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The System Approach
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
1
What is a “System”? A system is a collection of parts, which interact with each other to function as a whole. --- Draper Kauffman, “Systems Thinking” A system is a perceived whole, whose elements “hang together” because they continually affect each other over time and operate toward a common purpose. --- Peter Senge, “Fifth Discipline” A system is a network of interdependent components that work together to try to accomplish the aim of the system. A system must have an aim (goal). Without aim there is no system. --W. Edwards Deming, “The New Economics”
INPUT
OUTPUT TRANSFORMATION
System: Input/Transformation/output scheme Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
2
What is a Solution? “input/transformation/output” system leading to added value to those who are willing to pay for such value addition! What is the Need ? Create and implement New Solutions Replicate known solutions in larger quantities
OUTPUT
INPUT
Perceived Needs: More Innovation More Entrepreneurship Work Smarter and Work Harder Keep Jumping From Job to Job Become Global Become Transformational Get Higher College Degrees Get More Skills Interdisciplinary
TRANSFORMATION
Now we know the why and what? But HOW?
What is a Solution? What is the Need? Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
What is a Solution? Solution:
“input/transformation/output” System, leading to added value with reward for such value addition!
INPUT
OUTPUT TRANSFORMATION
= KNOWLEDGE
Solution: KNOWLEDGE and its USE!
SYSTEM THINKING. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
4
Manufacturing: A collection of Physical Processes and Service Processes. Input
???
Transformation
Physical Processes
Output
Product
Service Processes
Service Processes: Anything to do with Information and logistics That collect process, analyze and disseminate information and decision making Physical Processes: Where physical change happens on the work material (e.g.): Cutting, grinding, EDM, ECM, Welding, Forming, Forging, ….. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Physical and Service Processes - Features Process Category
Physical Processes
Service Processes
Description Domain specific activities; directly impacted by technical professionals and their academic/sector specific skills
Domain neutral Information and logistics activities; impacted by IT applications solutions
Characteristic Features • • • • •
Physical sciences intensive Physical goods and inventory Relatively low end-user contact Capital/investment intensive Long development and implementation cycle
• • • • •
IT applications intensive Information and database Active end user contact Network and connectivity Relatively short development and shorter implementation cycle
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Quantum Improvement in Service Processes are Already Taking Place Traditional vs. World Class Today ? Set-up Time Quality
Plant or Space Utilization Work as a Function of Touch Time Value added Time/Total Time Material Velocity (Turns) Flexibility Number of SKUs Manufactured/Setup Distance a Part Travel through the Plant (From Receiving to Shipping Deck) Reliability of the System or Equipment
World Class (10 tears ago) < 10 minutes Down to 1 minute 1,500 ppm, 0.15% 300 ppm, 0.3%
> 50%
Traditional 2- 4 hours 20 - 30 minutes 3 - 5% inside the Co.2 - 5% warranty cost 15 - 25% of sales (true cost of quality) 25 - 30%
25 - 30%
2 - 4%
> 100 (3 days)
2 - 4 (3 months)
270 parts/machine tool
25 parts/machine tool
300 feet
> 1 mile (up to 2 or 3 miles)
90 - 95%
65 - 75%
Tools: Lean, Six Sigma, ERP, BPOs, Outsourcing, ……… Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Manufacturing Processes What is the Need? 95
100 75 Total Cost (Per Unit of Value or Benefit)
Situation
Present
Requirement to Meet Global Competitive Need: • New Materials • New Applications • New Processes
Incremental Improvement is not enough
Quantum (Large Scale) Improvement is the real need
“Better Mouse Trap” “Different Mouse Trap”
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Physical Processes Transformation -- Process -- USE
Known Solution
Unique or Industry/Sector Specific
Service Processes Information (IT) Logistics (LT)
Generic or Industry/Sector Neutral
Model for end of 20th Century manufacturing Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
New Solution
Service Processes Information (IT) Logistics (LT)
Generic or Industry/Sector Neutral
Physical Processes Transformation -- Product -- Process -- USE
Unique or Industry/Sector Specific
Model for Advanced Manufacturing for the 21st Century. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
System Thinking
Manufacturing Process - It is not a “Black Box” Input
Transformation
Output Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
11
System Thinking
Manufacturing Process - It is not just a Statistical Process
Input
Machine Tool Work Material Processing Tool Operational Factors
Transformation
Process Measures or Macroscopic Variables
Output
Technical/Economic Out put
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Statistical Process Control
12
The “System Approach” Machine Tool
Consumables Tools / Software
Microscopic Interactions Work/ Component
Technical Output What is the process producing?
