Friday, October 3, 2008

TIG welding - an overview



By Marty Rice, Contributing Writer

Welding instructor Marty Rice explains the gas tungsten arc welding (GTAW) process, more commonly known as tungsten inert gas (TIG) welding.

As I've said before, I like to begin my articles by relating a personal dumb but funny learning experience. Why do I do this, you might ask?
 
Because I'm not afraid to admit I make mistakes; after all, I'm human. I've been taught by, worked for, and even been friends with a few people who think they are some kind of perfect. You know the type; it's their way or the highway. You could show them a better way, but they would still do it their way because they wouldn't dare admit that you could be right.
 
Not me. Even though I've been in the welding field a long time, I still make a mistake now and then. And sometimes I don't see a solution to a problem, even when it's staring me in the face. I'm not afraid of learning something new either. If there's a better way of doing it, bring it on!
I tell my new welding students that it's OK to make a mistake in our shop, because that's just what's going to happen when you're a "newbie." Newbie is a very affectionate term soldiers who had been there awhile called us new guys when we first arrived overseas—that, or FNG, which I think must've meant "funny new guy." What's most important with my newbies is that they learn from their mistakes, and don't repeat them.
 
A former student, Michael Salceda, now is an apprentice in the Ironworkers Union. He comes around and helps me when his work is rained out or slow. When Michael heard the story I'm about to relate, he just shook his head and said, "Mr. Rice, you should have had a pair of pliers or wire cutters in your truck." Yep, he was right; wire cutters would've saved me some pain and money.
 
My son and I bought a bike to fix up from The Motorcycle Man in Dickinson, Texas, close to Galveston. We planned to pick it up and then eat some good seafood down on the coast.
 
We found the shop and loaded the bike in my son's truck. I then pulled out the package of tie-down straps I had just bought—four tie-downs and each one had four wide, hard plastic bands around them. I popped the first band off with my pocket knife, but the next one was difficult to cut. I tried to pop it upward when it slipped and my pocket knife (did I mention I had just sharpened it?) stuck into the bone in my left inside forearm.
 
Should have left it there, but my first reaction was to jerk it out. When I did, blood shot out of my arm like a garden hose, because I had hit an artery! (Also nicked a tendon and hit muscle, but no permanent damage, thank goodness.) I applied pressure with my hand, and Bill (the Motorcycle Man) wrapped my arm in a towel and whisked me to his car for a trip to the hospital.
 
After I suppressed my urge to scream like a child, and once I realized I wasn't going to die, I thought about what a shame it was that I wouldn't get to eat some good seafood while I was in that part of Texas. (It's funny how my mind works in a crisis situation.)
But thanks to the marvels of modern medicine, I was down on the coast eating fresh oysters and having a cool one just a couple of hours later. Besides having a bruise from my hand to my elbow, I was just fine.
 
Most welders carry pocket knives. Be careful with them! I received a very painful reminder to use the right tool for the right job.
 
Before I turn this whole article into my freak accident story, here's my synopsis of the tungsten inert gas (TIG) welding process and some of the tools it requires.

 

Background

Some older welders still refer to TIG as "heliarc," which is what the process originally was called.
 
Heliarc was perfected around 1941 and was used to weld on magnesium, aluminum, and stainless. It was especially helpful in the war effort for welding on airplanes.
 
Heliarc used pure helium as an inert (meaning it won't combine with other elements) shielding gas to protect the weld pool from the atmosphere. (Nitrogen, hydrogen, oxygen, carbon dioxide, and other elements cause weld defects if introduced to the weld pool.)

 

Enter Argon

After a while it was discovered that argon has some advantages over helium. Because argon is heavier than helium, less flow rate is needed. (We use about 20 to 25 cubic feet per hour (CFH) in our shop.) The lower flow rate requirement makes argon better for flat welding. Helium is good for overhead, because it is lighter and thus flows upward.
 
Argon allows easier arc starting and a smoother, more stable arc than helium does. Actually, argon pretty much is the most widely used shielding gas nowadays.
Since the heliarc process no longer used only helium, someone decided to rename it TIG for tungsten inert gas welding.
 
Later the same guy who changed the "library" to the "learning resource center" must have decided TIG was too easy, so he named it gas tungsten arc welding (GTAW). But most everyone I know in the shop and field still call the process TIG.

 

Nonconsumable Electrode

TIG uses a tungsten electrode that is nonconsumable. In other words it does not burn up like an electrode in stick welding or the wire in metal inert gas (MIG) welding does. The tungsten acts as the torch: It generates heat, which melts the metal and/or filler metal.
 
Thin metals can be joined by TIG welding without using filler metal.. Joining thicker metals requires using an approximately 3-ft.-long filler rod of various diameters that is fed into the weld pool with one hand, while the torch is manipulated with the other.
 
While MIG welding is relatively easy to learn, TIG isn't. It takes a lot more skill and know-how to make a good TIG weld. One of the best ways to learn TIG welding is to learn oxygen/acetylene welding or brazing first. Although oxyacetylene welding pretty much is obsolete as a major welding process, it is perfect for learning the premise of a good TIG bead. You have to hold the TIG torch at the right angle, keep the weld pool uniform, and add the correct amount of filler metal to produce a good bead. (And, of course, relax your hand, and watch the puddle!)

