Theory of Constraints (TOC) Blog #5: Repeat the Process

In our first four TOC blogs we:

•We provided a summary of TOC, Theory of Constraints

•Dove into Step #1: Identify the Constraints – Bottleneck analysis

•Continued into Step #2: Exploit the Constraint – Creativity over Capital

•Focused in Step #3: Subordinate – Prioritize and maximize opportunity

•Analyzed investment after all other avenues to elevate the constraint

As we finish this series for TOC, we will briefly discuss step 5, repeating the process, but focus more on an actual case study.

Step 5: Repeat the Process. The most important part of step 5 is to ensure that the gains made both in steps 1-4  are sustained. We do this through Layered Process Audits, OPLS to document key improvements related to Craftsmanship that could be lost over time, and many other tools available to ensure these efforts are all for not. Once this is in place, we move to our next bottleneck. Our case study focused on 7 different TOCs that we did in a 3.5M Square Foot Automotive Facility. This went on for years as we attacked the bottleneck. You will see in the case study that each plant area was involved.

My favorite memory of all of these TOCs from this plant was when we came to Trim Shop in Assembly. The area manager there told me “Let me fix things here first and then you can come in”, he wasn’t joking. We did a full deployment the next day and of the 24 Kaizens that we completed during this TOC, we finished 5 of them on day one simply by working with the line employees and skilled trades.

As you look to deploy TOC, hopefully you can see from these case studies that this is a journey, not just a destination…but the gains can be amazing if you apply the tools with your team and create a common goal and use TOC as your strategy to achieve.

Full Case Study with Details and Savings across 7 TOC’s…

Good Luck and if we can help you in any way, never hesitate to reach out!