Theory of Constraints

Lean Manufacturing Series

© 2009 Factory Strategies Group LLC. All rights reserved.

All rights reserved. 2 .Outline • • • • • • • • Introduction to Constraints Five Steps Of Theory of Constraints Drum Buffer Rope Evaporating Cloud Method The Batch Size Problem Chain Analogy Issues with TOC Measurements & Financial Issues © 2009 Factory Strategies Group LLC.

3 .Constraints • Any system can produce only as much as its critically constrained resource Constraint 60 units Per day 70 units Per day Maximum Throughput = 40 units per day 40 units Per day 60 units Per day © 2009 Factory Strategies Group LLC. All rights reserved.

Issues with TOC • Advantages ▫ ▫ ▫ ▫ ▫ Improves capacity decisions in the short-run Avoids build up of inventory Aids in process understanding Avoids local optimization Improves communication between departments © 2009 Factory Strategies Group LLC. 5 . All rights reserved.

U cell configurations. reduce both statistical fluctuation and dependent resources. in TOC. • Cells are used to reduce the dependencies. where one worker is moving with the processed piece from one machine to another • Predetermined schedules. TQM and JIT • All 3 methods attempt to reduce variation and recognize the interdependencies. 6 . All rights reserved.TOC. • Statistical process control is emphasized in the quality area to help identify ways to reduce variations. © 2009 Factory Strategies Group LLC.

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