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Breakout Session # 1203 Bill Bellows, Associate Technical Fellow The Boeing Company Date: Monday, April 25 Time: 2:45-3 - PowerPoint PPT Presentation


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Thinking Beyond Interchangeable Parts - The Potential for Thinking Together and Leading Together in the 21st Century. Breakout Session # 1203 Bill Bellows, Associate Technical Fellow The Boeing Company Date: Monday, April 25 Time: 2:45-3:45 PM. Agenda. Aim Quality Thinking

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slide2

Thinking Beyond Interchangeable Parts - The Potential for Thinking Together and Leading Together in the 21st Century

Breakout Session # 1203

Bill Bellows, Associate Technical Fellow

The Boeing Company

Date: Monday, April 25

Time: 2:45-3:45 PM.

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide3
NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide4

Agenda

  • Aim
  • Quality Thinking
  • Interchangeable Parts
  • Better Thinking About Thinking
  • Better Value
  • Imagine the Possibilities…

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide5
Aim

Introduce the potential energy of integrating the management theories and thinking of

Dr. Genichi Taguchi

Dr. W. Edwards Deming

Dr. Edward de Bono

and many others...

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide6

Quality Thinking

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide7

W. E. Deming on Quality

“A product or a service possesses quality if it helps somebody and enjoys a good and sustainable market.”

* Source: The New Economics, W. Edwards Deming, 1993

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide8

Genichi Taguchi on Quality

“Quality is the minimum of loss

imparted to the Society by a product after its shipment to a customer.”

* Source: Introduction to Quality Engineering , G. Taguchi, 1983

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide9

Edward de Bono on Quality

“The quality of our thinking will determine the quality of our future.”

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide10

Philip Crosby on Quality

  • “Zero defects is another way of saying ‘do it right the first time’”
  • Quality is defined as conformance to requirements

* Source: Let’s Talk Quality, P. Crosby, 1989

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

the boeing company vision 2016
Core Competencies

detailed customer knowledge

large-scale systems integration

lean enterprise

Values

leadership

integrity

quality

customer satisfaction

people working together

a diverse and involved team

good corporate citizenship

enhancing shareholder value

The Boeing Company - Vision 2016

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide12

Expectations

Value

Expectation

Disappointment

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide13

Expectation Dynamics

Value

Delight

Expectation

Satisfaction

Disappointment

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide14

InThinking

InThinking is about a transformation of the ways people think into effective predetermined patterns and sequences of thinking. The organization of thinking itself and the awareness that there is a choice of alternative ways of thinking when creating better solutions, presents a significant and exciting departure from traditional approaches.

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide15

Interchangeable Parts

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide16

Interchangeable Parts ??

Space Shuttle Main Engine

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide17

Interchangeable Parts ??

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide18

Quality Improvement

Background: On July 21, 1995, Toyota

was reported by the WSJ to have received catalysts from AlliedSignal Catalysts that were “100% defective-free”.

Question: Could AlliedSignal deliver catalysts that are even higher quality ?

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide19

Sorting Circles

Connect the 2 of these 3 circles that

are closest to being the same.

B

C

A

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide20

Sorting Circles, Part 2

Which 2 of these 3 circles are closest

to having the same diameter.

diameter

0

A

B

C

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide21

Cutting Wood

Given a piece of wood that will be cut into 2 pieces....

how many lines will be drawn across

the top face before the cut is made ?

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide22

Cutting Wood

target

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide23

Cutting Wood

target

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide24

Philip Crosby on Quality

  • “Zero defects is another way of saying ‘do it right the first time’”
  • Quality is defined as conformance to requirements

* Source: Let’s Talk Quality, P. Crosby, 1989

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide25

Decisions Decisions

Which 2 of these 3 circles are closest

to having the same diameter?

diameter

0

A

B

C

MIN

MAX

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide26

Quality Improvement

Background: On July 21, 1995, Toyota

was reported by the WSJ to have received catalysts from AlliedSignal Catalysts that were “100% defective-free”.

Question: Could AlliedSignal deliver catalysts that are even higher quality?

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide27

Taguchi’s Quality Loss Function

“Loss to

Society”

Lower

Specification

Limit

Upper

Specification

Limit

TARGET

(desired

value of

parameter)

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

a better view
A Better View

“The Taguchi Loss Function is a better view of the world.”

W. Edwards Deming

Source: Out of the Crisis, W. Edwards Deming, 1986

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide29

Interchangeable Parts ??

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide30

Better Thinking About Thinking

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide31

Investment Opportunities

Thinking

Technology

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide32

“The significant problems we face cannot be solved at the same level of thinking we were at when we created them.”Albert Einstein

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

profit beyond measure
Profit Beyond Measure

This book is dedicated

to the memory of

Dr. W. Edwards Deming

1900-1993

May the

Seventh Generation

after us know a

world shaped by

his thinking

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

perception thinking
Perception & Thinking

“How the world we perceive

works depends on how we think.

