WP_Post Object ( [ID] => 136 [post_author] => 5 [post_date] => 2013-04-15 19:56:29 [post_date_gmt] => 2013-04-15 19:56:29 [post_content] => Every day, we are faced with choices: a choice to do nothing; a choice to take the easy way out; or a choice to bear down and do the right thing. Our choices are influenced by many things including the people around us; the society in which we live and work, and our community. The pressures of everyday life influence our attitude toward quality; the workplace, careers, money. Maybe we rush through things here and rush through them there; maybe we cut corners, cheat a little and say to ourselves, "That's not perfect, but it's good enough." But, at the end of the day, who suffers? What do we lose when the culture of "good enough" is what drives our daily lives? Today, throughout most of our society we must all acknowledge that we are living in a culture where “good enough” is at the core of our troubles. We have taken the low road to what we know is right. We have lost the moral high ground to what is expedient, easy, and makes us a fast buck. But, if I ask you to really consider what it will take to make us great again I’m sure you’ll agree with me that the notion of “good enough” really isn’t good enough! [pullquote]When we all rally around the fact that quality is and must become everyone’s business, will we truly understand and appreciate the fact that “good” can never be “good enough!”[/pullquote] As I was building my core philosophy for “quality is everyone’s business,” I discovered that the greatest challenge was getting individuals, groups, and organizations (and eventually society as a whole) to recognize that hanging onto the status quo creates enormous waste, but more important, is not sustainable. The culture of “good enough” has become such a fixture in our mindset that we don’t even recognize the deep problems that it causes. This status quo pervades our lexicon and more importantly causes us to believe that nothing else can be done; meanwhile the waste and wasted opportunities pile up around our feet. I believe that if we all take the approach and make Quality a part of everything we do then we, as individuals and collectively as a society, will never believe that “good is good enough.” I have seen places where Quality, as I have described it, produces long lasting positive, effects. These are organizations where everyone is exposed to the Quality mindset. These organizations have done the hard work of taking everyone down the path of acculturation together to understand how the quality mindset requires a “real” change in the way individuals think and behave. And I believe that the individual is changed as well - their life is lifted, their outlook is lengthened, and their whole attitude toward personal responsibility is enlarged. What I have found is that when the Culture of Quality takes over, people observe and understand - they really listen. People not only listen to their customers, but to co-workers, associates, family, friends, and even neighbors. High achieving people explore and discover by looking for ways to do everything that they can to find the best solution; not the easiest solution, but the best solution possible. For these people, Quality means improving and perfecting everything that they do, every day. At the end of the day, when people rally around the fact that quality is and must become everyone’s business, will we truly understand and appreciate the fact that “good” can never be “good enough!” [post_title] => Is your quality suffering under the culture of “Good Enough”? [post_excerpt] => [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => quality-culture-of-good-enough [to_ping] => [pinged] => [post_modified] => 2013-04-20 19:01:17 [post_modified_gmt] => 2013-04-20 19:01:17 [post_content_filtered] => [post_parent] => 0 [guid] => http://subirchowdhury.com/?p=136 [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw )
WP_Post Object ( [ID] => 1239 [post_author] => 5 [post_date] => 2013-06-01 06:47:36 [post_date_gmt] => 2013-06-01 06:47:36 [post_content] => I recently read a commentary in the New York Times (“Solar Industry Anxious Over Defective Panels”; May 25, 2013, link), and something sounded familiar. Solar panels that are expected to have a 25-year life span are failing. Coatings are disintegrating and other defects have caused fires. Worldwide, the reports are coming in. The $77 billion solar photovoltaic industry is facing a quality crisis. This is a moment of truth for the solar photovoltaic industry, and yet, many manufacturers will chose to ignore the opportunity and instead repeat the same mistakes that the American automotive industry did in the 1970s. Remember the Ford Pinto that could explode if was hit from behind? What about Chevrolet's Vega that was rusting before it left the factory floor? There were other spectacular flops like the Cadillac Cimarron, Plymouth Volare, Dodge Aspen, all Oldsmobiles, and GM diesel engines: all self-inflicted wounds that damaged once sterling brands for decades and drove sales into the laps of their international competitors. Then, as now, assumptions are percolating among solar “PV” industry leaders about the “cause” of production problems they obviously do not understand. Is it really just cost-cutting in manufacturing materials that is causing 5.5% to 22% defect rate in solar modules? I was struck by the comment from Dissigno CEO, Dave Williams: "Quality across the board is harder to put your finger on now as materials in modules are changing every day and manufacturers are reluctant to share that information.” This is the type of thinking that will cost the industry (and their customers) billions of dollars before they resolve this crisis. In fact, isn’t it time to set a firm finger on quality and hold it there until there until something positive happens? American auto manufacturers learned three valuable lessons from their quality crisis:
