[Iefac.list] Second OSU-Emerson Workshop on Process Analysis and Improvement in the 21st Century

Thu May 13 11:35:11 EDT 2010

Second OSU-Emerson Workshop

on

 Process Analysis and Improvement in the 21st Century

Process Analysis Tools in the Lean/Six Sigma Toolkit: Back to the Past? 

Almost a century ago, IE's like Frederick Taylor (circa 1881), Harrington
Emerson (circa 1911), Frank and Lillian Gilbreth (circa 1917), Henry Gantt
(circa 1917) pioneered the science and graphical analysis tools for Methods
Analysis and Work Design.  Ironically, almost a hundred years later, despite
catchy names like Value Stream Mapping and Spaghetti Diagrams, we are still
using the same old manual pencil-and-paper tools for Lean/Six Sigma process
improvement projects.   A critical evaluation of the numerous Lean/Six Sigma
charting tools being used for Process Analysis and Improvement reveals
numerous flaws and limitations in their diagnostic capabilities, efficiency,
speed of execution and scalability, such as:

.         There is little, if any, integration of the inferences and
diagnostics that these charts pass to each other

.         The methods for collecting data to populate the charts are
cumbersome

.         The charts are inflexible and cannot "morph" their
format/structure to allow capture of a variety of data

.         Too many charts carry the same, often redundant, information

.         Manual charting is slow, labor-intensive, error-prone and, worst
of all, provides limited and superficial diagnostics

.         None of the charts can map and facilitate analysis of multiple
processes that utilize common resources

.         None of the charts can dynamically schedule and
synchronize/coordinate multiple processes that utilize common resources

.         None of the charts can  predict the impact of risk and uncertainty
on efficiency, cost and timely completion of the process (or multiple
processes)

.         Despite the existence of formal "thinking rules" for interpreting
these charts, their effective use remains an art form, and varies with the
user's expertise and experience 

Fundamental Goal of This Workshop

In an effort to improve and advance the methods and tools we use to analyze
and improve any work that we do, this workshop seeks to demonstrate the
numerous potential benefits of coupling state-of-the-art modeling and
analysis software for Process Analysis & Improvement with the creativity,
work experience and visualization-aided problem-solving skills of the human
mind.  

Benefits Of Attending This Workshop

.         Learn new ideas and methods for computer-aided process analysis
and improvement from the Smart ChartT project funded by the Defense
Logistics Agency

.         Participate in a team-based competition to critically analyze the
"Toast Kaizen" to see which team comes up with the most ideas for waste
elimination

.         Gain ideas from industry projects where process analysis and
improvement has been successfully applied in both manufacturing and service
environments 

.         Network with peers and fellow practitioners in this field

.         Explore opportunities for participating in current research
projects at OSU 

A Special Feature of This Workshop

This workshop will feature a plant tour that will be conducted by Curtiss
Keaton.  Curt is the Lean Manufacturing Champion at Emerson Network Power
(formerly Liebert Corporation).  Attendees will get to observe the results
of the "KITban" project that was done at the Columbus facility of Emerson
Network Power.  The tour will emphasize the things that worked well (as well
as the things that did not work well) and the associated lessons learned
from this implementation effort.

Presentation Topics and Featured Speakers

.         Team-based Competition: How Much Waste Can You Detect in the
"Toast Kaizen" Video? 

.         (Alwyn Aliwarga and Shahrukh Irani, The Ohio State University, and
Klaus-Juergen Schmitt, Hirschvogel Inc.) Learning To See and Seeing The
Whole using Value Stream Network Mapping

.         (Mark Romanchuk, PR Machine Works Inc.) Lessons Learned In-House
from Development of a Training Video on Waste Elimination

.         (Shahrukh Irani, The Ohio State University) PaFA (Patient Flow
Analysis) for Design of a Lean Hospital: Should we Re-Think The Basic Layout
of Any Hospital? 

