Archive for the ‘Creative Thinking’ Category
Thursday, April 9th, 2009 by Bryan
Who has heard of the acronym TRIZ? Until a few months ago, it would have meant nothing to me except as four nicely arranged capital letters. Honestly I still don’t know what the terminology of the acronym is because it is derived from a Russian phrase meaning “Theory of Solving Inventor’s Problems.” I do, however, have a basic understanding of the principles of TRIZ and how to apply them. TRIZ is a bunch of principles that can be used to solve any problem that you may encounter. This applies to work, home, play, or anywhere else. TRIZ was developed by G.S. Altshuller, a Russian, as a means to solve problems. There are 40 TRIZ principles that can help you out. You can Google TRIZ to find out more about TRIZ and its uses. For now, I am going to relate a recent example where we have used the principles of TRIZ.
We are currently in the design phase on a fairly large machine. Space and cost are issues with this project. The machine will be building parts that have a very defined manufacturing process with many steps. For us, we have mimicked the original process as best as we could. Our machine started out with 3 dial tables, with each one costing a sizeable chunk of cash. After laying out the machine and realizing that we had many open stations, we decided to change the order of operations, cleared this with our customer, and placed a particular operation up closer to the front of the process. This allowed us to remove a dial table from the machine saving us some much-needed real estate, and a bunch of money.
These principles have become a part of our culture here at Setpoint. I am quite certain that when this decision was made we were not intentionally applying a TRIZ principle, even though we did. The principle we applied was Merging. We took a similar process and placed them side-by-side.
There are many more examples of where we solved a problem by applying a TRIZ principle on this project. What we have learned is if you get to a place where you are stuck, pull up the TRIZ principles on the net and go through them one by one and see if one of them will help solve your problem.
Tags: Creative Thinking, Lean Thinking, problem solving, triz
Posted in Creative Thinking, Custom Automation, Humor, Process Improvement | No Comments »
Thursday, April 2nd, 2009 by Mark
How many companies are there where the employees don’t consider themselves as simply “employees,” but view their role as “Teammate?” Sound funny? Recently, I sent out a company wide query to determine what “SuperTeam” means. Some of the responses might interest you:
- “Group of knowledgeable individuals that meet together to brainstorm and solve problems. Superteam concept allows Setpoint to avoid repeating past mistakes and offers a diverse perspective on solutions.”
- “. . . it pushes the design to be imagined/created up front before you start actually designing because the designers are all working together to try to work out the kinks and problems that you can find. The benefit that I see is that you are able to learn from each other because each individual brings a unique set of experiences to the table, so as the designers do more together they have more opportunities to see how to fix something because they are collectively looking at it.”
- “I think the “super team” in this case mostly refers to the size. Examples would be “super volcano” or “Super Carrier”. That being stated, I truly believe that the sum of each individuals’ contribution to any endeavor, if every idea is at least heard, has the greater potential to be superior at completion, than if each individual were separate, even in their field of expertise. This seems to be the case over and over again.”
- “The Superteam concept takes advantage of all team members’ knowledge, experience, and background without the constant overhead of having them assigned to the project for the whole time. The theory is that everyone’s eyes on a project will produce a product faster, cheaper, and with fewer mistakes. Why not let everyone do their area of expertise only on each project, instead of each of us trying to do it all?” In other words, let Steve be the technical guru, and Roger could manage the administrative, schedule, budget and customer communications. This would (and has) allowed Steve to forego all the administrative duties and have more time to spend developing concepts and designs with the team(s), and Roger would spend less time doing engineering tasks and focus on project management. In essence, what we have in a super team environment is a Project Engineer/Architect (Steve), and a Project Manager (Roger), with each able to focus on their expertise.”
So what does Superteam mean to me? Simply this: Using our collective knowledge to solve any problem. I believe our design team at Setpoint has broken the stereotypical mold commonly used to solve design related problems. One example is the office space we created that has unofficially been dubbed our “War Room.” It’s an array of white boards and markers, this is where we take our designs by storm. We break away from our confined world of 3D CAD and step in front of an expanse of white boards that allow instant creativity to roam rapidly in a visual and interactive way. There is something energizing about gathering creative minds around a whiteboard and thinking on your feet, it’s proven to be a powerful and simple way to solve problems as a team.
One day as we were standing at the white boards sketching we thought, “Wouldn’t it be cool if we had a projector to throw some images onto this board? Then we could sketch right on the part.” The best part of this story is that we didn’t just let this idea fall through the cracks, we made it a reality. We don’t have the red tape other companies have in implementing new and innovative ideas, another benefit of a small company. On another day, we invited all the assembly technicians into the war room and fed them lunch while we reviewed a concept of a machine that was something we had never done before. We wanted their input to find the hidden dangers lurking in our design concept before we proposed it to a customer, and their input brought some common sense to our table of wild ideas.
