DBR

1. Identify the system’s constraints (or CCR- capacity constrained resource) Drum
a. Load calculations
2. Decide how to exploit the system’s constraint Buffer
a. For the CCR, we decide, in advance, and in detail, exactly how we are going to
use its scarce capacity! We reserve improvisation for emergencies- develop
constrained resource schedule
b. Use calculations to decide when to move (create schedule for constraint)
i. Consider cycle times, setups, etc.
c. Ensure there is always enough buffer for the constraint to chew on at any time,
prevent disruptions in the production process and ensures that the bottleneck is
always fully utilized
d. Set schedule for constraint, everything else will handle itself
e. The drum represents the internal constraint or the slowest resource in the chain
3. Subordinate everything else to the schedule Rope
a. Road runner work ethic
b. Make a schedule that optimizes the constraint (step 2 exploit) and everyone else
does whatever they need to do to help this schedule
c. Make a well thought out schedule in step 2: exploit that doesn’t let the constraint
starve and then give everyone else that road runner ethic in step 3: subordinate
d. Rope/material release schedule- material release schedule to the people who are
responsible for it
e. This involves coordinating the flow of materials and work through the entire
production process (rope calculations) to ensure that the bottleneck is always fully
utilized
f. Control the input of raw materials so you never have to worry about excess WIP.
If you control the inflow you don’t have to worry about extra WIP- ensures that
everyone else only works when they have work to do and doesn’t work when they
don’t need to
g. The rope: To prevent overproduction, we time the first or gateway operation to
the drum. No more material will be released to the system that can be produced at
the constraint
h. How long before it is needed at the constraint should the material be released?
i. The buffer
ii. If I buy all on day 1 I might run into a cash flow problem and overwhelm
the system with too much stuff (build inventory and carrying costs)
DBR Steps
Step 1: Drum
The first step in the DBR approach is to identify the production constraint, or the “drum” which
is the bottleneck that limits the overall throughput of the production process. The drum is the
machine or process step that has the slowest cycle time or the lowest capacity, which determines
the maximum rate of production for the entire system.
- Load calculations
Step 2: Buffer
The second step is to create a buffer, or safety stock, in front of the drum to protect it from
variability and ensure that it always has work to do. The buffer is designed to absorb any
fluctuations in demand or supply, so that the drum can operate continuously without interruption.
- Schedule constraint
Step 3: Rope
The third step is to establish a “rope” or a production schedule that is synchronized with the
drum’s capacity. The rope sets the pace of production for the entire system based on the capacity
of the drum, and ensures that all upstream processes supply enough work to keep the drum busy,
while all downstream processes are ready to receive the output from the drum
- Roadrunner ethic
- Rope/material release schedule

The goal of the DBR approach is to optimize the flow of work through the production process by
focusing on the bottleneck or constraint, and synchronizing all other processes to the capacity of
the drum. By doing so, organizations can achieve higher throughput, shorter lead times, and
better quality, while minimizing the waste and inefficiencies that result from overproduction,
excess inventory, and idle capacity.