Process Parameters/ Constraints
System Output Why are we interested in the process?
Process Economics Measurement during the process
Measurement and Analysis
Diagnostic Tools & Methods Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
13
Manufacturing Process: It is a “System” Input
Transformation Work / Components
Output
Microscopic Interactions Technical Output Mechanical
Electrical
Thermal
Chemical
Tools/ Consumables
Economic/ System Output Macroscopic Variables/Measures
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Why do we need The System Approach ? Machine Tool
Consumables Tools / Software
Microscopic Interactions Work/ Component
Jigsaw puzzle
Process Parameters/ Constraints
Process Solution is a puzzle and requires either...
> One person with many years of experience with many companies, products and applications. There are few people like this.
> Or, many people, each with a little knowledge, to fit together and solve the “puzzle” – the problem. This is very difficult and inefficient.
Why are we interested in the process?
What is the process producing?
Process Economics
Measurement during the process
Diagnostic Tools & Methods
System Output
Technical Output
Measurement and Analysis
Use the System Approach • Every person has the same information • Everyone’s knowledge is integrated into a common framework • Awareness: Fill all the boxes as much as we can. Then ask questions where the box is empty • Analysis: Which question to be asked and in what order?
Dr. K. (Subbu) Subramanian >STIMS So what do we do? Based Technology Innovation and Management Solutions) Institute (Science [email protected]
15
The System Approach: Integrating the Knowledge End User
Tools/ Consumables
Process
Raw Materials
Machine Tool
Supplier – Application/USE
of every one involved in the Process (e.g): Grinding Process Transformation
Industry: -- Transportation/Energy/ Housing/High tech./DYI/ ….
Use: --- Raw Materials/ S.F. Goods/ Components/Sub Assembly/ Assembly/Repair/ Maintenance
Geography Application: --- Rough/Precision/U. Precision
Grinding - Process
Materials / Parts
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Product
Metal --- Ferrous/Non Ferrous/Alloys Non – Metals --- Ceramics/Glass/Carbides --- Wood/Concrete/Minerals --- Composites/Crystals 16
Sources of “Knowledge” 20st Century Paradigm:
End of 20th Century Skills for
Academic Education
Transformation (Recognized by chance)
Industry/ Sector Specific Knowledge
Industry/ Sector Specific Knowledge
Academic Education
Transformational Skills (to Identify, Create and Implement “New” Solutions).
(Primary Source of Knowledge)
20th Century Paradigm
End of 20th Century
Sources of Knowledge and their order – 20th Century Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Ordering of “Knowledge” required for success in the 21st Century Skills for Transformation Industry / Sector Specific Knowledge Academic Education
• • • •
Building blocks to be used in an inter-dependent manner; Knowledge Integration in all three building blocks as needed. Use resources available from any where Generate impact across the globe.
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Transformational Skills for 21st century Technical Professionals.
