Archive for the ‘News’ Category

Quality in Education a Concern in India

Monday, January 25th, 2010

Public and private universities have largely failed to implement the aims and objectives of higher education, the University Grants Commission (UGC) has observed. The problem may be due to the fact that the term “quality” hasn’t been defined for education. In the quality profession a thing hasn’t been operationally defined unless it includes an objective method of measuring it. The UGC, and The Daily Star article, presume that everyone understands the meaning of “quality education” as they discuss the failure to achieve it. However, those of us working in quality in business have learned that unless an operational definition has been developed, different people have different ideas of what a term such as quality education means. After reading and re-reading the Star article, I must admit that I don’t have a clue as to what the UGC is using as their operating definition. The authors talk about the distribution of the universities and a “concern over the standard of eduction in both public and private universities.

After failing to define just what quality is, and how it hasn’t been achieved, the UGC goes on to identify the root causes. “The reasons for the failure include influence of partisan politics on student bodies, session jam, lack of transparency and accountability in the activities of teachers and students, uncontrolled consultancy and part time jobs of teachers, it said.” They also offer a variety of solutions, such as “Practical steps should be taken on an emergency basis to build a national consensus taking opinion of all political parties. Students and teachers’ politics aimed at protecting their collective interests can be encouraged.”

The poor quality of education has been a political issue since at least the time I became an adult, which was a very long time ago. If analysis such as that in the UGC report is the best we can do it will be an issue for some time to come. I suggest that concerned individuals would do well to take a lesson from the community of quality professionals and define precisely what is meant by the term “quality education.” This will then become what they are solving for, the Y, the response variable, the metric which tells them if they are making progress. Until this step is taken we will continue to see the kind of rambling, pointless analysis

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Terrorist List Errors Cause Problems for Many

Monday, January 18th, 2010
Despite TSA Assurances, their watchlist has its problems

Despite TSA Assurances, their watchlist has its problems

We’ve all heard about the terrorist with high explosives in his pants who got through airport security despite being on the TSA’s watchlist. If the null hypothesis is that the passenger is not a terrorist (innocent until proven guilty,) then this is a case of failing to reject the null hypothesis when it is actually false, a Type II error. As you might suspect,  the other type of error occurs as well, non-terrorists are subjected to additional security. The situation is summarized in the table.

H0: Passenger is not a Terrorist
HA: Passenger is a Terrorist
Passenger is Not a Terrorist (H0 correct) Passenger is a Terrorist (HA correct)
Passenger is Passed Through Security Correct Type II Error
Passenger is Frisked at Security Type I Error Correc

More than one list is involved here. One is the well-known “no fly list,” which includes about 2,500 names, 90 percent of which are not US Citizens. The other is the Transportation Security Administration’s (TSA) “automatic selectee” list — its list of about 13,500 names of people who are not permitted to board an aircraft without being given the once-over by the agency’s machines and uniformed, latex-gloved personnel — is based on people’s names, not on physical factors like age. One such automatic selectee, 8-year old Cub Scout Mickey Hicks, has been on the list, apparently, since birth.  For the Hicks family, which travels a lot, this is something of a hassle.

Statistical risk is unavoidable. Whenever decisions are made there is a chance that the wrong decision will be made. The questions involved are extremely difficult, and extremely important. In this case the question is about the tradeoff between liberty and safety. However, according to the NY Times,

For every person on the lists, hundreds of others may get caught up simply because they share the same name; a quick scan through a national phone directory unearthed 1,600 Michael Hickses. Over the past three years, 81,793 frustrated travelers have formally asked that they be struck from the watch list through the Department of Homeland Security; more than 25,000 of their cases are still pending. Others have taken more drastic measures.

It is one thing to err on the side of safety when adding names to a secret list, but there is room for debate about the correct error rate. Hundreds to one seems a bit excessive, to me anyway.

