S4 E15 - Mike Beck - Engineering Excellence Through Deming's Lens

Profound

In this episode, I had a conversation with Mike Beck. We dive deep into W. Edwards Deming's seminal perspectives on quality and their application in the automotive and healthcare sectors. Mike, with his vast experience at General Motors and Toyota, shares compelling stories and insights on how Deming's principles transformed his approach to engineering and management.

Mike Beck's journey began as a mechanical engineer at General Motors in 1979, a time when the company held a dominant market share. His career took a significant turn after attending Deming’s seminar in 1984, which profoundly influenced his perspective on quality and management. This episode captures Mike's evolution from a reliability and test engineer to a leader in statistical methods and quality improvement at GM.

Key Discussion Points:

1. Early Career and Deming’s Influence:
   • Mike details his early career at General Motors, the transition of GM from the market leader, and his first exposure to Deming’s teachings which significantly shifted his approach towards statistical methods and leadership​​.
2. Implementing Statistical Methods:
   • He discusses his application of statistical methods in engine development, particularly using Taguchi methods and design of experiments (DOE) to tackle the issue of bore distortion in the Quad 4 engine​​.
3. Deming’s Consultancy at GM:
   • Mike shares insights from GM's decision to hire Deming as a consultant, and how this influenced the creation of the Powertrain Statistical Network and a master’s program in statistics, fostering a culture of continuous improvement and statistical thinking within the company​​.
4. Transition to Toyota:
   • His move to Toyota offered a unique comparison between American and Japanese approaches to quality. Mike highlights Toyota’s meticulous production engineering processes, incremental changes, and the profound cultural differences that underpin their success in quality management​​.
5. Cultural and Management Lessons:
   • Mike elaborates on the concept of "catchball" in Hoshin Kanri, emphasizing the importance of alignment and communication in achieving organizational objectives. He also contrasts the Western and Eastern views on time and efficiency, shedding light on how Toyota’s approach to planning and reflection contributes to their sustained excellence​​.

Show Notes:
Mike's Email: [e-mail]