Aaron U. Bolin, Ph.D.

Today and Tomorrow: Commemorative Edition of Ford's 1926 Classic by Henry Ford My rating: 4 of 5 stars Brilliant, though somewhat utopian in outlook. I was somewhat surprised to see that Henry Ford outlined a complete and modern continuous process improvement program back in 1926 -- long before quality circles, total quality management, and lean six sigma. The basic message of the book is that good business management can save the world. Ford cites multiple examples from Ford Motors where better management improved the bottom line and also improved the lives of his workers. The book reads somewhat like an Ayn Rand novel - the producers of the world carry the load for the moochers. Ford does offer ample advice and has a very quotable writing style. The only thing that kept me from giving it five stars was the constant droning about how Ford Motors is the best thing since sliced bread. Otherwise, this is a very good book, maybe a must read, for those interested in continuou

We just completed the first annual training cycle (Oct 2012-Sept 2012) of our resurrected Continuous Process Improvement program. Our first year goals (and invested resources) were fairly modest. We planned to train an initial cadre of practitioners (check), execute several proof-of-concept projects (check), re-institute the local CPI collaborative (check), grow an in-house instructional capability (check), and embed CPI as an integral part of the strategic planning process (semi-check). In some ways, I think we might have aimed too low. It is common to achieve 1000% improvements in simulated processes during training. In our most recent class, we improved over a baseline production of 4 products in 10 minutes to a final production of 46 products in 10 minutes -- 1150% improvement in production and a cycle time improvement from 150 seconds per product down to about 13 seconds per product. If we could accomplish that in real life -- our biggest problem would be trying to figure out ho

We took a different approach to Lean Six Sigma training for the Society of Hispanic Engineers Eastern Leadership Technical Conference in San Juan, Puerto Rico on February 24, 2012. We did three things that were just a little bit different from our normal approach: 1. We adapted the Navy's Lean Six Sigma curriculum to offer it in a workshop format. The hands-on nature of the workshop format aligned well with the typical curriculum already, but we had to make some adjustments for the space and time constraints of a conference workshop. 2. We simplified the process simulation just a little bit to minimize the materials requirements. We put together a meaningful simulation experience using only a single piece of paper. It made it a lot easier to travel with the materials. 3. We increased the enrollment cap from 20 seats to 60. The 20 seat limit was originally set to make the instruction highly interactive. To maintain the interactivity, we incorporated more co-facilitators for th

As 1 of 1 employees responsible for our local Continuous Process Improvement (CPI) program, expanding awareness of and involvement in the program can be a challenge. In fact, it is even a bit more challenging because 50% of my position is devoted to other project work. Even providing training can be difficult. If I'm out of the office for several days to deliver training, then both the CPI program and my other job duties suffer. We recently took advantage of the fact that the local cadre of Green Belts were eager to exercise their knowledge of lean six sigma principles to offer a Yellow Belt course. The standard Yellow Belt curriculum that we use is two full days of instruction and is led by a Black Belt. Our team team altered the training schedule so that the course could be offered in a three half-day format. I served as the Black Belt lead instructor, with three Green Belts sharing the instructional duties. The re-worked schedule and the abundance of instructors worked won