The problem is exacerbated by the extreme difficulties encountered in getting one’s name off of the automatic selectee list. Thousands of people who aren’t terrorists cannot prevent the list from misidentifying them, causing them delays and embarrassment when trying to board commercial aircraft. In a free country it is incumbent on the authorities to make every effort to correct their errors once they have become known.

Another issue is that the TSA’s list is also used for purposes other than airport security. Sen. Frank Lautenberg (D-N.J.), encouraged by New York City mayor Michael Bloomberg, wants to prohibit anyone on the FBI’s terrorist watchlist from possessing a firearm. Yet, the list and its criteria are secret, and Lautenberg’s bill would criminalize the exercise of a constitutionally protected right while denying a person the opportunity to clear himself of accusations in a fair and open hearing before a court of law. Besides that, one can argue that the tolerable error rates for the purpose of airport security would be different.

Also, it makes me very nervous to hear about lists of citizens being kept by governments. These are not people who have been accused of any crime. They are not being sought to be brought in for questioning or for trial. There are no warrants out for these people. History tells us that such lists will inevitably be misused by those in power, often to terrible ends.

The TSA’s process for doing this is obviously broken and in need of quick and drastic improvement. Six Sigma can help the TSA do this. One can only hope that they take advantage of it soon. Our safety and liberty depends on it.

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Lean Financial Services

Friday, January 8th, 2010

The Wharton School and Boston Consulting Group (BCG) have released a special report investigating the reasons why the financial services sector is lagging in their adoption of lean tools and practices. The study finds that the attitudes are changing, albeit slowly. Apparently lower costs, fewer errors, improved efficiency and reduced cycle times appeal to bankers. Who knew?

Lean’s manufacturing origins are probably part of the problem. Non-manufacturing organizations have a difficult time making the mental adjustment between manufacturing and services terminology. I recall many years ago teaching a class where I presented a control chart of a manufacturing process. The data showed the diameters of truss rods. This was a public seminar and I had a mix of students from manufacturing, health care, insurance, services and other industries. These students were truly baffled as to how they could make this work with their businesses. Sensing the reason, I though I’d try something. I wrote the first few rows of the data table that was used for the control chart, but I didn’t put a title on the table. Then I went around the room one-by-one and asked the students some questions about their businesses. For the health care student I wrote the title on the table as “Infections per 100 Surgeries.” For the insurance student “Claims Processed per Worker per Hour.” For the service department student “Service Calls Requiring a Follow Up Visit.” As I addressed each student’s particular application, I could visibly see the light come on.

This exercise caused me to be somewhat disappointed in analysis presented by the Wharton/BCG report’s authors. Deepak Goyal, a partner in BCG’s New York office, commented “Finance is just a different kind of factory. It is a processing factory, and there’s a lot of waste.”  Another comment was “Becoming lean involves eliminating the “seven deadly sins” of waste in a process — overproduction, waiting, poor transportation/logistics, over-processing, sub-optimal inventory control, rework, and unneeded movement.” Yeah, sure. But I doubt that people in the financial sector know precisely what these guys are talking about. I suspect that a few specific financial sector examples of each type of waste would go a long way towards improving understanding. I mean, is it supposed to be obvious that sub-optimal inventory control is a problem at a bank?

Still, the report is a wealth of valuable information for those seeking to expand the reach of Lean to non-traditional areas. Those of us who are professionals in this area can glean a lot of useful guidance from the report, because we already understand Lean and Lean Six Sigma. We can add a great deal of value by translating the report into terms that our clients and employers understand so they can see exactly how these important process excellence philosophies and technologies can be applied to the processes in the financial sector.

Then, perhaps, the lines at the teller window and the waiting times for loan approvals won’t be quite so long!

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iSixSigma Names Project and Program Finalists

Thursday, December 24th, 2009

iSixSigma.com has announced the finalists for the most successful lean six sigma start up program, most successful re0energized lean six sigma program and the largest-breakthrough improvement projects. “The iSixSigma Live! Awards recognize programs and projects that have demonstrated outstanding accomplishment,” said Jessica Harper, editor in chief of iSixSigma. “All entries demonstrated admirable efforts in applying Lean Six Sigma at their organizations. There were some, however, that stood out among the rest in their achievement of breakthrough results.”

