Assembly Magazine logo
search
Ask ASSEMBLY AI
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Assembly Magazine logo
  • TRENDS
    • Ask ASSEMBLY AI
    • Trends
    • News
    • New Products
  • INDUSTRIES
    • Aerospace
    • Appliance
    • DFMA Assembly
    • Medical Devices
    • Green Manufacturing
    • Lean Manufacturing
    • Machinery Assembly
    • Electronics Assembly
    • Automotive
  • TECHNOLOGIES
    • Adhesives & Dispensing
    • Assembly Presses
    • Automated Assembly Systems
    • Manufacturing Management
    • Manufacturing Software
    • Motion Control
    • Screwdriving & Riveting
    • Robotics
    • Test & Inspection
    • Plastics & Metal Welding
    • Wire Processing
    • Workstations
  • AUTONOMOUS & ELECTRIC MOBILITY
    • AEM Magazine Archives
    • Autonomy
    • Electrification
    • Mobility Services
    • Assembly & Testing
    • AV/EM News
  • MEDIA
    • Ask ASSEMBLY AI
    • Podcasts
    • Assembly News Now
    • Assembly TV
    • Webinars
    • eBooks
  • EVENTS
    • Calendar
    • The ASSEMBLY Show
  • MORE
    • Exclusives >
      • Plant of the Year
      • Capital Spending
    • Buyers Guide >
      • Supplier Insights
    • Classifieds
    • Featured Products
    • Newsletters
    • Store
    • White Papers
    • Columns
    • Sponsor Insights
  • INFOCENTER
    • Assembly & Test Solutions
  • EMAGAZINE
    • eMagazine
    • Archive Issues
    • Advertise
    • Contact Us
    • Sign Up
ColumnsDFMA AssemblyLean Manufacturing Assembly

When Best Practices Aren’t Best

Yesterday’s best practice is not tomorrow’s.

By Dr. Mike Shipulski
April 1, 2013

Manufacturers vigorously seek out best practices because they can improve metrics, such as stock price, sales and profitability. There’s only one problem: Best practices are the actions that solved yesterday’s problems.

Best practices are often thought of as discrete tools or processes, but there’s a hierarchy to them. Up a level from the discrete tool is a methodology or a collection of processes, such as lean or Six Sigma. Up another level is a coordinated set of methodologies that makes up a framework—how a company goes about its business or an important initiative. There are best practices for all levels, and their place in the hierarchy is defined by the problems they solve.

Companies seek best practices for the right reason—to multiply the benefit of previous success. But they’re sometimes pursued like they’re ends unto themselves. Once deemed “best,” they can become gospel, scripted and unchangeable. But yesterday’s best practice is not tomorrow’s, and yesterday’s script is not right for today’s performance.

There are countless unique tools and processes, and each company has unique objectives, culture and problems. This variation makes every context unique, which makes every problem different. There can be no predestined best practice for a given problem, yet there is commonality that holds together best practices as a family.

All best practices are solutions in search of problems, and every problem has a context. Start with the problem and its context, and the ideal best practice will emerge. The right best practice is a result of the context (the situation we’re in, why we’re in it, and where we want to go) and the problem (what’s in the way). The latter comes in two flavors: “what we have isn’t good enough” (continuous improvement), and “we’re missing something” (discontinuous improvement or innovation).

Here are three scenarios for continuous improvement:

Profits are too low because manufacturing costs are too high. Likely best practice: Use lean to reduce wasted time.

Profits are too low because quality is poor. Likely best practice: Use Six Sigma to reduce process variation.

Profits are too low because product cost is too high. Likely best practice: Use design for assembly (DFA) to reduce material cost.

For each scenario, the destination is the same, but the context is different, so the best practice is different. How lean, Six Sigma or DFA are implemented is governed by the lower level context (where we want to go) and the specific problems. The first tools to be used emerge from the problems to be solved.

Here are two scenarios for discontinuous improvement:

Profits are too low because the product isn’t selling in developing markets. The price is too high. Likely best practice: Redesign the product to provide 80 percent of its original functionality at 20 percent of the cost.

Profits are too low because the product isn’t selling in developing markets. The product doesn’t do what the market needs. Likely best practice: Use indigenous engineering so the product does what it should.

Again, the destination is the same, but the context is different, so the best practice is different. Each implementation is governed by lower level context and problems: the breadth of product functionality, the wrong product functionality, high material costs, or the fact that the product won’t run on batteries.

 Best is not universal and best is not static. Best is contextual. Best is best when it solves the problem; best is best when it meets company objectives. 