 

A Process for All Metals

If you watch "Orange County Choppers," "Monster Garage," or some of the other fabrication shows on TV, you probably have seen chromium molybdenum steel (chromoly) bike frames TIG welded, because TIG is good for all metals. I mainly teach TIG welding on mild steel first, followed by stainless steel, and then aluminum. It also is good for copper, magnesium, titanium, nickel, and a host of others.
 
In the classroom we use a 3/32" tungsten electrode with direct current, electrode negative (DCEN) on small-gauge to 1/4-in. mild steel and stainless, then switch to alternating current (AC) on aluminum.
 
(Remember, electricity always flows from negative to positive in DC and flows back and forth on a sine wave in AC.)
 
I always used to use tungsten electrodes with 2 percent thorium until talking with someone who told me that thorium is radioactive and probably not a good substance to be touching and breathing. Avoid thoriated tungsten electrodes that can pose health and environmental risks at elevated exposure levels.

 

Learning TIG

For those interested in learning TIG welding, I strongly suggest that you check out a local welding school or college to find a course that offers good training in both theory and practice. Some schools will let you take specific classes to accommodate exactly what you want to learn. I know that Dewayne Roy at Mountain View College in Dallas tries to customize his classes to adults wanting to learn TIG or MIG. Perhaps you will find such a place where you live.
 
A future article will discuss TIG welding machines. If you plan to purchase one, you can expect to lay out quite a few more bucks than you would for a MIG welding machine.

Recommended TIG Welding Sites

 

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Understanding Employee Motivation