Such awards are a source of information for firms seeking benchmark partners, case studies they can learn from, or just plain old inspiration. The lists include technology companies, hospitals, government and military candidates, proving that Lean Six Sigma’s reach is far and wide. Candidates for Largest-Breakthrough Improvement Project included organizations in four industries: customer Service, manufacturing, supply chain, and transactional. Areas addressed by the finalists were cycle-time, defects and error rates, process improvement, parts avaiability, advisor licensing, lead time, call abandonment and handle time, and efficiency.

I was most impressed with the variety, both in the industries represented and the projects. I’m often asked if “Six Sigma” or “Lean” will work in {name the industry or process}, my answer is “If you are working with a process, then you can improve with Lean, Six Sigma, or a combination of the two.” The iSixSigma awards confirm it.

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Why Healthcare Quality Stinks

Monday, November 30th, 2009
Tom Pyzdek

Tom Pyzdek

Let’s be honest, America’s healthcare non-system has its problems. Let’s not quibble over whether or not it is better than socialized systems. For one thing, the demand side is already socialized. Nearly 90% of the cost of healthcare is paid for by third parties, either the insurance company or a government program like Medicare or Medicaid. When a person doesn’t have to bear the cost of the product or service they receive, whatever the system is, it isn’t Capitalism. The supply side however, is pretty much free, at least in the sense that the patient has free access to whatever services and medications their primary care physicians prescribe. The physician doesn’t pay for it; the patient doesn’t pay for it. How about a CT Scan for that pain you’ve had for the past couple of days? Why not? You’re not paying for it!

Exactly what to call this arrangement escapes me. I think there’s plenty of ammo here for a lively political debate where both sides can point fingers at the failings of the other side. There’s plenty of blame to go around. However, it’s not my purpose to examine the whole healthcare issue in this single column. Instead, I’d like to discuss the impact of the current ridiculous situation on the field I’ve spent a lifetime in: quality.

Once upon a time I was working with hospitals trying to improve quality. I assume that we can all agree that this is a worthwhile effort. After all, there is little argument that there is room for improvement. The 1999 report “To Err is Human” by the Institute of Medicine estimated that medical mistakes kill about a jumbo-jet full of people each and every day, and subsequent studies by other groups have shown this to be a low estimate. Anyway, I was lucky enough to work with groups of dedicated healthcare professionals who were able to make significant improvements in areas such as reduced infections, reduction of unnecessary c-sections, faster response times, etc.. The result was a reduction in the average length of stay, fewer readmissions, and other improvements that patients and their families were happy about. One of the most enthusiastic of those working on quality improvement was a young man who I will call Rob. Rob had a great deal of experience in all aspects of hospital administration and soon found himself appointed as administrator of a 500 bed medical center. All of us who had worked with Rob were delighted and we looked forward to an expansion of the quality improvement work Rob had championed when he was in middle-management.

For a while, that’s exactly what we got. Rob’s leadership support began making big dents in chronic problems that were costly in terms of unnecessary patient suffering as well as in waste due to preventable problems. Thanks to Rob I was able to attend meetings with the hospital board of directors, where Rob arranged to have quality improvement teams present their remarkable results to apparently enthusiastic board members.

Soon, however, the atmosphere at these meetings began to change. The chairman of the board, also the president of the bank which held most of the hospital’s debt, pointed out to Rob that the reduced patient-days, lower number of c-sections, reduced readmissions, etc. were cutting into the hospital’s revenue stream. He pointed out the obvious: private and government insurance company money was available to pay for treating a medical mistake, there was no way to know if many c-sections were necessary or not, a readmission paid the same as a first admission. In short, quality improvement was costing the hospital money.

