Dr.%20W%20Edwards%20Deming

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The Red Bead Experiment

• Dr. W Edwards Deming

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White Bead Production Corporation

• JOB POSTINGS
• 1 Industrial Engineer/C.I. Coordinator. Train
  workers, enforce procedures, report compliance to
  management
• 4 Willing Workers. Must be willing to put forth
  best efforts. continuation of job is dependent
  on performance. Educational requirements minimal.
  Experience in pouring beads is not necessary.
• 2 Inspectors. Must be able to distinguish red
  from white, able to count to 25. Experience not
  necessary.
• 1 Inspector General. Same qualifications as
  Inspectors and have a loud voice.
• 1 Analyst. Must write legibly, good in basic math
  be sharp

POSITION FILLED
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White Bead Production Corporation

• Procedure WBD-HT81-C White Bead Generation.
• Required Tools Paddle, for retrieval of beads.
• Required Materials Container with beads.

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White Bead Production Corporation

• Process Steps
• Ensure paddle holes are empty of all beads.
• Grasp the paddle by the handle. Ensure that the
  holes are orientated facing upwards.
• Slide the paddle down into the beads until paddle
  is covered with beads. Pick up paddle to 4 inches
  above the bead level.
• Tilt paddle at a 47 degree angle to release
  excess beads.
• Withdraw paddle, ensuring that one bead is in
  each hole.
• Present to Quality Control for count of beads
  produced.
• Empty paddle back into bead container.

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White Bead Production Corporation

• Do it Right
• the
• First Time!

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White Bead Production Corporation

• Take Pride
• in Your
• Work!

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White Bead Production Corporation

• Procedure
• Compliance
• Is Mandatory.

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White Bead Production Corporation

• The Goal is
• 0

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White Bead Production Corporation

• The Goal is
• 1

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System of Profound Knowledge
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Knowledge of Psychology

• Rewarding or punishing the Willing Workers had no
  effect on the outcome. Extrinsic motivation is
  not effective.
• People are not always the dominant source of
  variability.
• Slogans, Exhortations and Posters Are At Best
  Useless To The Willing Worker.
• People want to do a good job

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Knowledge of Variation

• Numerical goals and production standards can be
  meaningless. The number of red beads produced is
  determined by the process, not by the standard.
• We can use statistics to create a quality control
  chart and look for problem areas and to predict
  future performance.
• A faulty item is not a signal of "special"
  causes. A process can be stable, in-control and
  be producing 100 percent defective items.
  "Defects" are defined by specification, not by
  process.

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Knowledge of Variation
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Knowledge of Variation

• Mean- Also called the average, a measurement of a
  center point in a data set.
• Standard Deviation A measurement of variation.
  Specifically a measure of how a set of data
  values fluctuate around the mean.
• Upper/lower control limits The highest/lowest
  value that can be expected to occur for a
  particular data set. 99.7300 of all results
  will fall between the upper and lower control
  limits.
• 3X Standard Deviation Mean

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Knowledge of Variation
Day 1 Day 2 Day 3 Day 4 Day 5 Day 5.5 Total Average
24601 9 20 8 8     45 11.3 3.2 Std Dev
24602 9 12 9 8 10 12 60 10.0 9.5 3 Std Dev
24603 16 9 12 11     48 12.0 10.8 Mean
24604 13 9 6 11 13 11 63 10.5
Mean 10.8 10.8 10.8 10.8 10.8 10.8
LCL 1.3 1.3 1.3 1.3 1.3 1.3
UCL 20.3 20.3 20.3 20.3 20.3 20.3
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Knowledge of Variation

• Excel Formulas
• MEAN Formula AVERAGE(B2G5)
• 3X Standard Deviation Formula 3STDEV(B2G5)
  
• UCL Formula mean cell3x std dev cell
• LCL Formula mean cell-3x std dev cell

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Knowledge of a System

• Its the system, not the workers alone that
  determine results
• Rigid and precise procedures are not sufficient
  to produce the desired quality.

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Knowledge of a System
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Theory of Knowledge

• If you want to improve performance, you must work
  on the system.
• Quality is made at the top. Quality is an
  outcome of the system. Top management owns the
  system.
• Keeping the place open with only the "best"
  workers was acting on "superstitious" knowledge
• Management was "tampering" with the system by
  rewarding and punishing the Willing Workers.
• Management never looked in the box/Gemba

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Management is Prediction
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Lessons Learned

• Thoughts from a Willing Worker named Ann. A
  Willing Worker named Ann, after the experiment on
  the Red Beads came to a close, expressed to Dr.
  Deming some provocative thoughts. She wrote her
  thoughts down in the following letter
• When I was a Willing Worker on the Red Beads, I
  learned more than statistical theory. I knew
  that the system would not allow me to meet the
  goal, but I still felt that I could. I wished
  to. I tried so hard. I felt responsibility
  others depended on me. My logic and emotions
  conflicted, and I was frustrated. Logic said
  there was no way to succeed. Emotion said that I
  could by trying. After it was over, I thought
  about my own work situation. How often are
  people in a situation that they can not govern,
  but wish to do their best? And people do their
  best. And after a while, what happens to their
  drive, their care, and their desire?

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Dr. W. Edwards Deming 1900 - 1993

• The Deming System of Profound Knowledge
• Appreciation of a system
• Knowledge of variation
• Theory of knowledge
• Knowledge of psychology

• Once the individual understands the system of
  profound knowledge, he will apply its principles
  in every kind of relationship with other people.
  He will have a basis for judgment of his own
  decisions and for transformation of the
  organizations that he belongs to. The individual,
  once transformed, will
• Set an example
• Be a good listener, but will not compromise
• Continually teach other people
• Help people to pull away from their current
  practices and beliefs and move into the new
  philosophy without a feeling of guilt about the
  past."

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Funnel Experiment
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Funnel Experiment
Team Roles
Ball dropper Places ball in funnel Calibration
Technician Puts blue dot on drop location,
measures distance from target in mm, reports
results to analyst Quality Analyst Enters drop
distance into spreadsheet Targeting Specialist
Ensures funnel is located directly over target