The Pareto chart (not to be directly confused with the Pareto probability distribution function) is a simple approach to revealing significance in data. Before we plot our chart, we need to complete some initial work: Gather the data in a natural format (count, floating point [decimal], dollars, etc.) Sort the data from high to low […]

We have been on a bit a tear (or rant) about FMEAs. We suggest the FMEA documentation is part of the core of a design process. The ultimate approach we have seen is that of Michael Anleitner (The Power of Deduction: Failure Modes and Effects Analysis for Design, Quality Press, 2010), which uses functional analysis […]

There is only one way to describe this scenario and that is via a story.  Consider the organization that is coming to the end of the project.  The product is a complicated subassembly that goes into a larger system and has numerous interactions and incarnations of the design.  They are late in the delivery of […]

We submit that a Failure Mode and Effects Analysis (FMEA) review is a form of design review. After all, one of the purposes of a design review is to try and remove defects before they appear in the product and that is the entire rationale for the FMEA in the first place. Yet, most of […]

Brainstorming as neologism began with Alex Osborn of the advertising agency BBDO in 1942. His primary concern was creative thinking. In general, classical brainstorming generally follows this pattern: Gather a group of people Decide on a duration and quantity of ideas desired Solicit ideas from group members No editing, snide comments, or insults Collect ideas […]

The real kaizen is all about the 10,000 things. Maasaki Imai’s description of relentless, creeping quality improvement is apt. It also fits with the comprehensive philosophy of total quality management (TQM). We say “real” kaizen because we have so-called kaizen events that have nothing to do with inexorable cultural change and a whole to do […]

Project managers need to be able to assess product quickly with an intelligible set of quality metrics. In general, we recommend paired metrics; for example, in software development we can look at lines of code versus errors per line to keep both metrics “honest.” In the automotive world we like to see Cpk, which is […]

To reduce the chances of going too far down the wrong road, we qualify our projects with some sort of business analysis, for example internal rate of return or return on investment or some other fiduciary measurement.  If we are working from a staged-gate project management system, we will relentlessly review our project condition against […]