Understanding Employee Motivation

James R.. Lindner
Research and Extension Associate
The Ohio State University
Piketon Research and Extension Center
Piketon, Ohio
Internet address: lindner.16@osu. edu
Introduction to Motivation
At one time, employees were considered just another input into the production of goods and services. What perhaps changed this way of thinking about employees was research, referred to as the Hawthorne Studies, conducted by Elton Mayo from 1924 to 1932 (Dickson, 1973). This study found employees are not motivated solely by money and employee behavior is linked to their attitudes (Dickson, 1973). The Hawthorne Studies began the human relations approach to management, whereby the needs and motivation of employees become the primary focus of managers (Bedeian, 1993).
Motivation Theories
Understanding what motivated employees and how they were motivated was the focus of many researchers following the publication of the Hawthorne Study results (Terpstra, 1979). Five major approaches that have led to our understanding of motivation are Maslow's need-hierarchy theory, Herzberg's two- factor theory, Vroom's expectancy theory, Adams' equity theory, and Skinner's reinforcement theory.
According to Maslow, employees have five levels of needs (Maslow, 1943): physiological, safety, social, ego, and self- actualizing. Maslow argued that lower level needs had to be satisfied before the next higher level need would motivate employees. Herzberg's work categorized motivation into two factors: motivators and hygienes (Herzberg, Mausner, & Snyderman, 1959). Motivator or intrinsic factors, such as achievement and recognition, produce job satisfaction. Hygiene or extrinsic factors, such as pay and job security, produce job dissatisfaction.
Vroom's theory is based on the belief that employee effort will lead to performance and performance will lead to rewards (Vroom, 1964). Rewards may be either positive or negative. The more positive the reward the more likely the employee will be highly motivated. Conversely, the more negative the reward the less likely the employee will be motivated.
Adams' theory states that employees strive for equity between themselves and other workers. Equity is achieved when the ratio of employee outcomes over inputs is equal to other employee outcomes over inputs (Adams, 1965).
Skinner's theory simply states those employees' behaviors that lead to positive outcomes will be repeated and behaviors that lead to negative outcomes will not be repeated (Skinner, 1953). Managers should positively reinforce employee behaviors that lead to positive outcomes. Managers should negatively reinforce employee behavior that leads to negative outcomes.
Motivation Defined
Many contemporary authors have also defined the concept of motivation. Motivation has been defined as: the psychological process that gives behavior purpose and direction (Kreitner, 1995); a predisposition to behave in a purposive manner to achieve specific, unmet needs (Buford, Bedeian, & Lindner, 1995); an internal drive to satisfy an unsatisfied need (Higgins, 1994); and the will to achieve (Bedeian, 1993). For this paper, motivation is operationally defined as the inner force that drives individuals to accomplish personal and organizational goals.
The Role of Motivation
Why do we need motivated employees? The answer is survival (Smith, 1994). Motivated employees are needed in our rapidly changing workplaces. Motivated employees help organizations survive. Motivated employees are more productive. To be effective, managers need to understand what motivates employees within the context of the roles they perform. Of all the functions a manager performs, motivating employees is arguably the most complex. This is due, in part, to the fact that what motivates employees changes constantly (Bowen & Radhakrishna, 1991). For example, research suggests that as employees' income increases, money becomes less of a motivator (Kovach, 1987). Also, as employees get older, interesting work becomes more of a motivator.
Purpose
The purpose of this study was to describe the importance of certain factors in motivating employees at the Piketon Research and Extension Center and Enterprise Center. Specifically, the study sought to describe the ranked importance of the following ten motivating factors: (a) job security, (b) sympathetic help with personal problems, (c) personal loyalty to employees, (d) interesting work, (e) good working conditions, (f) tactful discipline, (g) good wages, (h) promotions and growth in the organization, (i) feeling of being in on things, and (j) full appreciation of work done. A secondary purpose of the study was to compare the results of this study with the study results from other populations.
Methodology
The research design for this study employed a descriptive survey method. The target population of this study included employees at the Piketon Research and Extension Center and Enterprise Center (centers). The sample size included all 25 employees of the target population. Twenty-three of the 25 employees participated in the survey for a participation rate of 92%. The centers are in Piketon, Ohio.
The mission of the Enterprise Center is to facilitate individual and community leader awareness and provide assistance in preparing and accessing economic opportunities in southern Ohio. The Enterprise Center has three programs: alternatives in agriculture, small business development, and women's business development. The mission of the Piketon Research and Extension Center is to conduct research and educational programs designed to enhance economic development in southern Ohio. The Piketon Research and Extension Center has five programs: aquaculture, community economic development, horticulture, forestry, and soil and water resources.
From a review of literature, a survey questionnaire was developed to collect data for the study (Bowen & Radhakrishna, 1991; Harpaz, 1990; Kovach, 1987). Data was collected through use of a written questionnaire hand-delivered to participants. Questionnaires were filled out by participants and returned to an intra-departmental mailbox. The questionnaire asked participants to rank the importance of ten factors that motivated them in doing their work: 1=most important . . . 10=least important. Face and content validity for the instrument were established using two administrative and professional employees at The Ohio State University. The instrument was pilot tested with three similarly situated employees within the university. As a result of the pilot test, minor changes in word selection and instructions were made to the questionnaire.
Results and Discussion
The ranked order of motivating factors were: (a) interesting work, (b) good wages, (c) full appreciation of work done, (d) job security, (e) good working conditions, (f) promotions and growth in the organization, (g) feeling of being in on things, (h) personal loyalty to employees, (i) tactful discipline, and (j) sympathetic help with personal problems.
A comparison of these results to Maslow's need-hierarchy theory provides some interesting insight into employee motivation. The number one ranked motivator, interesting work, is a self-actualizing factor. The number two ranked motivator, good wages, is a physiological factor. The number three ranked motivator, full appreciation of work done, is an esteem factor. The number four ranked motivator, job security, is a safety factor. Therefore, according to Maslow (1943), if managers wish to address the most important motivational factor of Centers' employees, interesting work, physiological, safety, social, and esteem factors must first be satisfied. If managers wished to address the second most important motivational factor of centers' employees, good pay, increased pay would suffice. Contrary to what Maslow's theory suggests, the range of motivational factors are mixed in this study. Maslow's conclusions that lower level motivational factors must be met before ascending to the next level were not confirmed by this study.
The following example compares the highest ranked motivational factor (interesting work) to Vroom's expectancy theory. Assume that a Centers employee just attended a staff meeting where he/she learned a major emphasis would be placed on seeking additional external program funds. Additionally, employees who are successful in securing funds will be given more opportunities to explore their own research and extension interests (interesting work). Employees who do not secure additional funds will be required to work on research and extension programs identified by the director. The employee realizes that the more research he/she does regarding funding sources and the more proposals he/she writes, the greater the likelihood he/she will receive external funding.
