tory about defects being found.
One critical element is never leapfrog a supplier. For example: if you
found the defect in shipping, and
you know it was caused in engineering, resist the temptation to just go to
the engineers. Just return it to your
supplier, let them return it to their
supplier, eventually it will make it back
to the source and create a ton of awareness along the way.
Sound crazy? Imagine you buy a
bike at Walmart, the tire is defective,
what do you do? Return it to Walmart!
It doesn’t even cross your mind to find
the company that did the assembly,
made the tire or supplied the rubber.
You don’t even consider that, so maintain that same mentality in the factory
too. It works wonders.
To kick this off what we did was positioned everyone in a circle in the order
of their work stations. We created fake
work orders and starting simulating
the release of orders to the factory.
It took no time at all for our typical problems to surface, and because
we were all there seeing it unfold we
could just yell “STOP,” then we would
all identify the problem and develop a
countermeasure. Then we would collect the work orders and start again.
With each iteration, we uncovered
the little tedious things that were
Once we were confident we had a
working system, we started to create
problems on purpose to stress test it.
Once again, when the wheels fell off
the wagon, we brainstormed a solution,
implemented and ran the simulation
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