Rob wasn’t blind to the implications. If he couldn’t get revenues up, he would be replaced. Furthermore, in addition to the pressure from the board, physicians were also grumbling about the impact of improved quality on their incomes. Quality was nice to talk about, but when it came to actually giving up the added income, well, that was another story. Rob had a simple choice: follow his conscience and lose his job, or return to business as usual. Soon the quality improvement activities were reduced to a few token people. Gradually, the improvements came undone. Rob eventually lost his job anyway, but the message was clear enough that his successors had no difficulty figuring it out.

In typical buyer/seller situations the problems would be resolved by competition. If one manufacturer’s television set isn’t as good as another the word will spread and people will vote with their dollars for the better value. However, try finding out about the problems at your local hospitals. Or about your physician’s performance relative to others in your area. I’ve tried. And while I’ve discovered some sources of information, the data seems skimpy to me and, shall we say, sanitized. I don’t see the kind of honest customer commentary I see in places like Amazon.com. I suspect there are forces at work making the world work this way.

To summarize: based on personal experience I can tell you that the quality tools that work with other industries work just as well in healthcare. This is no surprise, really. Healthcare has processes, and our tools help people rapidly improve processes. Quality healthcare can be as easily judged by healthcare consumers as by consumers of other services, and our tools help people rapidly improve quality. We can help remove waste from healthcare value streams as surely as we can from any other value streams.

But the missing element is the incentive to improve forced upon other industries by competition and easy access to information. In other industries, customers decide where to spend their own money and have to live with the costs and consequences of their decisions. They have access to frank and open assessments of others about their experiences with a particular supplier and the products and services they provide. They are free to move to a new supplier easily if they decide it is in their best interest to do so. None of these things hold true in healthcare. If we truly want to improve healthcare, in the sense of that we get higher quality service at a lower cost, then we need to address the root causes of the problem. Look at the proposed solutions to the healthcare crisis through this lens and ask yourself if they are treating the underlying disease or making it even worse.

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SAS software billionaire John Sall on Six Sigma

Thursday, October 8th, 2009

SAS software billionaire Sall on Six Sigma and the economic recovery: Big Brain Week continues – Burns on Business.

You would expect John Sall of SAS Institute to embrace the statistical approach. But he goes beyond merely giving a nod to the quality movement and Six Sigma. “The quality movement really changed the world…because of the appreciation for using data and measurement to show cost savings and revenue enhancements.” Said Sall. “Before Six Sigma, you were proving you were watching things rather than figuring out what you should do.”

In other words, you went from focusing on results to understanding what drove those results. This is, I believe, a critical distinction that is lost on most business schools. Business schools must teach aspiring managers all about command-and-control systems, guided by “results.” In my opinion you can’t figure out what needs to be done merely by watching results. Results tell you nothing about causes. They are effects. They are the Y in a transfer function that links them to causes and a process. The process is the set of actions that links the inputs and causes to the results. Business schools and accounting systems can not teach a business leader about these relationships.

Sall doesn’t promote Six Sigma. In fact, he seems to dismiss it. “As a brand, Six Sigma is not as strong. It overpromised. The brand will fade.” No doubt. Brands always fade, eventually. Still, as a brand Six Sigma has outlasted nearly all other contenders. SPC, TQM, Reengineering and many more have come and gone while Six Sigma remains. But it’s not about the staying power of the Six Sigma brand. John Sall sees it as analyzing data and experimentation. I believe that it’s about something deeper than this. It’s about understanding cause-and-effect. Statistical analysis helps with this, as does experimentation. But there’s another ingredient that isn’t emphasized nearly as much as it needs to be: thinking.

Thinking is a process of integrating new facts with all existing knowledge. It is a profoundly individual activity. Business schools act as if a leader can effectively lead by using command-driven management to direct activities and using results as feedback. This approach leads to superstitious learning and management actions that are based on trial-and-error . This approach is largely responsible for the failure of many formerly great enterprises.

Ultimately, management is not about Six Sigma, quality, analyzing data, or experimentation. It’s about knowing how to create and deliver consistent, long-term value for all stakeholders. These other things are tools to help managers figure out how to do this well.