Deploy
Emotional Intelligence for “New Solutions”. End to End Innovation Build Eco-system for Core technology Platforms
Develop
Emphasis on Science and “Mobile Diagnostics” System Approach (Knowledge Integration)
Discover
3 D View of Core Capabilities
Develop Common Language
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Transformational Skills required for success in the 21st Century • Identify “New” Solutions : • Develop a “Common Language” • 3D View of Core Capabilities
• Develop “New “ Solutions - Knowledge Integration: • The System Approach – relentlessly ask the question “Why?” and also find the answers. (the next wave after Lean and Six Sigma) • Scientific reasoning and use of Mobile Diagnostic Tools • Integration of knowledge from all sources from across the globe
• Implement “New Solutions”: • Innovation Culture : End to End Innovation • Emotional Intelligence of Leadership, Innovation and Entrepreneurship. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
20
Solution: with a nucleus composed of “Physical Processes” integrally linked with a collection of service processes
Service Processes
Physical Processes
Product
Professional
Physical Processes
Product
Process Department/Function
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Physical Processes
Product
Company
The System Approach:
Breadth or Scope “Zoom out” Knowledge
Depth or Uniqueness “Zoom in”
Experience
Service
Professional
Science
Engineering Management
Process Solution / Company
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Physical Technology
Alignment of core capabilities at each level. Finance/Mkt. Digital Drivers Technology
Industry Sector
Depth / Unique
Why not ? (Synthesis)
Breadth or Scope How and Why? (Analysis)
What? (Awareness)
Three levels of System Skills.
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
23
Traditional:
Cause Effect
Fish Bone Diagram
Need Investment
Technical Output
Transformation (Physics)
Expenses
Effect
System Output
Value or Benefit
Constraints
Engineering
Science Strategy
The System Approach Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
24
The System Approach: There are four input categories leading to the transformation and the outputs.
Capital, Equipment / Fixed Assets
Product / Unmet need
INPUT
Transformation
OUTPUT
Product
$$$$$$
Expenses / Resources/ V. Cost
Value or Benefits
Constraints
Sales, Profits, Business Performance Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Technology = Knowledge and its Integration ! = “Science” + “Engineering” + “Management” (Operations + Strategy)
Machine Tool
Work/ Component
Consumables Tools / Software Process Parameters/ Constraints
Engineering Microscopic Interactions
Management Technical Output What is the process producing?
System Output Why are we interested in the process?
Science Measurement
Process Economics Measurement and Analysis
Diagnostic Tools & Methods Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
26
Solution Technology Engineering
Technology: integration of Science, Engineering and Management, leading to new solution.
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Science:
Understanding the “Transformation” •What really happens during the “Process”? •Microscopic Interactions: • The represent the “Physical Science” • They can not be “seen” • They can be measured, analyzed and inferred Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Engineering: Application of the “Transformation”
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
29
What is “management” ? Strategy What ? Why ?
PLAN ORGANIZE COORDINATE CONTROL
Management PLAN How ? ORGANIZE COORDINATE When ? CONTROL
Operations Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Your Education: The system Approach for Grinding Processes; Can be used in every aspect of the job in the company
Manufacturing Technology
Application / USE Technology
Product Technology Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Process Technology
1.
Management (Strategy)
+ Management (Operations)
Establish the System Outputs: Why?
Identify the stakeholders, their benefits, and priorities
6. Document the New Solution (How?) With improvements in the technical and system outputs
2. Document the process as Input/Transformation/ Output System: What?
and Engineering
+
5. Implement the changes (How?) Simultaneously needed in all four input groups to influence the transformation
Science
The System Approach - Implementation Methodology
3. Establish the Technical Outputs: What do we want from the process?
4. Diagnose and Interpret:
Obtain the “vital signs”; what do they infer about the transformation (core capabilities): Why?
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Five Steps in the Scientific Approach to Problem Solving: —Diagnostics —Problem Solving Component Equipment PROCESS —Process Improvement Transformation Operational Tooling -—Process Maintenance Parameters —New Solution or Step Change Process Output
In-Process Measurement
Monitoring
>160%
Process Improvement
Diagnostic Tools
New Solution
120%
Base Line 100% 80%
Problem resolution Why ??? Diagnostics
Progressive Impact of “Science” Backed Up by Diagnostic Tools Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Technical Output
System Output
Knowledge Integration (1) : Sharing the power to gain new Knowledge.
You can’t get something for “nothing”! $ Investment Machine / Platform
$$$$$$$ Consumables Tools / Software
Transformation Need / Application/ Component
Technical Output
Process Parameters/ Constraints
What is the process producing?
System Output Why are we interested in the process?
