, share, group, regroup, title, arrange, vote, and assign. The paper also provides presents the benefits of NGT over other less formal brainstorming methods.
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Causal Mapping
This paper provides detailed information on how to create and use a causal map. The paper compares a traditional Ishikawa (Fishbone, Cause & Effect) diagram with the more general causal map and argues that the more general causal map is easier to use and more flexible. The paper presents a number of best practices for causal mapping that go far beyond the teaching normally provided with the Fishbone Diagram.
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Commonality
A paper that presents a practical argument for increasing commonality and also a mathematical model for evaluating the benefits of increasing commonality.
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Dollar Unit Sampling
A paper that presents a complete methodology for Dollar Unit Sampling (DUS). DUS is a powerful and useful method for sampling when you have a population with some importance measure such as the recorded amount available. Compared to random sampling, DUS provides greater representation of the larger recorded amounts in the sample and creates a more precise (tighter) confidence interval for the same sample size. It is also easier to use than other types of sampling methodologies such as stratified random sampling. DUS has become the standard approach for statistical auditing. This is a companion paper for the Excel workbook “dus.xls.”
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Drum-Buffer-Rope
This paper presents Goldratt’s drum-buffer-rope concepts. This is one of the main concepts of the Theory of Constraints.
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Economic Lot Scheduling Problem
A paper that presents a model for the economic lot scheduling problem. This is the problem of determining the lotsizes for a machine that is running at high utilization and where the setup times and costs are significant.
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Empirical Probability Distributions with Theoretical Tails
This paper presents approaches for generating values from both continuous and discrete empirical probability distributions. This paper contends that adding a theoretical “tail” to an empirical distribution allows simulations to experience values beyond the historical tail values – and allows these simulations to explore important real-world “catastrophic” issues more carefully.
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Error Proofing
This paper provides a framework and examples for understanding and applying both prevention and detection methods to improve both product and process design. The paper includes a number of examples and photos.
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Estimating Carrying Cost
This paper provides a detailed explanation for how to estimate the carrying charge and carrying cost parameters for lotsizing purposes.
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Estimating Confidence Intervals and Required Sample Sizes
A paper that provides a practical step-by-step explanation of how to estimate confidence intervals and the required sample sizes to achieve a user-specified confidence interval in a wide variety of situations.
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Estimating Ordering and Setup Costs
This paper provides a detailed explanation for how to estimate order cost and setup cost for lotsizing purposes.
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Forecast Error Economics
This paper develops a series of simple economic models for estimating the cost of a poor forecasting system. The paper considers the cost of the carrying inventory due to higher than needed safety stock and/or forecast bias and also the lost gross margin from customers due to inadequate safety stock. Through a series of models and discussions, the paper proposes a methodology for auditing and improving a forecasting system. The audit list in the last section should be a good tool for any firm desiring to audit its forecasting system. This paper is closely related to the paper entitled “Forecast Error Metrics.”
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