Because the state legislature has not increased appropriations to the centers for the next two years (funds for independent research and extension projects will be scaled back), the employee sees a direct relationship between performance (obtaining external funds) and rewards (independent research and Extension projects). Further, the employee went to work for the centers, in part, because of the opportunity to conduct independent research and extension projects. The employee will be motivated if he/she is successful in obtaining external funds and given the opportunity to conduct independent research and extension projects. On the other hand, motivation will be diminished if the employee is successful in obtaining external funds and the director denies the request to conduct independent research and Extension projects.
The following example compares the third highest ranked motivational factor (full appreciation of work done) to Adams's equity theory. If an employee at the centers feels that there is a lack of appreciation for work done, as being too low relative to another employee, an inequity may exist and the employee will be dis-motivated. Further, if all the employees at the centers feel that there is a lack of appreciation for work done, inequity may exist. Adams (1965) stated employees will attempt to restore equity through various means, some of which may be counter- productive to organizational goals and objectives. For instance, employees who feel their work is not being appreciated may work less or undervalue the work of other employees.
This final example compares the two highest motivational factors to Herzberg's two-factor theory. The highest ranked motivator, interesting work, is a motivator factor. The second ranked motivator, good wages is a hygiene factor. Herzberg, Mausner, & Snyderman (1959) stated that to the degree that motivators are present in a job, motivation will occur. The absence of motivators does not lead to dissatisfaction. Further, they stated that to the degree that hygienes are absent from a job, dissatisfaction will occur. When present, hygienes prevent dissatisfaction, but do not lead to satisfaction. In our example, the lack of interesting work (motivator) for the centers' employees would not lead to dissatisfaction. Paying centers' employees lower wages (hygiene) than what they believe to be fair may lead to job dissatisfaction. Conversely, employees will be motivated when they are doing interesting work and but will not necessarily be motivated by higher pay.
The discussion above, about the ranked importance of motivational factors as related to motivational theory, is only part of the picture. The other part is how these rankings compare with related research.. A study of industrial employees, conducted by Kovach (1987), yielded the following ranked order of motivational factors: (a) interesting work, (b) full appreciation of work done, and (c) feeling of being in on things. Another study of employees, conducted by Harpaz (1990), yielded the following ranked order of motivational factors: (a) interesting work, (b) good wages, and (c) job security.
In this study and the two cited above, interesting work ranked as the most important motivational factor. Pay was not ranked as one of the most important motivational factors by Kovach (1987), but was ranked second in this research and by Harpaz (1990). Full appreciation of work done was not ranked as one of the most important motivational factors by Harpaz (1990), but was ranked second in this research and by Kovach (1987). The discrepancies in these research findings supports the idea that what motivates employees differs given the context in which the employee works. What is clear, however, is that employees rank interesting work as the most important motivational factor.
Implications for Centers and Extension
The ranked importance of motivational factors of employees at the centers provides useful information for the centers' director and employees. Knowing how to use this information in motivating centers' employees is complex. The strategy for motivating centers' employees depends on which motivation theories are used as a reference point. If Hertzberg's theory is followed, management should begin by focusing on pay and job security (hygiene factors) before focusing on interesting work and full appreciation of work done (motivator factors). If Adams' equity theory is followed, management should begin by focusing on areas where there may be perceived inequities (pay and full appreciation of work done) before focusing on interesting work and job security. If Vroom's theory is followed, management should begin by focusing on rewarding (pay and interesting work) employee effort in achieving organizational goals and objectives.
Regardless of which theory is followed, interesting work and employee pay appear to be important links to higher motivation of centers' employees. Options such as job enlargement, job enrichment, promotions, internal and external stipends, monetary, and non-monetary compensation should be considered. Job enlargement can be used (by managers) to make work more interesting (for employees) by increasing the number and variety of activities performed. Job enrichment can used to make work more interesting and increase pay by adding higher level responsibilities to a job and providing monetary compensation (raise or stipend) to employees for accepting this responsibility. These are just two examples of an infinite number of methods to increase motivation of employees at the centers. The key to motivating centers' employees is to know what motivates them and designing a motivation program based on those needs.
The results presented in this paper also have implications for the entire Cooperative Extension Sysyem. The effectiveness of Extension is dependent upon the motivation of its employees (Chesney, 1992; Buford, 1990; Smith, 1990). Knowing what motivates employees and incorporating this knowledge into the reward system will help Extension identify, recruit, employ, train, and retain a productive workforce. Motivating Extension employees requires both managers and employees working together (Buford, 1993). Extension employees must be willing to let managers know what motivates them, and managers must be willing to design reward systems that motivate employees. Survey results, like those presented here, are useful in helping Extension managers determine what motivates employees (Bowen & Radhakrishna, 1991). If properly designed reward systems are not implemented, however, employees will not be motivated.
References
Adams, J. S. (1965). Inequity in social exchange. In L. Berkowitz (ed.), Advances in experimental social psychology. New York: Academic Press.
Bedeian, A. G. (1993). Management (3rd ed.). New York: Dryden Press.
Bowen, B. E., & Radhakrishna, R. B. (1991). Job satisfaction of agricultural education faculty: A constant phenomena. Journal of Agricultural Education, 32 (2). 16-22.
Buford, J. A., Jr., Bedeian, A. G., & Lindner, J. R. (1995). Management in Extension (3rd ed.). Columbus, Ohio: Ohio State University Extension.
Buford, J. A., Jr. (1990). Extension management in the information age. Journal of Extension, 28 (1).
Buford, J. A., Jr. (1993). Be your own boss. Journal of Extension, 31 (1).
Chesney, C. E. (1992). Work force 2000: is Extension agriculture ready? Journal of Extension, 30 (2).
Dickson, W. J. (1973). Hawthorne experiments. In C. Heyel (ed.), The encyclopedia of management, 2nd ed. (pp. 298-302). New York: Van Nostrand Reinhold.
Harpaz, I. (1990). The importance of work goals: an international perspective. Journal of International Business Studies, 21. 75-93.
Herzberg, F., Mausner, B., & Snyderman, B. B. (1959). The motivation to work. New York: John Wiley & Sons.
Higgins, J. M. (1994). The management challenge (2nd ed.). New York: Macmillan.
Kovach, K. A. (1987). What motivates employees? Workers and supervisors give different answers. Business Horizons, 30. 58-65.
Kreitner, R. (1995). Management (6th ed.). Boston: Houghton Mifflin Company.
Maslow, A. H. (1943). A theory of human motivation. Psychological Review, July 1943. 370-396.
Skinner, B. F. (1953). Science and Human Behavior. New York: Free Press.
Smith, G. P. (1994). Motivation. In W. Tracey (ed.), Human resources management and development handbook (2nd ed.).
Smith, K. L. (1990). The future of leaders in Extension. Journal of Extension, 28 (1).
Terpstra, D. E. (1979). Theories of motivation: borrowing the best. Personnel Journal, 58. 376.
Vroom, V. H. (1964). Work and motivation. New York: Wiley.