Portable Diagnostic Tools, Methods and data analysis
Stake holders (KNOWLEDGE) Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Share Holders Benefits (POWER) 34
Knowledge (System Thinking)
Knowledge Integration (2) : Using the power together with new Knowledge. • • • • • • •
Higher Productivity Better Quality New Solutions New Products New Markets Sales Increase Profit Growth
Power (Resources) Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
35
The System Approach – Summary •
Every process represents a Input/ Transformation /Output system. • We need to define the “context” of the system to further develop solutions based on that.
•
The outputs of any system can be identified in two Categories: • Technical Output: “What” is the Solution? What are the deliverables?
•
System Output: “Why” are we interested in the solution? Why these deliverables?
•
The inputs to the system can be grouped under four distinct categories: • Machine Tool, Abrasives, coolants and other consumables, Work Material or components to be finished and Operational parameters •
All inputs to the system are channeled through these four input categories
•
All those who contribute to the inputs: • Also seek/gain their benefits through the “system outputs”! • They are also the sources of knowledge pertaining to the system. • Weakness in knowledge or contribution in any of these four input categories ultimately affects the system / solution outputs.
•
The system is configured or designed to transform/modify or change the input into the outputs, to achieve the finished parts of required quality, productivity, cost and performance.
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
36
Transformation or Microscopic Interactions • • • •
Is not a black box or “statistical” It is the effect or interactions, which occur when the inputs are brought together. Represents the “Phenomena” of nature, which are “subtle” and intangible BUT, they can be inferred through: • • • •
•
•
•
• •
Changes in inputs and their effect Changes in outputs Measurements or data obtained in real time (when the transformation happens) Interpretation of the real time signals and inferences based on them
They are useful to understand the effect of changes in inputs and their result as seen in the outputs in a deterministic manner . This knowledge on the cause and effect as influenced by the transformation is called “Science”. Application of the Transformation or microscopic interactions through proper integration of the relevant inputs across the four input categories to obtain the required technical outputs is called “Engineering”. Establishing which transformation to use and why (Strategy) and how to execute that efficiently, economically and in a timely manner (Operations) is called “Management”.
The System Approach is a frame work or methodology to integrate the Science, Engineering and Management aspects of any Input/Transformation/Output system. Hence the System Approach enables the engineer to span wide (zoom out) to address the engineering and management aspects and also dive deep (zoom in) on the scientific aspects of the problem or solution as required. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
37
The System Approach – Summary •
When all input groups are changed simultaneously for the same effect on the “transformation,” – the science - the output is always “quantum” or large scale in nature, (i.e.), the whole is larger than the mere sum of its parts.
•
When the input groups are changed or altered individually (one at a time and over a period of time), even for the same effect on the transformation, the output is generally incremental in nature. • In this case, the conflicting effects of the input groups and their variability over time, sometimes cancel each other, resulting in minimal net gain. • This is the serious underlying risk in all our efforts toward continuous improvement.
•
Signals pertaining to the “Transformation” represent the vital signs of the system / process or the solution. They are collected as in-process data. Digital Tools are very useful to collect and process such in-process data.
•
Power of Digital data:
•
Data and analysis of signals pertaining to the Transformation can be used for: — Diagnostics — Problem Solving — Process Improvement -— Process Maintenance — New Solution or Step Change
Mine, Model, Experiment, Decide, Predict
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
38
The System Approach – Summary Data and analysis of signals pertaining to the Transformation can be used for: • Collect and compare base line information Feature recognition
• Resolve Process problems. • Estimation of the capability of the equipment and other inputs to the system: Stiffness, Accuracy, Precision, Process capability,…
• Analysis / Performance comparison: Over time Across machines or across systems. Across plants or locations Analytics Data Science
• Development of New Products (R&D) • Implementing “New “ Products and Processes
• Complaint Investigations Reduce learning time Reduce credits or warranty costs Reduce set up and debugging efforts. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
39
The “System Approach” Machine Tool
Consumables Tools / Software
Microscopic Interactions Work/ Component
Technical Output What is the process producing?
Process Parameters/ Constraints
System Output Why are we interested in the process?
Process Economics Measurement during the process
Measurement and Analysis
Diagnostic Tools & Methods Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
40
Thank You!