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Evil Process-FDA’s Broken Approval Process

Thursday, August 13th, 2009

Last night I watched a great movie, Living Proof, which documented a true story about a doctor struggling to get a promising breast cancer treatment drug approved. In one of the scenes the doctor has just completed a Phase I clinical trial and has to explain to one of the patients why she won’t be allowed to move on to the next phase. Essentially, the reason is FDA rules. For all practical purposes the woman is sentenced to death. She had responded favorably to the experimental drug, but not favorably enough to move to the next phase.

Ok, you might say. But surely she could be given the drug outside of the clinical trial, right? Wrong. She is denied access to the only medicine that could possibly save her, presumably in the name of safety.

This isn’t an isolated case. Because I’ve rented similar movies in the past Netflix recommends a host of other movies about people fighting heroic battles to get potential cures through the FDA’s approval process. In the article, Whose Life is it Anyway? former FDA commissioner Scott Gottlieb is quoted as saying that the FDA is failing to use its authority to strike a balance on this issue. Gottlieb suggests a number of process improvements. Too bad his suggestions probably won’t be taken seriously.

I’m one of the lucky ones. When I turned 50 I was diagnosed with severe Barrett’s esophagus. The standard of care is what could be termed “watchful waiting.” It involves periodic endoscopies and drug treatment. In my case, the drugs did no good and my condition got steadily worse. My checkups went from every two years, to every year, to every six months. The biopsies looked more and more like cancer, putting me and my family through periodic nightmares as we awaited the biopsy results. Eventually, I was sure, my condition would progress to esophageal cancer. Like most cancer treatments, the treatments for esophageal cancer are expensive, gruesome and ineffective.

Finally, after eight years of this, I spent my own money to buy 30 minutes of time with a physician at Mayo clinic in Scottsdale. As luck would have it, he had a clinical trial starting. I qualified, received the treatment, and am now completely free of Barrett’s esophagus. While I was blessed, my nephew’s father-in-law was less fortunate. His Barrett’s degenerated into cancer and he died during my clinical trail. It will probably be several years before the treatment is approved and made available to the public. In the meantime, more people will die.

The FDA’s drug approval process is over 50 years old. It takes years and costs hundreds of millions of dollars. Thousands die while the FDA slogs along. It doesn’t take Six Sigma or Lean training to see that this process is screaming for improvement. It just takes a heart.

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My Prescription for the Healthcare Crisis

Thursday, July 16th, 2009

Inspired by Some questions not asked in health care debate – BizTimes.

Like many, I am concerned about healthcare in America. The above story outlines a number of issues with our system

  • A medical error rate 5 to 9 times higher than some other countries
  • Out of control healthcare costs

The author discusses the fact that Six Sigma has only recently been introduced in American healthcare, and then only on a limited basis. He details a horror story involving his father’s care and decries the fact that such stories abound. From this he concludes that the solution to these problems is…more government involvement in American healthcare.

I’m sorry, but I don’t get the connection. I agree with the above facts and would dearly love to have American healthcare professionals use more process excellence tools, including Six Sigma, Lean, and quality improvement. But I don’t see how more government address the root cause of our problems. In fact, I see little or not effort made to drill down to the root cause of the problems in healthcare. Let me make a stab at it.

  • I believe that government programs have contributed to the problem by helping create a disconnect between the patient and the healthcare provider.
  • I believe that the current system limits the choice of patients as to who will provide their care.
  • I believe that patients do not have access to the information they need to adequately assess the quality of their healthcare providers.
  • I believe that special interests (e.g., pharmaceutical companies, medical device companies, insurance companies, professional groups, etc.) manipulate government programs and limit access to information for their own advantage.
  • I believe that political groups use the fear of illness to manipulate voters for the interests of the politicians.
  • I believe that more government control of healthcare would exacerbate the above problems.