This article is online at http://www.joe. org/joe/1998june /rb3.html.
 
 

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Camshaft Design




Camshaft Design.
Camshaft design today is an extremely complex process employing the use of computers in every phase of design analysis and testing not to mention the years of experience required to make these phases become reality. As complex as it is however, camshaft design, in its simplest form, may be broken down into two segments.
The first segment involves lobe placement on the camshaft. This establishes the very critical valve train event timing in relation to piston and crankshaft positions. It also establishes the displacement or separation of the intake lobe in relation to the exhaust. This placement is very critical and must be exactly the same for each cylinder. Lobe placement is one segment of the camshaft design experience that relies heavily on the designer's experience. As you already know, you may advance or retard the camshaft in the engine, but altering the displacement requires a new camshaft.
The second segment involves designing the lobe and clearance ramp profiles. By far, this is the most critical and difficult segment of camshaft design. In today's race engines you must develop a lobe profile that is aggressive enough to produce the desired rate of lift yet smooth enough to avoid new valve train problems. You must walk a very thin line here to take advantage of the attainable high R.P.M. power available with today's cylinder head designs, yet not lose it all to stress, deflection and failure of the valve train. More recently, significant power gains have been found through several new approaches to clearance ramp profiles.
Camshaft Terminology.
Camshaft terminology can sometimes become very confusing. The diagram below should help to explain some of the terms used in the design and selection of camshafts.
 
  1. Max Lift or Nose
  2. Flank
  3. Opening Clearance Ramp
  4. Closing Clearance Ramp
  5. Base Circle
  6. Exhaust Opening Timing Figure
  7. Exhaust Closing Timing Figure
  8. Intake Opening Timing Figure
  9. Intake Closing Timing Figure
  10. Intake to Exhaust Lobe Separation
 

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Quality Control: How To Respond To "Just Give Me a Dashboard!"




Quality Control: How To Respond To "Just Give Me a Dashboard!"

Buzzwords such as "dashboard" are currently exerting a great deal of attraction for my clients. Most everyone who's working to improve their company's performance management systems (which Gartner refers to as corporate performance management, CPM, rather than BPM) seems to be considering implementing data visualization tools that show, at a glance, how well the organization is meeting its goals. The IT and business communities are well aware of these technologies and expect great results from them. But many companies put too little thought into the development of dashboards.
 
Although the business value of displaying key performance indicators (KPIs) in a dashboard format is widely accepted, the circumstances under which such a tool delivers the most value are not widely understood. Vendors make the problem worse by promising results in just hours or days. Clients considering buying or building dashboards frequently say to me, "I need a quick way of presenting strategic performance indicators for my top management." The demand by business managers to receive a dashboard -- any dashboard -- as quickly as possible is often shortsighted and counterproductive. But the request provides an opportunity to get it done right.
Finance and IT must argue against moving forward with incomplete, poorly considered dashboard initiatives because the failure of such a project could harm the prospects for future business intelligence and CPM efforts. They must be prepared to redirect the "Just give me a dashboard!" demand into a more constructive discussion.

Learning From the Past

The demand for better management information hasn't changed much over the past two decades. In the 1980s, executive information systems (EISs) attained great popularity by promising to meet executives' need for accurate data about the performance of the business. Unfortunately, most EIS systems failed because their maintenance was too expensive to justify for the relatively small number of users who valued the information they provided. Their usefulness was limited because they were not integrated with the company's other reporting streams. Management viewed them as offering just one more set of data that had to be reconciled with other metrics and observations. As a consequence, these systems seemed to complicate matters, rather than providing clarity for decision-making.
The business need for quality information hasn't changed appreciably since EISs were popular, but two circumstances today boost dashboards' value. First, the business case for dashboards is easier to make. The technology required for a dashboard is much less expensive than EISs were, and today's dashboards are much easier to deploy to a large number of users, which mitigates the risk of running a pilot project. Second, dashboards today have the potential to truly simplify information for senior management, instead of adding to the confusion. The methodologies for managing performance are much clearer; they include the Balanced Scorecard, Six Sigma, and activity-based management. These concepts help companies identify the metrics executives actually need and avoid inundating them with information they don't need.

Setting the Right Scope

Unfortunately, the failure of EISs 15 years ago seems to be far from the minds of managers demanding dashboard solutions today. Most of those who lived through the EIS craze have forgotten the lessons learned, and younger managers were never exposed to them. Inquiries about today's dashboards sound very similar to requests for EIS systems two decades ago. The wrong response from finance and IT could doom a dashboard to the same fate as its predecessors.
One problem with many dashboard projects is that although executives ask for a "strategic" tool, they also want it to be "simple" -- and they want it immediately. They usually allot a very small budget to the project, as well, because they don't want to fund an expensive business intelligence initiative that may not generate ROI. This attitude leads to a misalignment between expectations that are high and strategic in nature and results that are limited and tactical. Another common problem is that executives seek individual metrics that seem important, rather than developing a system of metrics in a complete Balanced Scorecard framework or strategy map. Managers who are impatient with the timeline required to design a quality dashboard end up with metrics that don't present a clear picture of corporate progress.
In addition, many dashboard project managers avoid sharing results with the broader management team and keep costs to a minimum so that they can sail along below the organization' s radar screen. This is a valid strategy for initially testing the applicability of the dashboard concept, but if the initiative doesn't graduate beyond a "proof of concept" style project, the resulting system will not provide optimal performance. Companies focused on implementing the fastest and cheapest solution possible are not helped by CPM software vendors that encourage use of their products to complete a dashboard within a week or to choose KPIs within a few hours.