.         (Brian Gregory, Healthcare Systems Engineering and Analysis, and
Deborah Gregory, University of New England) Fostering Teamwork between IT
and Healthcare Practitioners: Financial Benefits of Pursuing Process
Improvement using Constraint Theory, Lean and Behavioral Psychology

.         (Steve Sexton, Emerson Network Power) Increasing Rolled Thruput
Yield on Emerson's Large 610 UPS Assembly Line using Lean Six Sigma 

.         (Dan Gillon, Emerson Network Power) Work Measurement using TIMER
PRO Software 

.         (Curt Keaton, Emerson Network Power) KITban: Multi-Item Kanban for
Sheet Metal Fabrication 

.         Plant Tour

Would You Like To Receive An Electronic Copy of the Workshop Schedule?

To receive an electronic copy of the agenda, please email
<mailto:irani.4 at osu.edu> irani.4 at osu.edu or leave a voicemail at (614)
688-4685.     

 Date

June 15, 2010

Location

The workshop is being held on the premises of Emerson Network Power, 1050
Dearborn Drive, Columbus, OH 43229

Driving Directions to Emerson Network Power

1.      From Worthington Galena Road turn East on to Dearborn Drive.

2.      You will pass a few small buildings on the left, then you will see
the Liebert (now Emerson Network Power) plant on the left.

3.      You will see the executive entrance that sticks out in front of the
rest of the plant. Go on past this entrance then turn left into the next
driveway.

4.      As soon as you pull in off Dearborn Drive, you will see a large
awning on the front of the building. Turn right and drive toward the end of
the large awning.

5.      You will see an entrance with a sign reading "Security Entrance".
Directly in front of this security entrance there will be visitor parking.
Please check for designated parking spots that have been set aside for this
workshop and kindly do not park in employee spots.

6.      Come in to the security entrance and we will greet you there.

How To Register?

The Registration Fee for the workshop is $75 per person payable by check to
"Advanced Manufacturing Interest Group, The Ohio State University".  To
receive the Registration Form, please email  <mailto:irani.4 at osu.edu>
irani.4 at osu.edu.  After you have completed the form, please mail it with
your check to:

Dr. Shahrukh Irani

Department of Integrated Systems Engineering

The Ohio State University

210 Baker Systems Engineering

1971 Neil Avenue

Columbus, OH 43210

***** The Registration Fee has been waived for all speakers *****

Cancellation Policy

No cancellations will be entertained.

Event Logistics

Attendees are responsible for making their own travel and hotel
arrangements.  Breakfast, lunch and snacks/beverages during both morning and
afternoon sessions will be provided.

Pre-Workshop Preparation

None. 

Electronic Dissemination of Presentations

During or after the workshop, attendees are welcome to contact individual
speaker/s to obtain their presentations.

Do you have any questions about this Workshop?

Please email  <mailto:irani.4 at osu.edu> irani.4 at osu.edu or call him at (614)
688-4685.

Future Events

.         Computer-aided Speed-Ups for Kaizen Events (5S, Setup Reduction,
Cell Layout, etc.)

.         Streamlining Flow in Any Jobshop using the Lean Advisory Tools

.         Value Network Mapping

.         Integration of Lean and Theory Of Constraints.

.         JobshopLean2010 Conference

In Appreciation

This workshop would not have been possible without the tremendous support
and encouragement of the employees and management of Emerson Network Power,
Worthington, OH.  In particular, we wish to sincerely thank Curtiss Keaton
(Lean Manufacturing Champion) and Ed Potokar (Plant Manager).

Acknowledgements

This workshop is made possible by federal funding for the project Smart
ChartT: Intelligent Process Improvement Tools for Forges (BAA01-008, ATI
Subcontract No. 2008-624).  This project is part of the Forging Advanced
Systems and Technologies (FAST) Program which is sponsored by the Defense
Supply Center (DSCC) Philadelphia, PA, and the Defense Logistics Agency
(DLA), Ft. Belvoir, VA, and cost shared by industry.  The Ohio State
University acknowledges and appreciates the support from the Forging Defense
Manufacturing Consortium and Advanced Technology Institute.

Ohio State Serving The State of Ohio

This workshop supports the mission of the Ohio Manufacturing Institute (
<http://www.omi.osu.edu> www.omi.osu.edu).

======================================

Shahrukh A. Irani

Associate Professor

Department of Integrated Systems Engineering

The Ohio State University

294 Baker Systems Engineering

1971 Neil Avenue

Columbus, OH 43210

Phone: (614) 688-4685 Fax: (614) 292-7852

URL: http://ise.osu.edu/biosketch_SIrani.cfm 

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