The world we perceive is a world we bring forth through our thinking.”

H. Thomas Johnson

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide35
NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide36

The First Step

Once the individual understands the system of profound knowledge, he will apply its principles in every kind of relationship with other people. He will have a basis for judgment of his own decisions and for transformation of the organizations that he belongs to.

W. Edwards Deming

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

Source: The New Economics, W. Edwards Deming, 1993

what s old
What’s Old?
  • Reducing Variation, Cost, Waste, Inventory, etc
  • Talk about “Working Together”
  • Striving for “Zero Defects” and “Zero Waste”
  • Continuous Improvement
  • Using Metrics for Alignment*

*without a thinking transformation

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

what s new
What’s New?
  • Resource & Relationship Management (Striving for Balance)
  • Thinking & Learning Together - Then Working Together
  • Continuous Investment
  • Using Thinking for Alignment
    • InThinking and Enterprise Thinking

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide39

Twin Day

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide40

Variety Day

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide41
NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide42

Counting Straws

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide43

Counting Heads

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

togetherness
Togetherness
  • What does it mean to “work together” ?
  • What does it mean to “learn together” ?
  • What does it mean to “think together” ?

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide45

The First Step

The first step. The first step is transformation of the individual. This transformation is discontinuous. It comes from understanding of the system of profound knowledge. The individual, transformed, will perceive new meaning to his life, to events, to numbers, to interactions between people.

W. Edwards Deming

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

Source: The New Economics, W. Edwards Deming, 1993

assumptions
Assumptions
  • A better way to operate an organization is to invest resources with the ability to manage customer delight, satisfaction, and disappointment
  • Better investment results from discovering opportunities to invest
  • The discovery of opportunities for investment is limited by how thinking is conditioned

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

what is needed
What is needed ?

Thinking that

promotes

better

discovery

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

transformation
Transformation

Potential Energy

“Better Thinking”

Kinetic Energy

“Better Value”

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide49

iscussion

iscussion

eming

eming

iscussion

roup

roup

eming

The New

The New

roup

Managing

Managing

Leading Systems

Leading Systems

DDG

DDG

Economics

Economics

Variation as a

Variation as a

DDG

(12 hrs)

(12 hrs)

(2nd Thursday,

(2nd Thursday,

(12 hrs)

(14 hrs)

System

System

(2nd Thursday,

6:30

6:30

-

-

8:30pm)

8:30pm)

(AKA the “Organization

(AKA the “Organization

6:30

-

8:30pm)

(9 hrs)

(9 hrs)

Workshop”)

Workshop”)

iscussion

iscussion

ngoing

ngoing

iscussion

ngoing

Enterprise Thinking

Enterprise Thinking

(9 hrs)

(9 hrs)

OD

OD

(AKA “Understanding Variation”)

(AKA “Understanding Variation”)

OD

(4th week,

(4th week,

Kepner

Kepner

-

-

Tregoe

Tregoe

(4th week,

Th

Th

/Fri, 12

/Fri, 12

-

-

2pm PT

2pm PT

(24 hrs)

(24 hrs)

Th

/Fri, 12

-

2pm PT

(Problem Solving and

(Problem Solving and

Decision Making)

Decision Making)

Six Thinking

Six Thinking

Understanding

Understanding

Hats

Hats

(8 hrs)

(8 hrs)

Taguchi Methods

Taguchi Methods

-

-

Part 1

Part 1

DATT

DATT

DATT

(16 hrs)

(16 hrs)

(16 hrs)

(40 hrs)

(40 hrs)

irect

irect

irect

echniques

echniques

pplied

pplied

pplied

hinking

hinking

hinking

Lateral Thinking

Lateral Thinking

Understanding Taguchi Methods

Understanding Taguchi Methods

-

-

Part 2

Part 2

(16 hrs)

(16 hrs)

(40 hrs)

(40 hrs)

A Thinking Roadmap

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide50

A Thinking Roadmap

TARGET AUDIENCES: Members of management, individual contributors, suppliers, and customers who are providing leadership in "enterprise thinking" activities. Family members, "members of the community" and students are welcome to attend. "Members of the community" are citizens who are involved full or part time, or in a volunteer capacity, in community related work. Examples include hospital employees, teachers, religious leaders, scouting leaders, and youth sports volunteers.

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide51

A Day With Genichi Taguchi

Since the early 1990’s,

Dr. Taguchi has made

regular visits to southern

California to both consult

and appear at conferences.

These visits often included

“One Day” seminars, which

Boeing engineers have participated in on a routine basis. This photo was taken at the last workshop he offered

in Los Angeles in 1999.

