About Podcast
This Episode is Sponsored By:
In a world where even the most advanced manufacturing lines still ship millions in scrap each year, why do so many organizations never truly conquer defects? That’s the question Dr. Frank Barsi set out to answer. What followed was a life of bold pivots from escaping socialist Hungary by swimming a frozen border lake, to serving as a U.S. Army Ranger in Vietnam, to becoming one of America’s first quality engineers helping shape the flight controls of the F-35 and F-22 before driving Six Sigma transformations at Boeing, Lockheed Martin, and Parker Hannifin.
In this episode, Dr. Barsi guides us through the untold history of quality engineering, explaining how post-war waste spurred government specs like MIL-I-45208 and MIL-Q-9858A, how W. Edwards Deming’s return from Japan ignited a U.S. manufacturing revolution, and why statistical process control was the critical pivot from sorting defects to preventing them in real time. Along the way, he reveals the mindset shifts and cultural nuances that make or break every process improvement effort.
Here’s what you’ll take away:
- The true origin of Six Sigma: how Motorola’s high-volume electronics lines sparked a methodology now used in every industry.
- Beyond inspection: why controlling quality during production is exponentially more powerful than catching defects afterward.
- The DMAIC roadmap: a peek at Define-Measure-Analyze-Improve-Control and how it eradicates variation.
- Cultural levers for success: what feudal Japan teaches us about obedience, and why American ingenuity can both help and hinder process discipline.
- A masterclass in lean innovation: Dr. Barsi’s groundbreaking Six Sigma project that slashed a $60K-per-piece titanium casting defect rate from 100% to zero.
Join us for a conversation that’s equal parts engineering epic and operational playbook perfect for leaders, operators, and anyone determined to turn process rigor into profitable performance.
Bring Processes Under Control First : Learn why consistency is the foundation of improvement and how process stability enables lasting quality gains.
Adapt to Cultural Approaches : Understand how U.S. creativity contrasts with Japan’s precision culture, and how 5S methods can meet both efficiency and autonomy needs.
Apply Six Sigma Beyond Manufacturing : Discover how the methodology works for any process by focusing on inputs, outputs, and reducing variation.
Transform Long-Standing Failures : See how a titanium casting project cut 20-year losses, eliminated defects, reduced lead time, and slashed costs through Six Sigma innovation.
Leverage Technology for New Standards : Use defect mapping, advanced machining, and digital inspections to replace outdated processes and set new industry benchmarks.
Pursue Continuous Improvement : Go beyond initial Six Sigma success by refining processes for faster delivery, lower costs, and higher quality.Special Guest: Frank Barsi, Ph.D. – Retired Aerospace Quality Engineer & Technical Lead
Location: Corona, CA USA
Air Date: Aug. 8, 2021
Websites:
- U.S. Department of Defense: the Department of Defense provides the military forces needed to deter war and ensure America’s national security. It consists of the following branches of military: Army, Marine Corps, Navy, Air Force, Space Force, Coast Guard, and National Guard.
- Lockheed Martin: a global security and aerospace company that “…is principally engaged in the research, design, development, manufacture, integration and sustainment of advanced technology systems, products and services.”
- Boeing: “…the world’s largest aerospace company and leading manufacturer of commercial jetliners, defense, space and security systems, and service provider of aftermarket support. [They] support airlines and U.S. and allied government customers in more than 150 countries. [Their] products and tailored services include commercial and military aircraft, satellites, weapons, electronic and defense systems, launch systems, advanced information and communication systems, and performance-based logistics and training.”
- Parker Hannifin: a Fortune 250 global leader specializing in motion and control technologies. “For more than 100 years the company has engineered the success of its customers in a wide range of diversified industrial and aerospace markets. Parker’s engineering expertise and broad range of core technologies uniquely positions the company to help solve the world’s greatest engineering challenges.”
- Alcoa: the company that invented the aluminum industry in 1888. Their name is “…synonymous with operational excellence and leadership in the production of Bauxite, Alumina and Aluminum products.”
Books:
- Out of the Crisis: a book by W. Edwards Deming.