Looking for quick answers on assembly and manufacturing topics? Try Ask ASM, our new smart AI search tool. Ask ASM →

KEYWORDS: best practices continuous improvement

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Mike Shipulski is a leading authority on lean manufacturing, product development, and design for manufacturing and assembly. His column appeared every other month, alternating with Austin Weber’s “On Campus.” E-mail Mike with comments via mike@shipulski.com or follow his blog at www.shipulski.com.


Recommended Content

JOIN TODAY
To unlock your recommendations.

Already have an account? Sign In

  • Made in the U.S.A.

    Consumer Products Manufacturing: Made in the USA

    Supply chain lessons learned during the coronavirus...
    Automated Assembly Systems
    By: Austin Weber
  • Best Practices for Press-Fit Assembly

    Best Practices for Press-Fit Assembly

    In manufacturing, ironclad formulas for success are hard...
    Assembly Presses
    By: Jim Camillo
  • aem0523leader-tesla1.jpg

    Tesla Rethinks the Assembly Line

    Engineers at Tesla Inc. have developed a new process that...
    Automotive Assembly
    By: Austin Weber
Manage My Account
  • eMagazine Subscription
  • Assembly Newsletters
  • Online Registration
  • Subscription Customer Service
  • Manage My Preferences

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the ASSEMBLY audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of ASSEMBLY or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • ultrasonic welding
    Sponsored bySonobond Ultrasonics

    Engineering Efficiency in High-Performance Assembly: How Ultrasonic Welding Enhances Throughput, Reliability and Quality

  • UV curing system
    Sponsored byDymax

    Why UV Intensity Alone Doesn’t Define Curing Performance

  • wooden pallets
    Sponsored byLEAN Manufacturing Products

    Eliminating Waste on the Shop Floor: Applying Lean Principles to Improve Manufacturing Efficiency

Popular Stories

ASSEMBLY News Now, episode-30: Volvo Redesigns EV Manufacturing

Volvo Redesigns EV Manufacturing

Boeing CEO Kelly Ortberg announces 1 billion investment

Boeing Plans $1 Billion Wichita Investment, Workforce Training Center

automated consumer goods assembly system

Best Practices for Cycle Time Optimization

Watch the latest episode of ANN now!

Events

July 24, 2025

From Shop Floor to CFO: How Manufacturers Are Closing the Loop Between Operations and Finance

On Demand Learn how manufacturers are bridging the gap between the shop floor and ERP systems to gain real-time visibility, streamline operations, and kick-start digital transformation—without waiting years.

Sponsored by:

PicoStratusGreen
July 30, 2025

Buffer Analysis and Design Fundamentals for Manufacturing Excellence

On Demand In this presentation, Dr. Herman Tang shares practical insights from his industry experience and research on buffer management in manufacturing operations.

View All Submit An Event

Poll

Difficult Assembly Processes

Which assembly process gives you the most difficulty?
View Results Poll Archive

Products

Manufacturing Cost Policy Deployment (MCPD) Profitability Scenarios: Systematic and Systemic Improvement of Manufacturing Costs

Manufacturing Cost Policy Deployment (MCPD) Profitability Scenarios: Systematic and Systemic Improvement of Manufacturing Costs

See More Products
Register for webinar - Modernizing Automotive Assembly: Why Upgrading Legacy MES is a Business Imperative

Related Articles

  • Free Webinar to Discuss Best Practices for 5S

    See More
  • Uncommon Sense: The “Best Practices” Hoax

    See More
  • Best Practices for UV-Cure Adhesives

    Best Practices for UV-Cure Adhesives

    See More

Related Products

See More Products
  • supply chain.jpg

    Supply Chain Management Best Practices, 3rd Edition

  • Testing Adhesive Joints: Best Practices

See More Products

Related Directories

  • Lean Manufacturing Products

    Lean Manufacturing Products LLC is a leading provider of innovative solutions designed to enhance operational efficiency and productivity in various industries. Specializing in lean manufacturing principles, we offer a comprehensive range of high-quality products, including racking systems, safety equipment, and modular storage solutions. Our mission is to help companies streamline their processes, reduce waste, and create more effective work environments. With a commitment to exceptional customer service and cutting-edge design, Lean Manufacturing Products LLC partners with businesses to implement best practices that drive success and foster continuous improvement.
×

Never miss the latest news and trends driving the manufacturing industry

Stay in the know on the latest assembly trends.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Manufacturing Division
    • Store
    • Want More?
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • Newsletters
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Instagram
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2026. All Rights Reserved BNP Media, Inc. and BNP Media II, LLC.

Design, CMS, Hosting & Web Development :: ePublishing