William Edwards Deming

William Edwards Deming (1900-1993) was an American statistician and physicist, as well as a pioneer in the field of quality management. In the 1940’s he developed the process-oriented perspective of business activities, which were later introduced into various tutorials on quality management.

However, for many years Deming’s discoveries received very little attention in the U.S. Not so in Japan. There his insights were of great interest to leading industry managers. Why? The explanation given is that in the U.S. a maximization of production volume was the primary focus of industry following the worldwide reduction of production capacity following WWII.

This was possible to do without problem in the un-damaged USA. War-torn Japan, however, had limited resources for production, which pulled the optimization of processes into the foreground.

Deming’s story is initially a comparison between the U.S. and Japan. Yet the reasons why Japan’s industries became so process-oriented surely provide insight as to how Germany became to be so process-focused as well.

Listen to the first 3.5 minutes of Steve Jobs:

Audi assembly 2023

You can see how Audi R8, RS5, S5, A5 and Q2 is produced. There is even video of making E-engine of Audi.

https://youtu.be/fplEc51KLQ8

YouTube comments:

“Great video displaying the quality in manufacturing Audi takes in building their cars. Also, I did not know that Audi had supermodels working for them. ;)”

“The level.of automation in the factory is just amazing. The quality checks are spot on. The ergonomic set up of workstations are splendid.”

“Great content! I love this I absolutely love Audi and what they are going. They are a great company. I don’t think you would get this kind of quality from a Tesla. Keep up the great work!”

MAN truck manufacturing

How MAN trucks are made. Production by robots and employees in Scania, Renault, DAF, MACK, Freightliner etc. Manufacturing video from start to finish.

https://youtu.be/MWa2U9Rqgy8

YouTube comments:

“Convincing efficient precision machinery and correspondingly qualified personnel. My admiration.”

“Just as Tesla is revolutionary car assembly and dominate in BEVs with its Gigafactories and Gigacastings it will soon be revolutionizing in SemiTruck production and dominate in BE Trucks.”

Adam Smith and the division of labor

Adam Smith’s understanding of a process – in the sense of division of labor – can be read in his famous statement about how a pin is producted:

”One man draws out the wire, another straights it, a third cuts it, a fourth points it, a fifth grinds it at the top for receiving the head: to make the head requires two or three distinct operations: to put it on is a particular business, to whiten the pins is another … and the important business of making a pin is, in this manner, divided into about eighteen distinct operations, which in some manufactories are all performed by distinct hands, though in others the same man will sometime perform two or three of them.”

Optimum pairings

In one episode of the American television show Community, when eight people have to divide into partners, they first divide without considering any variables or long-term consequences. Shortly afterwards, however, they are so annoyed with their imperfectly chosen lab partners, that they decide to find a way to be in their optimum pairings.

This leads to them spending all night, and most of the following day, trying to decide what those optimum pairings are. They try several different systems to find new partners, including dividing by hair-color/gender/race, old/young, highest/lowest GPAs, and finally by rating each other then pairing the most popular with the least popular, etc.

After a failed attempt to implement the rating system, the 8 people succumb to fighting, angry at each other for the rankings they received. Finally, more than 12 hours after beginning the optimization process, the characters realize that their class is about to start, but none of them have done their work. 

They go to class, and the teacher is so angry with them for not doing their work, and not even knowing who their partners are, that he forces 7 out of the 8 “partners” to all share one set of lab equipment, while the rest of the class no longer has to share.

German artisans

Germans believe that processes — how the work is done — are the key to success. Americans, however, favor relationships, or how to gain and retain customers.

By tradition, Germany is more a culture of artisans (Handwerkerkultur) than of traders (Händlerkultur). The Germans have always made things. And they believe that process — how the work is done — is the key to success. Good processes lead to good products, bad processes to bad ones.

One well-known German manager, Klaus-Hardy Mühdeck, the CIO of ThyssenKrupp, is even nicknamed the Prozesspapst, the Process Pope, and has changed his title to Chief Process Officer. Because processes govern the internal workings of a company, whoever has the say over process has the say over how the work is done, and thus over the company. As the Germans see it process is power. And Germans want the power. Who doesn’t?

Tesla Giga Factory Berlin

Elon Musk wanted the factory in Germany. Why? Great automobile culture. Largest economy in Europe. Central geographic location. And, perhaps most importantly, great engineers. It makes you wonder what Henry Ford would have thought of this.

YouTube comments:

“This might just be the coolest car related video ever made. I can just imagine the person in the production meeting that suggested this and you just know when Elon heard about it he was like ‘Yep that’s sick’.”

“Tesla makes the best car commercials without making car commercials.”

“One of the best process walkthroughs I have ever seen. Amazing footage. Amazing piloting. Amazing process. Well done!”

“I’m a Tesla employee in Berlin and I was there on our ceremonial day. I can say that I saw with my bare eyes the guy who is controlling the drone. He has some amazing skills, so this video is made by him and its not fake. Cheers!”

Bureaucracy

1. Non-elected government officials. Administrative policy-making group. 2. Specialization of functions, adherence to fixed rules, hierarchy of authority. 3.A system of administration marked by officialism, red-tape and proliferation. From French bureaucratie: bureau desk and –cratie a kind of government. (MerriamWebster)

VW advanced manufacturing

Richard Hammond visits the Wolfsburg Volkswagen Factory in Wolfsburg, Germany, and gets an exclusive inside look on their new robotic arm tech, and their unique chairs built to quickly get human workers in and out of a car.

Volkswagen is known for its emphasis on quality and precision in its production processes, which is a key factor in the company’s success as a leading global automotive manufacturer.

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