It’s this mentality of “Let’s bring in the assembly crew to get their input on this sub-frame” or “Let’s bring in one of our customers’ machine operators to look at how this machine actuates” that brings unity to the Superteam.
Synergy: (from the Greek syn-ergos meaning working together) is the term used to describe a situation where different entities cooperate advantageously for a final outcome. Simply defined, it means that the whole is greater than the sum of its parts. The essence of synergy is to value differences.
- A dynamic state in which combined action is favored over the sum of individual component actions.
- Behavior of whole systems unpredicted by the behavior of their parts taken separately. More accurately known as emergent behavior.
The other positive element that lies within the Superteam – is improved creativity. The Superteam idea cultivates friendships, fun, and good social dynamics. Creativity is CORE to Setpoints ability to be innovative and solve problems. Forcing solutions by relying on previous known methods will work, it’s how Setpoint has survived so long. However, creativity seems to flow better when we are relaxed, when we are happy, and when our minds are free to search for solutions by roaming. There is a time and place for both methods, but in years gone by I dare say the creative approach has been suppressed. The Superteam approach is to take the best of both these methods and balance them. It’s a matter of leadership, it requires an intuitive approach that can’t be learned in books. Like a coach who knows each of his players on an interpersonal level. This is where Superteam excels, optimizing the team members to let each player engage in their strengths to achieve the desired outcome on the project. This change toward balanced creativity has been gradual at Setpoint, but is now more and more common on each project.
They say a chain is only as strong as it’s weakest link. That may be true, but the Superteam approach is to ask, “Wait, why are we using a chain? Let’s use something better.” That’s what sets us apart.
Tags: Creativity, Social Dynamics, Superteam, Synergy, Teamwork
Posted in Creative Thinking, Ethics, Project Management | No Comments »
Thursday, March 26th, 2009 by Malorie
A normal day in the purchasing department consists of many different tasks and in order to maintain accuracy they all must be followed. From getting quotes to the actual order process there are many steps involved which seem to all be equally important. It is so easy for me to skip some of the steps if I’m in a hurry or get interrupted. When these crucial steps are overlooked I always regret it later because I can’t retrace my steps when an error or question arises.
One of our main focuses at Setpoint has been to make the Lean transformation and cut out as much waste as possible in our daily tasks and ongoing projects. Purchasing is a huge part of Setpoint’s business so to cut out wastes is a huge deal and any savings that I can generate automatically goes to the bottom line as profit. It’s a huge task that I want to achieve success at; therefore I’m always thinking and looking at ways to change what I do to make it more efficient and achieve the same, if not better, results with myself, Setpoint, the vendor, and my customers being satisfied.
In the past five years that I have been in this department I have seen some dramatic changes for the better but I know it can still be better and leaner. Success has yet to be achieved and that is my ongoing ultimate goal.
Tags: Creative Thinking, Custom Automation, Efficiency, Industrial Automation, Lean, Lean Automation, Lean Systems, Lean Thinking, problem solving, Process Improvement, toyota production system
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Thursday, March 19th, 2009 by scotts
In our current economic state with two continuing wars and the pressures of day to day life, it is easy to forget how truly blessed we are to live in the United states of America, or even to be a part of the modern day world with its modern conveniences.
While “here” is not perfect, we have opportunities to solve problems, and to come out better in the end. We have talented people working on problems, but more importantly finding solutions and providing breakthroughs to further build upon. The human knowledgebase grows exponentially each day; opinions and new points of views can be shared, discussed, researched, and collaborated on with mere keystrokes using the power of the internet.
From the M.I.T. breakthroughs on batteries allowing quicker charge times, to power distribution partners such as IBM and their Smart Grid Technologies allowing the transmission of power, such as wind, solar, hydroelectric, or geothermal, from remote renewable production sites to the consumers.
It is not whether we can recover from the challenges we face today, but rather when we recover that is the only unanswered part of the equation. Perhaps we should just take a moment to be grateful for the things we have, rather than focused on the things we’ve lost or don’t have.
Tags: Gratitude
Posted in Creative Thinking | 1 Comment »
Thursday, March 12th, 2009 by Clark
At Setpoint we follow the Mahan (Mahan Khalsa) culture of selling. Following are some high level points we closely follow and practice in our daily business relationships with our clients.
Mahan selling is not a technique but rather a culture that establishes a partnership between Consultant and Client. Too many times sales professionals spend an inappropriate amount of time advocating their products or service before even understanding what the client’s needs, issues and opportunities are.
Mahan selling focuses on understanding completely every aspect of the customer’s needs before trying to pitch a solution that may not be even close to what is needed. By focusing efforts on the customers issues and opportunities, a sales professional can bring far more “value add” to the table and in the long run provide the solutions that exactly meet the customer’s needs. Not kind of, or sort of…exactly.
