Industrial Engineer Engineering and Management Solutions at Work

October 2014    |    Volume: 46    |    Number: 10

The member magazine of the Institute of Industrial Engineers

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Focus

Keeping pace with IIE in the July 2011 issue of Industrial Engineer

Rich Calvaruso  Russ Pirasteh  Jason Daugherty  Tim Copes 

 

Expert knowledge

Engineering Lean and Six Sigma Conference keynoters ready to share

Lean and Six Sigma have been staples of IIE training events for at least a decade, whether as the Lean Management Solutions Conference started by John Fargher or the Operational Excellence Conference of the early 2000s. This fall IIE brings back these themes at the Engineering Lean and Six Sigma Conference 2011.

The keynote speakers at this year’s conference, which will be held Sept. 12-14 in Atlanta, bring a wide array of experience from some of the top manufacturing companies. And they have some very distinct ideas about why lean and Six Sigma methods are so pervasive in industry.

“No matter what you do or what you make, you’re going to have some problems,” said Richard Calvaruso, lean leader for GE Appliances in Louisville, Ky. “So lean and Six Sigma are both focused around helping you solve those problems — getting to the root causes, trying to make processes better.”

WEB EXCLUSIVE: Jet stream

Go to www.iienet.org/IEmagazine/jul11/ELSS-Boeing to read about how a Boeing team used Lean+ tools and value stream mapping to streamline engine tests and achieve fuel and time savings of nearly 50 percent.

Calvaruso plans to discuss the success of new model lines his team put into production in 2009 using lean techniques.

“The lines used significantly less space, significantly less inventory, lots of productivity, double-digit productivity since we put the line in each year. But the bigger part of what that line did is it opened eyes for people so they could actually see what the real opportunity was. [It showed people], ‘Wow, this lean stuff can really drive some big change,’” Calvaruso explained.

Russ Pirasteh, vice president of operations excellence for the Stephen Gould Corp., asserts that while lean and Six Sigma are wonderful approaches, often they are misapplied.

“When we find a new hammer, we think everything is a nail and we’ve got to use it. I think we have been using these techniques on everything and expecting them to do certain things, and if they didn’t perform, we tried to shove it. Just like … a round hole and a square peg,” said Pirasteh.

Pirasteh will share his iTLS® approach of integrating lean, Six Sigma and the theory of constraints (TOC) and explain how it achieves results. The concept is described extensively in the book, Profitability with No Boundaries: Optimizing Lean, TOC, and Six Sigma Results, which he wrote with Bob Fox.

“The goal of iTLS was to identify — now that we have recognized that these three are so important … in what formula do I use them in order for me not to waste the entire resources in the organization.”

Jason Daugherty will bring award-winning techniques from Deere & Company. He is the business unit team leader for Greeneville Factory Operations in Greeneville, Tenn., and his facility won the 2011 Shingo Prize for its lean transformation.

“At all levels of the organization, we work to have different functional teams, and we use that as part of our lean transformation,” Daugherty asserted. “So be it inventory levels, problem solving, continuous improvement, whatever it may be, that’s how we’ve improved. So it’s not one specific thing.”

At the conference, Daugherty plans to convey the importance of focusing on employees and Six Sigma implementation.

“It’s just a tool. Empowering your people to use those tools [is what is] really going to make the difference in anyone’s organization. It’s the training and focus on how to use the tools and then allowing them to do that,” he said.

As vice president of manufacturing and quality for Boeing Commercial Airplanes, Tim Copes is excited about showing how Boeing manages the pressures and complexities of its business by having a strong industrial engineering function and applying lean and Six Sigma to make a difference. Considering how more than 3 million people fly on Boeing airplanes every day, they have to rely on the best manufacturing methods.

“What we do out on the manufacturing floor is critically important and has to be right every time. We have the same competitive pressures that many other companies do, and we need to use tools like lean and Six Sigma to improve our production capabilities. Using these tools can greatly improve a company’s competitive advantage and needs to be a central part of the manufacturing function,” said Copes.

To find out more about the conference and the four keynote speakers, go to www.iienet.org/leansixsigma. To read full interviews with GE’s Richard Calvaruso and author Russ Pirasteh, go to www.iienet.org/leansixsigma/Calvaruso and www.iienet.org/leansixsigma/Pirasteh.

Power to the people?

Check the latest IM to se if employee empowerment is right for your organization

Popular media and the business press abound with stories about the success reaped by turning over decisions to employees. In the May/June issue of Industrial Management, Golnaz Sadri, a professor of organizational behavior, gives managerial tips for achieving that change.