Defending Against Misguided Managers

Even when senior managers approach dashboards with skewed expectations, finance and IT staff should embrace their desire for such a system. A request for a dashboard is a sign that executives realize they need better management information. The resulting project can be an excellent test of which corporate data is readily available at high quality and which data is entered manually and fragmented. The project team can use a strategy map to evaluate how complete and predictive a company's management information is. In that sense, the dashboard initiative itself can function as a performance indicator by showing the auditability, speed, quality, and alignment of the information that's reported to top management.
Assuming that some trouble spots appear in the review of the quality of management data, the dashboard development process should include the following activities:
Properly define corporate metrics. Defining the right metrics is a collaborative process, and the discussions it entails can lead to a common understanding companywide about which KPIs are most important and how they relate to one another. The process starts with the executive team clarifying corporate strategy, determining the contribution that business units will make to that strategy, assigning project "owners" to supervise performance, and agreeing on a set of KPIs. But executives' definitions of metrics should allow room for clarification and refinement. Metrics shouldn't be imposed from the top down, either by management or by outside experts. That's a recipe for setting unrealistic targets, which almost always leads to failure because staff will find ways to evade performance measures they oppose. In contrast, when all of an organization' s stakeholders engage in a collaborative process that is initiated and led by management, then facilitated by a project team, they create conditions favorable to operational alignment throughout the company. And, after all, operational alignment is one of the objectives of a management dashboard.
Over time, companies should improve on their first set of metrics, refining the KPIs through a process I compare to peeling an onion, so that they eventually reach the core of the matter. Metrics that are not linked to objectives -- and objectives that are not linked to strategy -- are not useful. The groundwork required to select the right set of metrics is an integral part of any dashboard implementation project.
Consider metrics holistically to ensure you've selected the right ones. Organizations that don't use a framework such as the Balanced Scorecard to make sure their set of metrics is coherent can't expect to achieve value other than anecdotal indications of performance. To be predictive, metrics must be considered in the context of a strategy map, a cause-and-effect diagram of the relationships among objectives -- or, at a level of greater detail, among KPIs. Without a strategy map, a dashboard is nothing more than a means of visualizing uncoordinated metrics.
Give data management as much attention as it needs. Dashboards are always easier to create for companies that have already implemented a solid data warehouse infrastructure. This simplifies the integration of the needed data and its aggregation to the relevant levels. The dashboard is, after all, nothing more than the most aggregated level of corporate data.
Some vendors' software demos assume that customers have a good grasp of the KPIs that would be most beneficial to their business and that all the necessary data is already available and is both integrated and cleansed. This is seldom the case. Eighty percent of the effort behind most scorecard or dashboard initiatives consists of defining the metrics and finding the right data. In this regard, the lack of a budget for a dashboard initiative can actually work to a project team's advantage. Low funding may direct attention to the organization' s need for a comprehensive business intelligence and data warehousing strategy. The result of an effective business intelligence strategy is that the top layer -- the performance indicators in a dashboard -- can be automatically derived from the lower levels of information that the company already has available. All of the necessary data is there; the dashboard project simply aggregates it to one more level.
Gain the buy-in of managers throughout the company. The support of middle managers is crucial for translating a CPM strategy into action. The people in this layer of the organizational chart are responsible for the activities that bring corporate strategy to life. In my experience, whenever a CPM data-visualization tool provides basic drill-down capabilities, usage at the middle-management level takes off. The drill-down of KPIs into relevant breakouts provides tactical information that convinces middle management of the dashboard's value.
Yet middle management is often the group within a company that most actively resists CPM.. Business managers frequently fear that new reporting mechanisms will somehow expose them or threaten their power. One strategy for obtaining their buy-in is to cite the pressures that surround corporate compliance audits. Sarbanes-Oxley provides plenty of justification for simplifying reporting streams into "one version of the truth." Dashboard project leaders can also put the matter to managers in a more positive light by building a business case for sharing management data with many different stakeholders. Before the organization can assemble such information, all contributors of corporate performance data will have to examine their processes and develop controls to ensure that the information is accurate and timely.
Putting together a top-quality performance management dashboard isn't easy. Managers often expect a new tool to be a panacea, when technology actually is the least of their problems. The key to success is strategic alignment -- one version of the truth, with dashboards thoroughly integrated into management processes. The best dashboards are free; they're nothing more than the last step of aggregation of a well-defined set of metrics and management reports. If management demands a dashboard, treat it as a chance to pursue a complete business intelligence strategy.
Frank Buytendijk is vice president of corporate strategy for Hyperion. He helps drive strategic direction for Hyperion worldwide. Before joining Hyperion in early 2006, Buytendijk was a research vice president with Gartner.
 

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Time & Motion Studies




Time & Motion Studies

The idea of a Time and Motion Study is often still associated with production lines and manufacturing industry. It gained a bad reputation as a source of disagreement between "management" and "workers". However if used properly it can be of benefit to modern companies and their workforce.
This is a massive field - what follows is a brief overview.
Factory Life
Factory Life in 1898

History

Scientific Management

Time and Motion studes have their roots in the work of Frederick Winslow Taylor who in 1911 published his famous article "The Principles of Scientific Management". Essentially this involved getting the best person for each job and training them to do it the best way possible. Although Taylor believed in cooperation between management and workers, "Taylorism" can be seen as formalising the management/worker divide. Management would be responsible for deciding how things were done with workers simply doing what they were told. It was seen as dehumanising, reducing skilled workers to the status of mechanical parts and resources.