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
41
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
1
What is a “System”? A system is a collection of parts, which interact with each other to function as a whole. --- Draper Kauffman, “Systems Thinking” A system is a perceived whole, whose elements “hang together” because they continually affect each other over time and operate toward a common purpose. --- Peter Senge, “Fifth Discipline” A system is a network of interdependent components that work together to try to accomplish the aim of the system. A system must have an aim (goal). Without aim there is no system. --W. Edwards Deming, “The New Economics”
INPUT
OUTPUT TRANSFORMATION
System: Input/Transformation/output scheme Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
2
What is a Solution? “input/transformation/output” system leading to added value to those who are willing to pay for such value addition! What is the Need ? Create and implement New Solutions Replicate known solutions in larger quantities
OUTPUT
INPUT
Perceived Needs: More Innovation More Entrepreneurship Work Smarter and Work Harder Keep Jumping From Job to Job Become Global Become Transformational Get Higher College Degrees Get More Skills Interdisciplinary
TRANSFORMATION
Now we know the why and what? But HOW?
What is a Solution? What is the Need? Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
What is a Solution? Solution:
“input/transformation/output” System, leading to added value with reward for such value addition!
INPUT
OUTPUT TRANSFORMATION
= KNOWLEDGE
Solution: KNOWLEDGE and its USE!
SYSTEM THINKING. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
4
Manufacturing: A collection of Physical Processes and Service Processes. Input
???
Transformation
Physical Processes
Output
Product
Service Processes
Service Processes: Anything to do with Information and logistics That collect process, analyze and disseminate information and decision making Physical Processes: Where physical change happens on the work material (e.g.): Cutting, grinding, EDM, ECM, Welding, Forming, Forging, ….. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Physical and Service Processes - Features Process Category
Physical Processes
Service Processes
Description Domain specific activities; directly impacted by technical professionals and their academic/sector specific skills
Domain neutral Information and logistics activities; impacted by IT applications solutions
Characteristic Features • • • • •
Physical sciences intensive Physical goods and inventory Relatively low end-user contact Capital/investment intensive Long development and implementation cycle
• • • • •
IT applications intensive Information and database Active end user contact Network and connectivity Relatively short development and shorter implementation cycle
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Quantum Improvement in Service Processes are Already Taking Place Traditional vs. World Class Today ? Set-up Time Quality
Plant or Space Utilization Work as a Function of Touch Time Value added Time/Total Time Material Velocity (Turns) Flexibility Number of SKUs Manufactured/Setup Distance a Part Travel through the Plant (From Receiving to Shipping Deck) Reliability of the System or Equipment
World Class (10 tears ago) < 10 minutes Down to 1 minute 1,500 ppm, 0.15% 300 ppm, 0.3%
> 50%
Traditional 2- 4 hours 20 - 30 minutes 3 - 5% inside the Co.2 - 5% warranty cost 15 - 25% of sales (true cost of quality) 25 - 30%
25 - 30%
2 - 4%
> 100 (3 days)
2 - 4 (3 months)
270 parts/machine tool
25 parts/machine tool
300 feet
> 1 mile (up to 2 or 3 miles)
90 - 95%
65 - 75%
Tools: Lean, Six Sigma, ERP, BPOs, Outsourcing, ……… Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Manufacturing Processes What is the Need? 95
100 75 Total Cost (Per Unit of Value or Benefit)
Situation
Present
Requirement to Meet Global Competitive Need: • New Materials • New Applications • New Processes
Incremental Improvement is not enough
Quantum (Large Scale) Improvement is the real need
“Better Mouse Trap” “Different Mouse Trap”
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Physical Processes Transformation -- Process -- USE
Known Solution
Unique or Industry/Sector Specific
Service Processes Information (IT) Logistics (LT)
Generic or Industry/Sector Neutral
Model for end of 20th Century manufacturing Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
New Solution
Service Processes Information (IT) Logistics (LT)
Generic or Industry/Sector Neutral
Physical Processes Transformation -- Product -- Process -- USE
Unique or Industry/Sector Specific
Model for Advanced Manufacturing for the 21st Century. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
System Thinking
Manufacturing Process - It is not a “Black Box” Input
Transformation
Output Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
11
System Thinking
Manufacturing Process - It is not just a Statistical Process
Input
Machine Tool Work Material Processing Tool Operational Factors
Transformation
Process Measures or Macroscopic Variables
Output
Technical/Economic Out put
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Statistical Process Control
12
The “System Approach” Machine Tool
Consumables Tools / Software
Microscopic Interactions Work/ Component
Technical Output What is the process producing?