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide52

A Day With Edward de Bono

Regular meetings with Edward de Bono began in 1999.

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide53

A Day With Tom Johnson

Regular meetings with Tom Johnson began in 1999.

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide54

A Day With Russell Ackoff

In addition to regular meetings with Genichi Taguchi and Edward de Bono and Tom Johnson, we have hosted Russell Ackoff. In 2003, 2004, and 2005, he presented 1-day seminars in Canoga Park and Huntington Beach.

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide55

The In2:InThinking Network

The In2:InThinking Network was formed in 2001 by a group of students of the work of W. Edwards Deming and related theorists. The aim of our network is to make thinking about systems, variation, knowledge, and psychology, and their interaction – which comprises Deming's System of Profound Knowledge tm - more conscious. We believe that such thinking about thinking, which we call "inthinking," will allow people to better perceive relationships and interdependencies in human endeavors, and consequently act to make those endeavors more valuable, more satisfying, and more joyful.

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide56

Dr. Taguchi and the In2:IN

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide57
2005 In2:IN Forum: “Daring to Lead: Influencing Better Thinking For A Better Future”, April 7-10, 2005 in Los Angeles

The aim of the 2005 In2:IN Forum is to continue to elevate the consciousness of individual and collective thinking. We have asked "leading edge" thinkers to share with us their efforts to “Dare to Lead”. Join us in learning, connecting, and preparing to provide leadership with better thinking in the 21st century. Learn more about the forum at our website. The registration fee is $300 per person.

The In2:InThinking Network - www.in2in.org

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

transformation1
Transformation

Potential Energy

“Better Thinking”

Kinetic Energy

“Better Value”

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide59

Better Value

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide60

Better Value – Tube Fit in Hole

Consider a tube fit into a hole

Tube

Flames

Manifold

.2305 + .0005 Hole

Liquid hydrogen

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide61
Traditional Approach

Ream/ rework holes

Braze flow thru holes

Crack welds

Add grind operation

Add etch operation

Add better etch operation

Tube

Excess braze

Next assembly part

Better Value – Tube in Hole -

Next Assembly

Manifold

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide62

Better Value – Drilled Hole Data

MACHINING RESULTS FOR 1080 HOLES

FREQUENCY

500

TARGET

LOWER SPEC LIMIT

UPPER SPEC LIMIT

400

300

295

200

206

166

121

100

101

80

42

31

0

0.2300

0.2302

0.2304

0.2306

0.2308

0.2310

0.2312

0.2314

0.2316

0.2318

12

10

7

5

2

2

1

1

1

1

1

1

1

0.2301

0.2303

0.2305

0.2307

0.2309

0.2311

0.2313

0.2315

0.2317

0.2319

HOLE DIAMETER, INCHES

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide63
Traditional Approach

Ream/ rework holes

Braze flow thru holes

Crack welds

Add grind operation

Add etch operation

Add better etch operation

Better Approach

Improve hole drilling

To target

Better distribution

Successful first-cycle braze

No excess braze

Tube

Manifold

No excess braze

Next assembly part

Better Value – Tube in Hole -

Next Assembly

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide64

416

"AFTER #1"

Better Value – Drilled Hole Data

Post Taguchi Experiment

MACHINING RESULTS FOR 1080 HOLES - "BEFORE" & "AFTER"

FREQUENCY

500

TARGET

LOWER SPEC LIMIT

UPPER SPEC LIMIT

450

400

315

300

295

246

200

209

206

179

166

121

100

109

101

80

74

53

42

34

31

20

13

12

11

0

10

7

6

5

4

4

3

2

2

2

2

1

1

1

1

1

1

1

1

1

0.2300

0.2302

0.2304

0.2306

0.2308

0.2310

0.2312

0.2314

0.2316

0.2318

0.2301

0.2303

0.2305

0.2307

0.2309

0.2311

0.2313

0.2315

0.2317

0.2319

HOLE DIAMETER, INCHES

"BEFORE"

"AFTER #2"

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide65

Interchangeable Parts ??

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

visioning
Visioning

“it’s not what the vision is that is important...

it’s what the vision does...”

Peter Senge

Source: The Fifth Discipline, Peter Senge, 1992

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

slide67
NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

imagine the possibilities
Imagine the Possibilities...
  • when operating in an “Enterprise Thinking” environment
  • if we could develop a broader appreciation of “continuous and connected learning”
  • if we could develop a deeper appreciation of “working together”, “learning together” and “thinking together”

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”

imagine the possibilities1
Imagine the Possibilities...
  • and the markets we could create

Working Together

Investing Together

Designing Together

Building Together

Learning Together

Thinking Together

Leading Together

NCMA World Congress 2005

“Prime Time: Contract Management at the Core of the Enterprise”