Gilbreths

Time and Motion study was refined in the early twentieth century by Frank and Lillian Gilbreth. The Gilbreths' preferred "motion study" to Taylor's "time study", however the term "Time and Motion" has tended to stick in popular terminology.
The Gilbreths studied the actions taken by workers at certain task with the aim of streamlining the processes involved. One of their most famous experiments involved analysing the work of bricklayers and significantly reducing the number of "operations" involved. This change benefited both employer (increased productivity) and employee (decreased fatigue).

Therbligs

The Gilbreths developed a categorisation system for the different basic activities which went to make up a task. These were called Therbligs (an anagram of "Gilbreths") . The basic Therbligs numbered around 15 (the system developed over time) and included such actions as "find", "select" and "rest". Each of these was represented by an icon, for example an eye for "find". The activity of a worker could then be plotted on a Simo Chart ("Simultaneous Motion Chart") for optimisation.
 

Hawthorne Effect

One problem for Time and Motion studies is what is known as the Hawthorne Effect (named after a factory not a person). This in essence says that employees change their behaviour when they know that they are being measured - the mere act of performing a study can improve performance. It's a form of "observer effect" akin to a productivity placebo.
The Hawthorne Effect also showed that productivity tends to improve whatever changes are made, then return to normal over time. This recognises that workers are human beings and that knowing they are valued can in itself inspire better performance.
The Hawthorne Effect doesn't undermine the value of Time and Motion studies but does emphasise that people are the most significant element of any workplace.
 

MTM

The original Time and Motion Study concepts led during the twentieth century to the development of Predetermined Motion Time Systems (PMTS) such as Methods-Time- Measurement (MTM). This was released in 1948 by Maynard, Stegemerten, & Schwab and is today found in three versions: MTM-1, MTM-2 and MTM-3

Mutual Benefits

In the"bad old days" of industrial relations, Time and Motion studies were often seen as a tool for the management to exploit the workers. The Time and Motion study - sometimes carried out in secret - could be used to pressurise people to work harder or lose their jobs. It's not surprising that many workers came to resent the whole concept of time & motion.
It needn't be that way. Modern analysis methodologies and software packages have little in common with the old image of a "Motion Man" timing workers with a stopwatch. A Time and Motion study carried out openly with full buy-in from all concerned can be of mutual benefit. Improvements can be made to working conditions and methods that both improve productivity and make working less stressful or reduce fatigue.
Perhaps the best way to ensure full cooperation is to ensure that any benefits of the study are shared between company and workforce. If efficiency improvements are identified then the gains can be shared between shareholders and workers, with the latter benefiting from greater wages or shorter hours.
Unfortunately too many companies today still see a Time and Motion study as simply a way to increase profits with no benefit returning to the workforce who are ultimately responsible for those profits.
 

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Friday, September 5, 2008

Cause & Effect Diagram




Cause & Effect Diagram

The cause & effect diagram is the brainchild of Kaoru Ishikawa, who pioneered quality management processes in the Kawasaki shipyards, and in the process became one of the founding fathers of modern management. The cause and effect diagram is used to explore all the potential or real causes (or inputs) that result in a single effect (or output). Causes are arranged according to their level of importance or detail, resulting in a depiction of relationships and hierarchy of events. This can help you search for root causes, identify areas where there may be problems, and compare the relative importance of different causes.
Causes in a cause & effect diagram are frequently arranged into four major categories. While these categories can be anything, you will often see:
  • manpower, methods, materials, and machinery (recommended for manufacturing)
  • equipment, policies, procedures, and people (recommended for administration and service).
These guidelines can be helpful but should not be used if they limit the diagram or are inappropriate. The categories you use should suit your needs. At SkyMark, we often create the branches of the cause and effect tree from the titles of the affinity sets in a preceding affinity diagram.
The C&E diagram is also known as the fishbone diagram because it was drawn to resemble the skeleton of a fish, with the main causal categories drawn as "bones" attached to the spine of the fish, as shown below.
The fishbone diagram, as originally drawn by Kaoru Ishikawa, is the classic way of displaying root causes of an observed effect
Cause & effect diagrams can also be drawn as tree diagrams, resembling a tree turned on its side. From a single outcome or trunk, branches extend that represent major categories of inputs or causes that create that single outcome. These large branches then lead to smaller and smaller branches of causes all the way down to twigs at the ends. The tree structure has an advantage over the fishbone-style diagram. As a fishbone diagram becomes more and more complex, it becomes difficult to find and compare items that are the same distance from the effect because they are dispersed over the diagram. With the tree structure, all items on the same causal level are aligned vertically.
The cause and effect diagram can also be drawn with right angles, which makes it less tangled, and easier to see what layer of causality is being considered at any given time.

To successfully build a cause and effect diagram:

  1. Be sure everyone agrees on the effect or problem statement before beginning.
  2. Be succinct.
  3. For each node, think what could be its causes. Add them to the tree.
  4. Pursue each line of causality back to its root cause.
  5. Consider grafting relatively empty branches onto others.
  6. Consider splitting up overcrowded branches.
  7. Consider which root causes are most likely to merit further investigation.
Other uses for the Cause and Effect tool include the organization diagramming, parts hierarchies, project planning, tree diagrams, and the 5 Why's.


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How Real is the Green Supply Chain?