Process Parameters/ Constraints
System Output Why are we interested in the process?
Process Economics Measurement during the process
Measurement and Analysis
Diagnostic Tools & Methods Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
13
Manufacturing Process: It is a “System” Input
Transformation Work / Components
Output
Microscopic Interactions Technical Output Mechanical
Electrical
Thermal
Chemical
Tools/ Consumables
Economic/ System Output Macroscopic Variables/Measures
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Why do we need The System Approach ? Machine Tool
Consumables Tools / Software
Microscopic Interactions Work/ Component
Jigsaw puzzle
Process Parameters/ Constraints
Process Solution is a puzzle and requires either...
> One person with many years of experience with many companies, products and applications. There are few people like this.
> Or, many people, each with a little knowledge, to fit together and solve the “puzzle” – the problem. This is very difficult and inefficient.
Why are we interested in the process?
What is the process producing?
Process Economics
Measurement during the process
Diagnostic Tools & Methods
System Output
Technical Output
Measurement and Analysis
Use the System Approach • Every person has the same information • Everyone’s knowledge is integrated into a common framework • Awareness: Fill all the boxes as much as we can. Then ask questions where the box is empty • Analysis: Which question to be asked and in what order?
Dr. K. (Subbu) Subramanian >STIMS So what do we do? Based Technology Innovation and Management Solutions) Institute (Science [email protected]
15
The System Approach: Integrating the Knowledge End User
Tools/ Consumables
Process
Raw Materials
Machine Tool
Supplier – Application/USE
of every one involved in the Process (e.g): Grinding Process Transformation
Industry: -- Transportation/Energy/ Housing/High tech./DYI/ ….
Use: --- Raw Materials/ S.F. Goods/ Components/Sub Assembly/ Assembly/Repair/ Maintenance
Geography Application: --- Rough/Precision/U. Precision
Grinding - Process
Materials / Parts
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Product
Metal --- Ferrous/Non Ferrous/Alloys Non – Metals --- Ceramics/Glass/Carbides --- Wood/Concrete/Minerals --- Composites/Crystals 16
Sources of “Knowledge” 20st Century Paradigm:
End of 20th Century Skills for
Academic Education
Transformation (Recognized by chance)
Industry/ Sector Specific Knowledge
Industry/ Sector Specific Knowledge
Academic Education
Transformational Skills (to Identify, Create and Implement “New” Solutions).
(Primary Source of Knowledge)
20th Century Paradigm
End of 20th Century
Sources of Knowledge and their order – 20th Century Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Ordering of “Knowledge” required for success in the 21st Century Skills for Transformation Industry / Sector Specific Knowledge Academic Education
• • • •
Building blocks to be used in an inter-dependent manner; Knowledge Integration in all three building blocks as needed. Use resources available from any where Generate impact across the globe.
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Transformational Skills for 21st century Technical Professionals.
Deploy
Emotional Intelligence for “New Solutions”. End to End Innovation Build Eco-system for Core technology Platforms
Develop
Emphasis on Science and “Mobile Diagnostics” System Approach (Knowledge Integration)
Discover
3 D View of Core Capabilities
Develop Common Language
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Transformational Skills required for success in the 21st Century • Identify “New” Solutions : • Develop a “Common Language” • 3D View of Core Capabilities
• Develop “New “ Solutions - Knowledge Integration: • The System Approach – relentlessly ask the question “Why?” and also find the answers. (the next wave after Lean and Six Sigma) • Scientific reasoning and use of Mobile Diagnostic Tools • Integration of knowledge from all sources from across the globe
• Implement “New Solutions”: • Innovation Culture : End to End Innovation • Emotional Intelligence of Leadership, Innovation and Entrepreneurship. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
20
Solution: with a nucleus composed of “Physical Processes” integrally linked with a collection of service processes
Service Processes
Physical Processes
Product
Professional
Physical Processes
Product
Process Department/Function
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Physical Processes
Product
Company
The System Approach:
Breadth or Scope “Zoom out” Knowledge
Depth or Uniqueness “Zoom in”
Experience
Service
Professional
Science
Engineering Management
Process Solution / Company
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Physical Technology
Alignment of core capabilities at each level. Finance/Mkt. Digital Drivers Technology
Industry Sector
Depth / Unique
Why not ? (Synthesis)
Breadth or Scope How and Why? (Analysis)
What? (Awareness)
Three levels of System Skills.