The goal is to be in tune with the customer’s business issues and opportunities. This can only be achieved by allowing the customer to express what these issues and opportunities are. Too many times customers just want to know a number or be given a solution to what they perceive as “The” issue.
At closer examination, and with some sincere questioning by the sales professional, a complete, prioritized list of these issues and opportunities can be compiled. The way to get to a solution that exactly meets your client’s needs is by a “No Guessing” approach to finding out what issues and opportunities your solution will solve or help the client take advantage of.

Any time you feel the conversation or sales cycle may not be going in the right direction, Mahan calls this a yellow light. Our typical reaction to yellow lights in sales is similar to how we drive on the road. Most people speed up and zoom right through the yellow caution lights. In the Mahan culture we are encouraged to slow down for these yellow lights and express your concerns to the customer.
If we let the customer turn the so called yellow lights to green, rather than trying to hurry through the issues and do it ourselves, we will be more successful in finding a way to serve their needs. In fact, if done correctly, having the customer solve the issues or yellow lights can usually create a more positive impression of you and your company’s ability to serve their needs.
One of the main reasons we try to get an upfront list of issues and opportunities is because there is always a direct correlation between the customers likelihood of buying our solutions at a certain price and the number of issues and or opportunities we and the clients feel our solutions can solve or capitalize on.
So remember, never guess what the client’s needs are. Ask clarifying questions on what their needs are. Get out all the issues and opportunities they hope your solution will solve. And always slow down for yellow lights in the sales cycle and allow the customer to turn any yellow lights to green.
Tags: Efficiency, Lean Systems, mahan, sales
Posted in Creative Thinking, Lean Automation, Lean Systems, Marketing, Process Improvement | No Comments »
Tuesday, February 24th, 2009 by Bob
Managing a project consists of many tasks that need to be scheduled, delegated to the members of the team, completed, and followed up on by the project manager in order for the project to be successful.
One of the main tasks of the project manager is to track the overall progress and profitability of the project by the total hours and cost of goods charged to the project compared to what the bid has allotted. At Setpoint we have an open book policy for all projects. Anyone can go to the team board and see exactly what the progress is of any project at any time. This board shows the project revenue, the bid cost of good sold (COGS), actual COGS, project gross profit (GP), earned GP, percent complete, the week’s hours, the week’s GP, the week’s GP per hour, and the GP per hour to date for each project.
Reporting these numbers can sometimes be a tightrope walk for the project manager who reports the progress of each of his projects to management and the team of assemblers and programmers working on them. The management team wants answers to why the progress of the project is behind the forecast numbers he gave them at the beginning of the month. The assembly and programming team members working on the project are wondering why the hourly rate is so low or they are expecting the percent complete to be much higher. There are usually good answers for both teams.
As a project manager, I take the conservative approach. Sometimes a projects progress is well ahead of the hours that were in the bid, and sometimes the cost of goods is less than what is in the bid. This doesn’t often happen, but when it does I don’t like to take all the “good news” on the progress report until I am sure that all the parts have been accounted for in accounts payable and the majority of the debugging has been done on the machine. Some people might call this “sandbagging,” I call it proper project management. Can you be too conservative? Sure you can. But I ask you this; would you rather take all the “good news” at the point of discovery and find out later that one of the key, and very costly, components was not accounted for or was overlooked in the procurement state? Maybe you find out the scope of the project was not communicated to the programmer correctly and you now have two more weeks of programming to do. This is usually not the norm, but it happens. You now have costs or time you need to “give back” on the next progress report, or several reports, making it look like you have made no progress when the team is still working hard on the project.
Yes, in reality the end result should be the same; but let’s say your team can earn bonuses for completing projects ahead of schedule and below cost. I for one do not want to get the team excited about their efficiency and the prospect of getting a bonus for their efforts one week just to have it taken back the next. It doesn’t help the morale of the team. There is a “happy medium” for claiming the ‘good news” that differs from project to project. This is one of the hardest tasks to conquer for a project manager.
So call me a “sandbagger,” I’m ok with that.
Tags: Creative Thinking, Efficiency, Industrial Automation, Lean Automation, Lean Systems, Lean Thinking, Open Book Management, problem solving, Process Improvement, Project Management
Posted in Creative Thinking, Custom Automation, Industrial Automation, Lean Automation, Lean Systems, Open Book Management, Project Management | 2 Comments »
Thursday, February 12th, 2009 by Tanya
Waste elimination is one of the most effective ways to increase the profitability of any business. Processes either add value or they add waste to the production of a good or service.
To eliminate waste it is important to understand exactly what waste is and where it exists. While products significantly differ between factories, the typical wastes found in environments are quite similar. Anything that is unproductive, or doesn’t add value that a customer will pay for is considered muda or waste. For each waste there is a strategy to reduce or eliminate its affect on a company, thereby improving the overall performance of the company.