- Dr. Deming: The American Who Taught the Japanese About Quality: a book by Rafael Aguayo.
- Physics of the Future: How Science Will Shape Human Destiny and Our Daily Lives by the Year 2100: a book by Michio Kaku.
- The Future of the Mind: The Scientific Quest to Understand, Enhance, and Empower the Mind: a book by Michio Kaku.
Professional Organizations:
- The International Aerospace Quality Group (IAQG): the organization responsible for setting the “…standards for quality within the worldwide supply chain of the aerospace industry.”
- American Society for Quality (ASQ): an organization that serves as the voice of quality via education, best practices, case studies, and training with membership in 130 countries.
Videos & Online Courses:
- Neil deGrasse Tyson Teaches Scientific Thinking & Communication: a MasterClass course taught by popular astrophysicist, Neil deGrasse Tyson. In this class, you’ll learn how to “…think like a skeptic, open your own mind through scientific literacy, distill data, and navigate bias to discover objective truths—and deliver your ideas in ways that engage, excite, and inspire.”
- Learn What 5S is and How it Applies to Any Industry:
- What is a Failure Mode and Effects Analysis (FMEA)?
- Writer, Producer & Host: Alicia Butler Pierre
- Podcast Editor: Olanrewaju Adeyemo
- Video Editor: Gladys Jimenez
- Transcription: Outsource Global
- Show Notes: Hashim Tale
- Sponsors: HubSpot, ThinkSmart Whiteboard
More About Guest, Dr. Frank Barsi:
Frank Barsi, Ph.D. was born and raised in communist Hungary and emigrated to the US in 1972. He quickly joined the U.S Army and served three years of active duty and three years of reserve. His professional career started shortly thereafter which led him to a career in aerospace for the expanse of forty years in various technical leadership positions at companies like Boeing Aircraft, Lockheed Martin, and Parker Hannifin Aerospace Group. He helped develop projects like the F22 (Raptor) and the F35 (JSF) Primary Flight Controls.He also served as the Technical Lead on Corporate Continuous Improvement Programs including the introduction and implementation of various Six Sigma training programs. This included Six Sigma process control concepts that resulted in production improvements of over two hundred different aerospace parts to a 100% first-pass yield (which historically had a 100% failure rate for the previous twenty years). Since then, these manufacturing processes achieved a Six Sigma production output and have maintained this status, to date.
Dr. Barsi holds a Ph.D. in Material Science and Engineering and another Ph.D. in Theoretical Particle Physics. He also has a Master’s degree in Metallurgy, a Bachelor of Science degree in Mechanical Engineering, and certifications in Six Sigma Master Black Belt ( Motorola Solutions DMAIC system) and Statistical Process Control Trainer. He’s also an expert in the concept of the Prior Production Approval Process (PPAP). Dr. Barsi now enjoys a life of retirement that includes exploring hobbies like welding, machine milling, cooking, and gardening.
More About Host, Alicia Butler Pierre:
Alicia Butler Pierre is the Founder & CEO of Equilibria, Inc. Her career in operations began over 20 years ago while working as an engineer in various chemical plants and oil refineries. She invented the Kasennu™ framework for business infrastructure and authored, Behind the Façade: How to Structure Company Operations for Sustainable Success. It is the world’s first published book on business infrastructure for small businesses. Alicia hosts the weekly Business Infrastructure podcast with a global audience across 53 countries.
More About Sponsor, HubSpot:
HubSpot offers a full platform of marketing, sales, customer service, and Customer Relationship Management (CRM) software — plus the methodology, resources, and support — to help businesses. Their CRM platform is powered by the same database, so everyone in your organization — Marketing, Sales, Service & Operations — is working off the same system of record. This allows for a smoother handoff between teams and results in a more delightful experience for your customers. More About Sponsor, ThinkSmart Whiteboard:
Thinksmart Whiteboard is a Windows App that turns your Tablet PC into a shared whiteboard. It allows you to create a whiteboard on your computer screen, then allows other people to write onto your whiteboard, even if they are in another location! Learn more.