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
23
Traditional:
Cause Effect
Fish Bone Diagram
Need Investment
Technical Output
Transformation (Physics)
Expenses
Effect
System Output
Value or Benefit
Constraints
Engineering
Science Strategy
The System Approach Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
24
The System Approach: There are four input categories leading to the transformation and the outputs.
Capital, Equipment / Fixed Assets
Product / Unmet need
INPUT
Transformation
OUTPUT
Product
$$$$$$
Expenses / Resources/ V. Cost
Value or Benefits
Constraints
Sales, Profits, Business Performance Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Technology = Knowledge and its Integration ! = “Science” + “Engineering” + “Management” (Operations + Strategy)
Machine Tool
Work/ Component
Consumables Tools / Software Process Parameters/ Constraints
Engineering Microscopic Interactions
Management Technical Output What is the process producing?
System Output Why are we interested in the process?
Science Measurement
Process Economics Measurement and Analysis
Diagnostic Tools & Methods Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
26
Solution Technology Engineering
Technology: integration of Science, Engineering and Management, leading to new solution.
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Science:
Understanding the “Transformation” •What really happens during the “Process”? •Microscopic Interactions: • The represent the “Physical Science” • They can not be “seen” • They can be measured, analyzed and inferred Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Engineering: Application of the “Transformation”
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
29
What is “management” ? Strategy What ? Why ?
PLAN ORGANIZE COORDINATE CONTROL
Management PLAN How ? ORGANIZE COORDINATE When ? CONTROL
Operations Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Your Education: The system Approach for Grinding Processes; Can be used in every aspect of the job in the company
Manufacturing Technology
Application / USE Technology
Product Technology Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Process Technology
1.
Management (Strategy)
+ Management (Operations)
Establish the System Outputs: Why?
Identify the stakeholders, their benefits, and priorities
6. Document the New Solution (How?) With improvements in the technical and system outputs
2. Document the process as Input/Transformation/ Output System: What?
and Engineering
+
5. Implement the changes (How?) Simultaneously needed in all four input groups to influence the transformation
Science
The System Approach - Implementation Methodology
3. Establish the Technical Outputs: What do we want from the process?
4. Diagnose and Interpret:
Obtain the “vital signs”; what do they infer about the transformation (core capabilities): Why?
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Five Steps in the Scientific Approach to Problem Solving: —Diagnostics —Problem Solving Component Equipment PROCESS —Process Improvement Transformation Operational Tooling -—Process Maintenance Parameters —New Solution or Step Change Process Output
In-Process Measurement
Monitoring
>160%
Process Improvement
Diagnostic Tools
New Solution
120%
Base Line 100% 80%
Problem resolution Why ??? Diagnostics
Progressive Impact of “Science” Backed Up by Diagnostic Tools Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Technical Output
System Output
Knowledge Integration (1) : Sharing the power to gain new Knowledge.
You can’t get something for “nothing”! $ Investment Machine / Platform
$$$$$$$ Consumables Tools / Software
Transformation Need / Application/ Component
Technical Output
Process Parameters/ Constraints
What is the process producing?
System Output Why are we interested in the process?
Portable Diagnostic Tools, Methods and data analysis
Stake holders (KNOWLEDGE) Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
Share Holders Benefits (POWER) 34
Knowledge (System Thinking)
Knowledge Integration (2) : Using the power together with new Knowledge. • • • • • • •
Higher Productivity Better Quality New Solutions New Products New Markets Sales Increase Profit Growth
Power (Resources) Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
35
The System Approach – Summary •
Every process represents a Input/ Transformation /Output system. • We need to define the “context” of the system to further develop solutions based on that.