Inventory is a waste that you see in many companies. Inventory is the amount of materials or work-in-process (WIP) within the system. Materials or work-in-process that hasn’t been sold to a customer represents unrecognized value. Accelerating the process of converting raw materials into a product or service helps increase cash flow. Reducing inventory or work-in-process reduces lead times and the amount of labor and capital. There are many reasons why companies have excessive amounts of inventory, but in a lean system the reasons need to add value.
Examples of inventory waste could include some or all of the following:
- Parts not needed (over-orders or not figured out yet)
- Material ordered too soon
- Material and tools on hand but not being used (spares)
- Material and tools not needed (extra)
- Material and tools over-purchased
- Material and tools purchased for “just in case”
- Material and tools lost, or not returned
- Not returning excess for return credit back to a vendor
- Not completing paperwork associated with returns to vendor (RMA)
- Over-purchasing of supplies, forms, envelopes, marketing material, etc.
- Storage and movement of over-supply
Tags: Automation Integration, Creative Thinking, Custom Automation, Efficiency, eliminate waste, Industrial Automation, Lean, Lean Automation, Lean Systems, Lean Thinking, Muda, problem solving, Process Improvement, toyota production system
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Wednesday, January 21st, 2009 by Shayne
Though tools are expensive, it’s important to use the proper tools for the job you are doing. If you don’t have the right tools you can run into many problems. Rounded off or stripped out bolts, wrong sized holes, and broken taps are a few of the problems you may face.
Using the wrong tool for the job makes disassembling parts, or changing out parts difficult. Also, the cost of replacing parts that may be ruined by using the wrong tools is avoided by using the proper tools.
Using power tools and air tools when possible is more efficient and can lower your costs in hours. Who wants to stand around and build something using a hammer and nails when you can use a nail gun instead?
Having the right tools for the job helps everybody deliver a quality professional product for their clients and reflects well on your company.
Tags: Automation Integration, Creative Thinking, Custom Automation, Efficiency, Industrial Automation, Lean, Lean Automation, Lean Thinking
Posted in Automation Integration, Creative Thinking, Custom Automation, Industrial Automation, Lean Automation, Lean Systems, Process Improvement, Project Management | No Comments »
Thursday, January 15th, 2009 by John
My experiences working with industrial companies over the past fifteen years has aided me in my understanding of the importance of lean manufacturing. In the early 1990’s overhauling a company to run lean manufacturing practices might not have seemed practical to many. The cost of upgrading and maintaining such ideas would be enormous and the thought of employees being displaced from their jobs was taboo. During this period of time the companies that have been unwilling to make the changes necessary to work towards the lean goals were going out like the dinosaurs that they were. The global economy now demands more. Competition and profitability are huge factors in what makes a lean business practice essential.
Working for a lean company that provides lean automation is a great thing. There are always new business theories and practices surfacing. It’s exciting to work for a company where approval of ideas is asked of everyone. All financial information is reviewed in a group meeting. Any of our ideas to better the company and the products are taken in and analyzed. If an idea is beneficial, everybody involved is rewarded and the company is bettered. It’s a good feeling to be part of such a team.
Long live the lean!!!
Tags: Industrial Automation, Lean, Lean Automation, Lean Systems, Lean Thinking, Open Book Management, Process Improvement, toyota production system
Posted in Creative Thinking, Industrial Automation, Lean Automation, Lean Systems, Open Book Management | No Comments »
Wednesday, January 7th, 2009 by Warren
At Setpoint we have been building lean automated equipment for over 16 years. One of the lessons we have learned is the importance for engineers and assembly technicians to work together to get the job done efficiently and give the customer the best possible quality, price, and on-time delivery. Many times if the two don’t work together things tend to have to be redone, redesigned, or ideas scrapped all together. I’ve seen this time and time again, which in turn affects the quality and price and doesn’t make anybody happy.
For many years I have maintained and assembled machines and have seen many designs and working environments that most design engineers aren’t even aware of. Because of this experience that myself and other assembly technicians have we can often give insight to these facts.
Working together also makes installation easier and better. Engineers don’t tend to think of having an easy connector to two parts of a machine so that they can be easily separated for shipping or how the air hoses or electrical components are connected so when the machine is prepared for shipping you don’t have to rewire part of it at install. When examples such as these are not kept in mind during the design phase, the onsite installation can take much longer to get the machine up and running on the customers’ floor than need be, which costs us more and doesn’t look good to the customer.
So we all need to just get along!
Tags: Automation Integration, Creative Thinking, Custom Automation, Industrial Automation, Lean Automation, Lean Systems, Lean Thinking, problem solving, Process Improvement
Posted in Automation Integration, Creative Thinking, Custom Automation, Industrial Automation, Lean Automation, Lean Systems, Process Improvement | No Comments »