Popular Manufacturing Myths: Eliminating Widely Held Beliefs That Reduce Competitiveness, 1st Edition (Hardback) book cover

Popular Manufacturing Myths

Eliminating Widely Held Beliefs That Reduce Competitiveness, 1st Edition

By Douglas B. Relyea

Productivity Press

135 pages | 25 B/W Illus.

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Hardback: 9781466566606
pub: 2013-04-18
eBook (VitalSource) : 9781466566897
pub: 2016-04-19
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Addressing the beliefs and attitudes that can be detrimental to your organization’s competitiveness, Popular Manufacturing Myths: Eliminating Widely Held Beliefs That Reduce Competitiveness offers time-tested insight into the most common myths encountered in manufacturing environments. It classifies these myths into management myths, shop floor myths, and if appropriate, shared management and shop floor myths.

Explaining the reasons why these deeply ingrained beliefs exist, the book outlines remedies that can help to quickly dispel them within your organization. It presents case studies that examine these myths and includes numerous real-world examples that outline simple, yet effective, solutions. Some of the myths dispelled in this book include:

  • Increasing line speed always decreases quality and creates more scrap
  • Reducing the cost of raw materials will decrease the cost of manufacturing
  • Increased inspection will boost quality
  • If it is successful in R&D, it will be successful in production
  • Process problems can only be solved by changing one process parameter at a time

Covering the basics of data collection tools, techniques, and analysis, the text offers simple methods to structure your data to assist in communicating clear and logical conclusions across the organization. The author keeps the arithmetic and statistics to a minimum, so readers only require a basic understanding of averaging and normal variation. However, for those who wish to understand a little bit more about a particular concept, technique, tool, or procedure, the book includes an addendum chapter with more detailed explanations and sample calculations.

Table of Contents

Introduction to Manufacturing Myths

The Human Factor

Natural Variation

An Adjustment Is an Adjustment

Is It Ok if I Tweak?

Expectational Myths

Expectational Myths

Two Safety-Related Expectational Myths

Safety versus Productivity

Accident Reports


Quality-Related Expectational Myth

Productivity versus Quality

The Sales and Marketing Connection

Dispelling the Myths

Data Myths

Dispelling the Myths

The Reality of Collecting Shop Floor Data

Misuse of Data

In Conclusion

Our Process Is Different

Management Myth: Our Process Is Different

The Control Chart

A Process Is a Process


In Conclusion


Measurement Process Myths

The Measurement Process


Measured Product

Measurement Procedures

Measurement Equipment

Accuracy versus Precision



Resolution versus Discrimination



In Conclusion

Only Adjust One Process Parameter at a Time

Evolutionary Optimization

Not Uncommon

Classes of Problems


The Problem-Solving Matrix

The Interaction Plot

In Conclusion

Raw Material Myths

Dispelling the Myth

Dispelling This Myth

In Conclusion


Control Charts

Process Capability Studies

Standard Deviation

Evolutionary Optimization




About the Author

Douglas B. Relyea is the founder and senior partner of Quality Principle Associates a New England-based consulting firm that specializes in the education and application of data analysis techniques to industrial problem solving.

Mr. Relyea has a degree in manufacturing engineering from Three Rivers Community College in Connecticut and a business degree from Eastern Connecticut State University.

He spent twenty years working at General Dynamics and a division of Rogers Corporation, specializing in extrusion, die stamping, machining and molding processes servicing the automotive and business equipment industries. During his time in industry he filled positions such as first-line supervisor, quality assurance manager, engineering manager, maintenance manager, and sales and marketing product manager. Most recently, Mr. Relyea contributed Chapter 19 of the Wire Association International Wire Handbook. This chapter is entitled "Elements of Statistical Quality Control."

In 1987 he left industry and formed Quality Principle Associates.

Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Quality Control