The solar industry must do as the auto industry has done: they must go all the way back to the design stage, dump their assumptions, check all processes, and re-examine everything right down to the basics of how they envision how their customers will use their products. They must deal with the physics involved, even the markets. Late in the 1980s, the auto industry adopted the practice of "robust engineering" - using extreme conditions of operations the basis of design and engineering. Adding to the quality process, they also considered how people work together and how they discuss and formulate solutions. For the first time, designers, engineers, production managers and marketers got together and discussed not only what the product had to do, but how it might fail. When you design for the two most extreme operating conditions that your product will experience, you eliminate 95% of the potential cause for failure. If your product must operate in a particular temperature range, you must ask, "Can we add 10 degrees either way to our operating design?" In the same respect, consider also how the product will be manufactured and sold. In this case, designers did not take into consideration possible price competition. Haven't we learned that cost-cutting is a reality for commerce and therefore qualifies as a "condition of operation"? This crisis of quality is not, as the writers of the story suggests, China's problem. While true that Chinese manufacturing has supplied many panels, it is up to the world industry to set the standard. The companies that purchase the modules must set the quality process, be honest about the product design, and resist any compromise. I appreciate Suntech CTO, Stuart Wenham's commentary that "we need to start naming names." In my book, those names should include the engineering directors and executives who missed the big cues and forgot the important lessons of what it means to adopt and maintain a robust and sustainable quality process. [post_title] => A Moment of Truth for the Solar Panel Industry [post_excerpt] => [post_status] => publish [comment_status] => open [ping_status] => open [post_password] => [post_name] => moment-truth-solar-panel-industry [to_ping] => [pinged] => [post_modified] => 2013-09-01 07:00:17 [post_modified_gmt] => 2013-09-01 07:00:17 [post_content_filtered] => [post_parent] => 0 [guid] => http://subirchowdhury.com/?p=1239 [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw )
- “Problem solvers” will solve nothing but they will drill through wads of cash with very little to show for it;
- Nearly all product quality failures begin at the design stage with inadequate specifications, standards, expectations; and
- No amount of correction at the production and service end will ever adequately “solve” anything; that’s like trying to put out the fire after the barn burns down.
WP_Post Object ( [ID] => 169 [post_author] => 5 [post_date] => 2013-02-19 21:00:30 [post_date_gmt] => 2013-02-19 21:00:30 [post_content] => No matter where they occur, a fire can be a devastating event. When they happen around where we live, we rush to the location with manpower and equipment to extinguish the flames. When I use the word “fire,” I’m thinking of the context of day-to-day management when there is a sudden problem that causes a specific crisis of some kind. It could be a malfunction in production, a faulty product, and an interruption in the supply chain. You could have a fire with personnel issues, a problem with your building, or transportation. Like real fires, the flash point may be obvious or hidden; there could be single cause or a chain of them. Most of the fires we deal with tend to be minor in scope – easily extinguished and quickly resolved. On occasion, you can have a very large and extremely complex fire that involves many aspects of your business. But just like any fire, bad assumptions can easily lead to a misdiagnosis and mistreatment. When I think of the average, run-of-the-mill fire, I think of one that starts with a terse phone call or sharp email. In the case of Paul A., the vice president of production at a sheet aluminum plant, it was both. The email came from one of his best clients who – for the third time in as many months – complained that the palleted rolls of sheet aluminum were not labeled properly. Forklift operators in the receiving department, the email complained, were taking too long to find shipping labels. He had heard a similar complaint from other clients. His reaction had been to spend $50,000 on new, larger labels that you could read almost 20 feet away. [pullquote]It seems to me that eventually, we may become weary of rushing to the scene of the problem and instead learn how to instill the high level awareness to prevent fires in the first place.