Solutions

I believe that solutions that address the disconnect between the person who provides the healthcare and the person who receives and pays for it will ultimately be needed to fix the problem. This is, I believe, the root cause of our current problems. An ideal solution would be one that:

  • Provides patients with complete, up to date, and accurate information on their provider. This would include information on outcomes, error rates, complaints, etc.
  • Allows patients to choose their care provider.
  • Provides patients with price data in advance.
  • Protects patients from paying for poor quality care, including any problems caused by misdiagnoses, complications from poorly done procedures, infections due to poor practices, etc.
  • Requires patients to pay at least some of the cost of their care directly to the provider.

In other words, I believe more freedom and more responsibility for patients would address the core problem of the current system. I believe that when patients are free to choose their care provider, have complete information on quality and price, and have a personal interest in the cost of their care, they will make better choices than faceless and nameless bureaucrats employed by insurance companies or the government.

Not to lay the whole blame on government. I believe that the process and quality improvement professions have a great deal to offer the healthcare profession in the form of methods, tools, techniques and systems to improve. But healthcare professionals are overly resistant to such suggestions, at least party because of parochialism and perverse incentives. If patients were provided the information they need to make the right choices, the ability to make these choices, and the financial incentive to do so, intransigent providers would either improve or pay the price. Ultimately, this would drive the demand for the services of quality and process improvement professionals. It’s what did it for every other industry in the world.

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Six Sigma Overkill

Thursday, July 16th, 2009

Six Sigma Economics | Product Design and Development.

I’m all for spreading the word about Six Sigma, but some authors get a little bit silly about it. This article is a case in point. The article is a very interesting analysis of the news that the stock market, as measured by various indexes, has improved a great deal in recent weeks. The stock prices of most leading manufacturers has risen markedly in such industries as automotive, aerospace, electronics and medical devices. In some instances, the improvements are quite remarkable. Since March 10 Ford’s stock price has doubled and Radio Shack has nearly doubled. More significantly, leading indicators such as the Purchasing Manager’s Index,  employment, order backlogs and inventories have also improved. In short, things are looking up, at least at the moment.

My argument is not with the good news, which I welcome. It’s with the headline. What does any of this have to do with Six Sigma? As far as I can tell, nothing at all. In a world full of people who find Six Sigma to be abstruse and difficult to comprehend, headlines like this one can only add to the confusion.

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GM and Toyota Call It Quits at NUMMI

Friday, July 10th, 2009

Toyota Motor Corp (7203.T) said on Friday it would consider liquidating its stake in a California-based joint venture with General Motors Corp (GMGMQ.PK) after the U.S. automaker pulled out of the venture. The venture started 25 years ago and it was originally set up in an attempt to help GM learn  more about Toyota’s Lean manufacturing technique. Toyota was looking for a US presence to help them deal with import restrictions imposed on them by the US government in an attempt to help protect US automakers from Japanese competition.

How has that worked out?

Toyota surpassed GM as the world’s largest automobile manufacture in 2008, while GM begged for a government bailout and declared bankruptcy. Over two decades later Toyota continues to practice lean in a culture dedicated to continuous innovation and improvement, US automakers GM and Chrystler seek government handouts. It seems as if American managers are, for some reason, immune to learning the quality improvement approach that was invented in the USA. Until they manage to do so, expect to see continued declines and job losses.

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Good books on Six Sigma and other topics

What is Six Sigma?

By Thomas Pyzdek, Author of The Six Sigma Handbook

For Motorola, the originator of Six Sigma, the answer to the question "Why Six Sigma?" was simple: survival. Motorola came to Six Sigma because it was being consistently beaten in the competitive marketplace by foreign firms that were able to produce higher quality products at a lower cost. When a Japanese firm took over a Motorola factory that manufactured Quasar television sets in the United States in the 1970s, they promptly set about making drastic changes in the way the factory operated. Under Japanese management, the factory was soon producing TV sets with 1/20th the number of defects they had produced under Motorola management. They did this using the same workforce, technology, and designs, making it clear that the problem was Motorola's management. Eventually, even Motorola's own executives had to admit "our quality stinks." Read More...