More important, writes Sadri, is figuring out whether employee empowerment is right for all — or any — levels of your organization. Giovani J.C. da Silveira and Rui S. Sousa put their operations management and industrial engineering experience together to tackle three manufacturing strategy paradigms: strategic choice (fit), best practices and competing through manufacturing (capabilities).

Researcher Tarikere T. Niranjan and operations and supply chain management professor Shashank S. Rao use their research to devise a toolkit that businesses can use to make sure they are outsourcing not too much, not too little, but just enough.

Finally, Zachary M. Leffakis combines his experience in heavy equipment and automotive manufacturing with academic research to offer five pillars of wisdom to help you manage the supply chain.

The benefits of excellenceHonors and Awards Banquet at the 61st Annual IIE Conference and Expo 

Dozens earn scholarships, felowships, other honors at annual conference

Fellowships and scholarships come in handy, particularly in tough economic times. And competing on challenging projects against your top peers can be a rare opportunity. That’s where IIE helps year after year by providing such recognition and events at the IIE Annual Conference and Expo.

Listed below are this year’s scholarship and fellowship winners as well as competition winners. Other honors and awards were published in the June issue of Industrial Engineer.

To see a complete list of winners, go to www.iienet.org/2011honors.

Scholarships and fellowships

A.O. Putnam Memorial Scholarship
Andrea Henery, University of Nebraska
Benjamin Willard Niebel Scholarship
Allanah Miller, Rutgers University

C.B. Gambrell Undergraduate Scholarship
Stephanie Bagiardi, University of Florida

CIE Scholarship
Katherine Fisher, The Ohio State University

Dwight D. Gardner Scholarships
Haley Helweg, Texas A&M University; Andreanne Leduc, École Polytechnique de Montréal; and Christina Lee, The Ohio State University

E.J. Sierleja Memorial Fellowship
Hector Vergara, University of Arkansas

Gilbreth Memorial Fellowships
Chia-Jung Chang, Georgia Institute of Technology; and Foad Mahdavi Pajouh, Oklahoma State University

Harold and Inge Marcus Scholarships
Kelsey Barnes, Texas A&M University; Margaret Zero, University of Illinois at Chicago; and Xuanya Zhang, Worcester Polytechnic Institute

IIE Council of Fellows Scholarships
Thomas Davich, University of Wisconsin-Madison; and Christopher Maloney, University of Miami

John L. Imhoff Scholarship
Karin Rozendaal, University of Pittsburgh

Lisa Zaken Award for Excellence
Lindsay Stoll, University of Nebraska-Lincoln

Marvin Mundel Memorial Scholarship
Steven Denman, The Ohio State University

Presidents Scholarship
Abigail Carda, South Dakota School of Mines & Technology

Society for Health Systems Scholarship
Samantha Russell, Georgia Institute of Technology

UPS Scholarship for Female Students
Carol Smith Cayo, Milwaukee School of Engineering

UPS Scholarship for Minority Students
Aeron Glover, University of Tennessee

Innovations in Curriculum Competition
First place (tie): Dale Masel, Ohio University, “Curriculum in Industrial and Systems Engineering Using Professional Concentration Areas”
First place (tie): Scott Sink, The Ohio State University, “Integration of a ‘Best in Class’ Lean Sigma Certification ‘Option’ into the ISE Curriculum in the College of Engineering at Ohio State”

IIE/Rockwell Automation Student Simulation Competition
First place: Southern Polytechnic State University, “Hornets — The Simulators” — Thuy Nguyen, Alex Moody and Larry Jackson; advisor, Greg Wiles
Second place: Ben-Gurion University, “BGU Simulators” — Tzahi Israel and Hadas Gur-Arie; advisor, Sigal Berman
Third place: Lehigh University, “The Lehigh Engineers” — Preston Zorner, Yousef Janajri and Cristina Cannella; advisor, Robert Storer

IIE Undergraduate Student Technical Paper Competition
First place: Benjamin Tran (Western Region), California State Polytechnic University-Pomona, “Improving Warehouse Performance at Unical Aviation Inc.”
Second place: David Vandegrift (Southeast Region), Georgia Institute of Technology
Third place: Kaycee Wilson (South Central Region), University of Oklahoma

IIE-IAB YouTube Video Contest
First place: California Polytechnic State University, San Luis Obispo
Second place: Wichita State University
Third place: University of Tennessee, Knoxville

Lean Division Best Practice Award
First place (tie): Sreekanth Ramakrishnan, Waren Boldrin and Michael Testani, IBM
First place (tie): Sudhendu Rai and Cyndi Quan-Trotter, Xerox Corp.
Second place: Joseph Ogabi, Triumph Aerostructures

Outstanding Faculty Advisor Awards
Global Level Honoree: Christopher Geiger, University of Central Florida

Regional Level Honorees:

Central and South American Region: Anael Espinal, UNITEC
Mid-Atlantic Region: Joesph Wilck, University of Tennessee
South Central Region: Baski Balasundaram, Oklahoma State University
Southeast Region: Christopher Geiger, University of Central Florida

Society and Division Honors

CIS Division Student Paper Competition
Akkarapol Sangasoongsong, Oklahoma State University

Construction Division Student Paper Competition
William Croll, University of Southern California

Lean Division Student Paper Competition
Fabiola Garza, Universidad de Monterrey

Lean Division Teaching Award
John Shewchuk, Virginia Tech

Process Industries Division Student Paper Competition
Mengjie Liu, Worcester Polytechnic Institute

SEMS Student Paper Competition
Mengqi Hu, Arizona State University

Operational Research Division Teaching Award
Sheldon Jacobson, University of Illinois-Urbana

SHS Student Paper Competition
Graduate Level: Martine Dagenais, École Polytechnique de Montréal
Undergraduate Level: Vanda Ametlli, Wayne State University

Work measurement expert, innovator diesKjell Zandin developed a new concept of work measurement called MOST Systems in the late 1960s. 

Kjel Zandin changed industry with MOST Systems

Kjell Zandin, creator of the MOST work measurement system, died May 3 in his native country of Sweden.

Zandin was an owner and director of H.B. Maynard and Co., which is now a part of Accenture, for 20 years, and he had more than 35 years of industrial engineering consulting experience. In addition to his work developing MOST, he was the editor of the fifth edition of Maynard’s Industrial Engineering Handbook, published in 2001, which his longtime Maynard colleague and friend Denis Meinert considers Zandin’s crowning career achievement.

“He has had a true impact on the world and those 35,000- plus MOST users and the millions who have been impacted by the use of MOST,” said Meinert.

Zandin became an IIE fellow in 2001 and was the first recipient of IIE’s Technical Innovation in Industrial Engineering Award in 1986. Zandin received the Royal Charter Award of the Institution of Production Engineers in Great Britain.

“[Zandin] dramatically transformed the IE profession and made a significant contribution to it with the development of MOST, a predetermined motion-time system,” said Bopaya Bidanda, Ernest Roth Professor and chairman of the Department of Industrial Engineering at the University of Pittsburgh.

Bidanda, who collaborated with Zandin on research projects, added that Zandin was always glad to mentor students and faculty. “He routinely presented guest lectures at the University of Pittsburgh and was always available to provide guidance and counsel to student projects.”

Meinert added, “Kjell was a persistent, smart, kind, gentle and meticulous giant of a person who cared very deeply for his family. He was a great friend.”

A winning Cinco de Mayo

Industrial Engineer magazine’s five awards include three golds

It was appropriate that the Magazine Association of the Southeast held its annual conference this year on Cinco de Mayo, as Industrial Engineer salsa’d away with five awards.

The magazine took home three first place awards: Golds for Best Single Issue, Best Feature and Best Profile. And it received a silver award for General Excellence and a bronze award in the Best Design category.

“We were really excited to receive so many awards this year,” said Monica Elliott, IIE director of communications. “It is always a team effort, and that team includes the entire IIE staff because everyone plays a part in the magazine’s success. But even though the peer recognition is gratifying, our primary goal is always to provide the most valuable content to our members and subscribers.”

IIE Managing Editor Michael Hughes also credited the staff, IIE members and all contributors.

“We exist because of the members,” he said. “They often generate story ideas and topical coverage. And some join our outstanding team of contributors by submitting features that highlight how the latest research and practices can be used in the field.”

The May 2010 issue, which featured a cover story on Toyota’s automotive recall problems, was the Best Single Issue. Judges liked the coverage of emerging industry trends along with the in-depth features.

“Clearly, this editorial team knows its readers and their information needs,” the judges wrote. “Content is provocative, readable and timely. ‘On the Boards’ is a great way to incorporate social networks in a print product, further encouraging reader interaction.”

The Best Single Issue award is for exemplifying the best of a magazine’s content, writing and design in a manner that is well-targeted to the publication’s readership and mission.

The May 2010 issue joined the March and August editions to take home the silver for General Excellence. That award honors best overall packaging, showcasing excellence in content selection, writing, reporting, design and illustration.

The March and July 2010 entries won the bronze for Best Design, while Elliott and Hughes won first-place awards for their writing.

Elliott’s “A Quality Vintage” from June 2010 was the Best Profile. The judges said Elliott took her audience outside their typical boundaries for a fresh take on some tools of their trade. The judges said Hughes’ article “Of Debris and Humanity” (August 2010), which won Best Feature, was well-written and had “good word flow and background mixed with information necessary for [the] reading audience.”

A winning Cinco de Mayo