•
The outputs of any system can be identified in two Categories: • Technical Output: “What” is the Solution? What are the deliverables?
•
System Output: “Why” are we interested in the solution? Why these deliverables?
•
The inputs to the system can be grouped under four distinct categories: • Machine Tool, Abrasives, coolants and other consumables, Work Material or components to be finished and Operational parameters •
All inputs to the system are channeled through these four input categories
•
All those who contribute to the inputs: • Also seek/gain their benefits through the “system outputs”! • They are also the sources of knowledge pertaining to the system. • Weakness in knowledge or contribution in any of these four input categories ultimately affects the system / solution outputs.
•
The system is configured or designed to transform/modify or change the input into the outputs, to achieve the finished parts of required quality, productivity, cost and performance.
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
36
Transformation or Microscopic Interactions • • • •
Is not a black box or “statistical” It is the effect or interactions, which occur when the inputs are brought together. Represents the “Phenomena” of nature, which are “subtle” and intangible BUT, they can be inferred through: • • • •
•
•
•
• •
Changes in inputs and their effect Changes in outputs Measurements or data obtained in real time (when the transformation happens) Interpretation of the real time signals and inferences based on them
They are useful to understand the effect of changes in inputs and their result as seen in the outputs in a deterministic manner . This knowledge on the cause and effect as influenced by the transformation is called “Science”. Application of the Transformation or microscopic interactions through proper integration of the relevant inputs across the four input categories to obtain the required technical outputs is called “Engineering”. Establishing which transformation to use and why (Strategy) and how to execute that efficiently, economically and in a timely manner (Operations) is called “Management”.
The System Approach is a frame work or methodology to integrate the Science, Engineering and Management aspects of any Input/Transformation/Output system. Hence the System Approach enables the engineer to span wide (zoom out) to address the engineering and management aspects and also dive deep (zoom in) on the scientific aspects of the problem or solution as required. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
37
The System Approach – Summary •
When all input groups are changed simultaneously for the same effect on the “transformation,” – the science - the output is always “quantum” or large scale in nature, (i.e.), the whole is larger than the mere sum of its parts.
•
When the input groups are changed or altered individually (one at a time and over a period of time), even for the same effect on the transformation, the output is generally incremental in nature. • In this case, the conflicting effects of the input groups and their variability over time, sometimes cancel each other, resulting in minimal net gain. • This is the serious underlying risk in all our efforts toward continuous improvement.
•
Signals pertaining to the “Transformation” represent the vital signs of the system / process or the solution. They are collected as in-process data. Digital Tools are very useful to collect and process such in-process data.
•
Power of Digital data:
•
Data and analysis of signals pertaining to the Transformation can be used for: — Diagnostics — Problem Solving — Process Improvement -— Process Maintenance — New Solution or Step Change
Mine, Model, Experiment, Decide, Predict
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
38
The System Approach – Summary Data and analysis of signals pertaining to the Transformation can be used for: • Collect and compare base line information Feature recognition
• Resolve Process problems. • Estimation of the capability of the equipment and other inputs to the system: Stiffness, Accuracy, Precision, Process capability,…
• Analysis / Performance comparison: Over time Across machines or across systems. Across plants or locations Analytics Data Science
• Development of New Products (R&D) • Implementing “New “ Products and Processes
• Complaint Investigations Reduce learning time Reduce credits or warranty costs Reduce set up and debugging efforts. Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
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The “System Approach” Machine Tool
Consumables Tools / Software
Microscopic Interactions Work/ Component
Technical Output What is the process producing?
Process Parameters/ Constraints
System Output Why are we interested in the process?
Process Economics Measurement during the process
Measurement and Analysis
Diagnostic Tools & Methods Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
40
Thank You!
Dr. K. (Subbu) Subramanian STIMS Institute (Science Based Technology Innovation and Management Solutions) [email protected]
41
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