How Real is the Green Supply Chain?

by Dan Gilmore 

I have held off writing about "the Green Supply Chain" and Sustainability for a long time, but here we go…As usual, I will probably get myself in a little trouble.. My "First Thoughts" on the subject – and what are to me the two key questions related to Green – are in this column. More over time.

Let's be clear upfront that in developed economies virtually 100% even of corporate executives, many environmentalists may be surprised to know, want a clean environment. All anyone has to do is visit Hilton Head Island, Yosemite National Park, or any of hundreds of other fantastic places and who could want anything but a wonderfully healthy ecosystem? The story is different in many developing economies, which is where we were 100 years ago.
Still, as with everything in life, there are trade-offs. We could outlaw cars tomorrow and get rid of a huge chunk of our carbon emissions, but of course only a few on the fringe would opt for that. And by the way, that might lead to a resurgence of horse-based transportation, which would have its own, shall we say, negative environmental impact (more on that theme in a bit). The point is that clearly not every Green decision is worth the trade-off.
Undoubtedly, in this environment, where Green is all the rage, it's hard for any company or individual to swim against the tide – and probably no one should. But I also get the sense right now that in many companies and circles if anyone was to actually suggest there are trade-offs to be considered, it might be a career-ending move, or make it appear you are some greedy, smog-loving cretin, which is nonsense.
Some points worth pondering:
  • It's no wonder many CEOs are at least publicly on board. When Fortune magazine named GE the world's most respected company a few years ago, it cited CEO Jeff Immelt's focus on Green as among the key factors. Other CEOs were watching, and would love to have themselves and their companies recognized in the same way.
  • It's clear to me at least that much of the corporate support for Green is as much for the potential to sell new products/technologi es as it is about saving the planet. As we recently reported, for example, a McKinsey survey found that 37% of manufacturing executives surveyed thought the risks and opportunities from the Green movement were roughly balanced for their firms, and another 21% thought the opportunities far outweighed the risks. So, you should take some of the Green rhetoric coming out of corporations with a grain of salt. (See Talk is Ahead of Action on Green Supply Chain, According to McKinsey Study.) GE may truly be interested in Green, but it's also happy to sell new, more expensive light bulbs and a new class of power generation equipment.
  • I don't like some of the coerciveness of the whole movement. I don't fully understand it, but there is something partly troublesome in the Carbon Disclosure Project's heavy hand in co-opting large investment banks to help pressure corporations to report carbon emissions, and sets in place a number of slippery slopes.
  • There are many obvious improvement areas that in retrospect should have been "No Brainers." Were transportation and packaging materials ever really so cheap that companies could afford to ship excess cube and pay for extra paper and plastic that were simply superfluous? I am confident that in the majority of cases, the return for the effort in improved packaging was always there, but was a treasure right in front of us that we just couldn't see. Nothing but positives here.
  • The interest in being Green obviously has been helped by the incredible rise in transportation and commodity costs. Whether you put a Green wrapper on it or not, taking out miles driven through network redesign, packaging changes, collaboration, etc., is just smart business right now.
  • We have to be very careful, however, to avoid knee-jerk decisions and the Law of Unintended Consequences. Easy example – certain cities banning plastic grocery bags in favor of paper, when it turns out - in total -the plastic is actually much more favorable to the environment. But there are many more examples. Most of us are aware, for instance, that the push for ethanol as a fuel has in part led to surging food prices worldwide, as demand for corn for energy purposes drove up the price for corn, led farmers to plant fewer soy beans, etc.  But it goes further than that. Farmers around the coast of Lake Erie in Ohio, for example, had been receiving some modest government incentive for leaving land fallow. Now, they find it more profitable to plant corn again. The result: the lake is being damaged by severe run off from the chemicals in the fertilizer that the farmers are now using again near estuaries.
To me, though, there are really two key questions.
First, will the consumer, or business customers, really pay more for the environmentally friendly product? I really haven't seen much data either way. One thing we absolutely know is that neither the consumer nor business will pay more for the "Made in the USA" product – but we think they will do so for the environmentally- friendly ones? Some segment, probably at the high end, likely would, but I am not sure how many beyond that, if offered a real choice. The implication of that, if it is accurate, is that Green improvements have to be at least cost neutral, and/or Green products must be mandated by government or Wal-Mart, Home Depot, etc.
Second, how will companies actually make Green decisions? My favorite example – what if there is a more environmentally- friendly industrial adhesive that will cost a couple of cents more a pound. Will a company buy that product instead of the regular adhesive? What if the raw material cost is the same, but manufacturing has to run the packaging line a bit slower because of slightly reduced performance?
The real issue is what framework will be put in place for making such decisions. Does the procurement manager have some guidelines in place that says you can increase supply chain costs under these circumstances or within these limits for a given level of Green improvement? How can any company manage these trade-off questions across potentially hundreds of decisions on a regular basis? Will it really be willing to increase supply chain costs to be more Green? And should the adhesive supplier put R&D into making the more Green product instead of reducing the cost of the current one?
I was at a recent conference and asked a new VP of Sustainability at a large consumer goods company these very questions. It was clear he wanted no part of an answer, and blew me off with some non-response about things will evolve. But that said a lot to me about the true state of affairs right now.
That's my perspective. As always, I am just trying to get at what's real.

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