[/pullquote] “I can read the labels 20 feet away,” emailed Paul. “And my eyes aren’t even very good. I think the forklift operators just like to complain.” Then the phone call came – from his best client: “Fix the problem, or we’ll go somewhere else.” That’s the moment that Paul realized that he had a real fire on his hands. Paul’s company produces very large rolls of the metal, some measuring six feet in diameter by 48 inches wide, stacked and trucked away on pallets. Each roll weighs a considerable amount and is chained to a flatbed trailer, usually without other products on board. From his vantage point, the shipping labels were huge. He could easily see them from his office window. Out of desperation, he called me for some quick advice. My first response – which is my usual reaction to problems like these – collect all the information you can from the frontline people. And if you collect enough honest and direct information, the solution will present itself. So, Paul issued a message through the chain of operations, and soon a frontline employee was dispatched to talk to the forklift operators herself. After a very short interview, she discovered that no one had trouble reading the old labels or the new ones. Their complaint was that the way the rolls were placed onto the pallets and into the trucks, the forklift operators had to dismount from their vehicles and climb up on the truck to find the label. The labels, the operators told her, were always turned 90 degrees away from where they could easily see them. The simple solution: change the labeling process so that the labels could be seen from the forklift operator’s point of view. Sometimes, a fire is prolonged by an attitude that we hold about our own processes – as it was in Paul’s case. In such cases, it could be a simple matter of opening our mind to new information. But wouldn’t it be great if we could put those fires out BEFORE they become a problem? The one problem with fires is that often management’s focus is on the firefighters, while pretty ignoring the fire preventers. It seems to me that eventually, we may become weary of rushing to the scene of the problem and instead learn how to instill the high level awareness to prevent fires in the first place. [post_title] => Combating Fires [post_excerpt] => [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => combating-fires [to_ping] => [pinged] => [post_modified] => 2013-04-15 10:11:39 [post_modified_gmt] => 2013-04-15 10:11:39 [post_content_filtered] => [post_parent] => 0 [guid] => http://subirchowdhury.com/?p=169 [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw )
WP_Post Object ( [ID] => 1243 [post_author] => 5 [post_date] => 2013-08-15 07:07:42 [post_date_gmt] => 2013-08-15 07:07:42 [post_content] => Not all waste is created equal. Some of it is extremely valuable; especially when it teaches us something about the way we run our business. The owner of an insurance brokerage in Los Angeles, CA – we will call him “Cooper” – relayed this story to us recently. Cooper was working late one night on a presentation for a new client. The printer in his office malfunctioned, so he routed a document he needed to the printer that the staffers shared. As he waited by the printer, he looked down at the trashcan and was startled by what he saw: heaping but neat stacks of printed email, dumped straight into the round file. At the time, his office had about 35 employees, so he imagined that it was an isolated incident. But he knew that he should take a closer look. The next morning, he asked his administrative manager about the trash and what he heard surprised him even more. Two years earlier, he had set what he thought was a mundane office policy to require a paper record of all emails relating to client business. Email was still a relatively new business tool. Cooper didn’t know that people tended to communicate with each other via the “Reply To” function. As a result, many emails grew into long strings of messages that included every comment made with the important details sprinkled all over. Outlook and other email managers help search for the important bits, but when you print, you get the whole enchilada including every joke, recipe, sports prediction, birthday greeting, salutation, and thanks. Because of the policy, agents were forwarding customer emails to staffers. At the close of every day, the staffers printed everything, kept what they needed and tossed out the rest. Cooper measured the stack of paper and found that it was almost even with a fresh package of paper, or about 500 sheets. The real shock came when the manager revealed that this stack was light. Not only did the process occur daily, many times the amount of waste was double, even triple what Cooper had seen. Cooper and the manager estimated that the cost of wasted paper from printing emails was running up a $300 a month bill; $7,200 since the email policy was passed. When they added toner and staff time, the total cost soared to more than $14,000. Talking with agents and staffers, he learned that everyone thought that the policy was wasteful and inefficient. And yet, no one took the initiative to anything about it. Not long after this incident, a non-paper solution was adopted and Cooper was pleased that he could reduce cost and increase efficiency from one small change. Then he realized that this one example was a symptom of other perhaps more costly problems and worried where they might be. About a year later, “The Ice Cream Maker,” was published. Cooper bought a copy and read it one afternoon. Inspired by the concept of using quality as the benchmark of behavior throughout his business, he bought a copy for everyone in his office. To this day, new employees receive a copy as part of their training. Another underlying message in this story is the fact that many businesses pass office policy without attention to a quality process. Had Cooper focused on the outcome rather than the solution, he might have avoided this problem entirely. Luckily, the trash was the clue. In my experience, the cost of such mistakes can produce even greater expense. Something to think about the next time you’re in a position to set what you think is a mundane office policy. [post_title] => Valuable Trash [post_excerpt] => [post_status] => publish [comment_status] => open [ping_status] => open [post_password] => [post_name] => valuable-trash [to_ping] => [pinged] => [post_modified] => 2013-09-01 07:18:10 [post_modified_gmt] => 2013-09-01 07:18:10 [post_content_filtered] => [post_parent] => 0 [guid] => http://subirchowdhury.com/?p=1243 [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw )