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An old-fashioned attitude to WIP in 2013 | Manufacturing Digital

An old-fashioned attitude to WIP in 2013 | Manufacturing Digital | TLS - TOC, Lean & Six Sigma | Scoop.it
Toyota pioneered modern lean manufacturing and created a highly efficient and reliable manufacturing system that the rest of the world sought to adopt with huge variations in success. A main thrust of Lean philosophy is to closely examine manufacturing processes, find unnecessary steps and eliminate them. The same philosophy suggests that we should only allow room for value adding steps – in terms of value perceived by the customer – as this drives up efficiency and enables us to manufacture simpler and faster. It is said that accumulating work-in-progress through the process ties-up resources and can obscure problems and is therefore deemed to not add value, so conventional Lean thinking is to eliminate this wasteful step.With this thinking comes a generally held view that Lean manufacturing and Accumulation cannot coexist....

Via Michel Baudin
Philip Marris's insight:

Michel Baudin commented, very pertinently I beleive, on this article (see his insight below).

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Michel Baudin's curator insight, September 14, 2013 12:29 AM

The gist of this article is that you should hold just enough WIP to meet your production requirements with the changeover times you currently have and protect your bottlenecks against malfunction in other resources.

 

So far, this is stating the obvious, and a visit to a Toyota plant or even dealership is enough to see that the Toyota system is not one with zero inventory. You see shelves of stampings, bins of bolts, and trees of wire harnesses. The Kanban system involves some inventory, and, in fact, the only approach that doesn't is just-in-sequence.

 

What is considered waste is not all inventory, but unnecessary inventory, accumulated for no valid reason anyone can explain. The article, however, goes further and asserts that it is cheaper to accumulate WIP than to expose and solve the problems that make it necessary, which is a return to the mass-production thinking that was prevalent in pre-Lean operations management.

 

What the Lean successes of the past decades have shown is (1) that the overall costs of WIP were understated and (2) that the ingenuity of production people and engineer was underestimated. You operate today and next week with the resources that you have, dysfunctional as they may be, and you hold WIP as needed to sustain production. As you do this, however, as an organization, you keep working at solving your problems so that you need less and less WIP month by month and quarter by quarter. This perspective is missing from the article.

TLS - TOC, Lean & Six Sigma
The combination of Lean, Six Sigma and Theory Of Constraints. How to build your own system by choosing what works for you.
Curated by Philip Marris
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The 2 for 1 rule to reduce WIP - 2 mins.

To reduce rapidly and simply the level of WIP (Work In Progress) and thereby reduce production lead times the "2 for 1 rule" is very pertinent. An organisation (for instance a factory) only allows itself to launch one new item into production after it has finished 2 items.

There are several ways of doing this; one of the most common is to control the number of Work Orders (WO). A new work Order can only be launched if 2 WOs have been completed (and closed).

This technique has been implemented dozens of times since 2010 and has demonstrated extraordinary results. The only real limiting factor is that you need a significant number of Work Orders initially in WIP; ideally over 100.

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5 Ways My Thinking Changed With the Help of a Lean Coach | Lean Enterprise Institute

5 Ways My Thinking Changed With the Help of a Lean Coach | Lean Enterprise Institute | TLS - TOC, Lean & Six Sigma | Scoop.it

Here’s what we learned: #5: Seek Countermeasures Versus Solutions. Before: As Socrates said, “There is no solution, seek it lovingly.” [...] After: With our coach, we learned the importance of thinking deeply about problems

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Theory of Constraints + Lean + Six Sigma = Ultimate Improvement Cycle

What caught my interest in Bob's book The Ultimate Improvement Cycle is that recently there has been an added push from TOC disciples to bring TOC on an equal playing field as Lean and Six Sigma. I find it interesting because bottlenecks and constraints are an integral part of Lean and Six Sigma training but TOC has never seemed to be on an equal platform.
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Racing Breakneck to the Bottleneck - new book by Mark Woeppel and Adam Brown

Subtitle: “How Theory Of Constraints and Lean Manufacturing were used to boost productivity 1,000 percent and save $700 million”

What can you do to boost capacity overnight […] These questions were central to the team that supplied equipment to the Gulf of Mexico during the Macondo spill and the historic mop up […] Mark and Adam tell the compelling inside story. What the team did to double, triple, even quadruple suppliers’ output in a matter of hours and days. How, using the Theory of Constraints, Lean Manufacturing principles, and common sense, they increased productivity and saved over a half billion dollars in expenses under the worst conditions. The book ends by discussing the principles behind the tactics, offering the process improvement lessons learned for application to any continuous improvement effort.

 

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Mark Graban Interviewed in the Journal “Healthcare”

Mark Graban Interviewed in the Journal “Healthcare” | TLS - TOC, Lean & Six Sigma | Scoop.it
Blog post at Lean Blog : Thanks to Dr. Russell B. Kerbel and Khin-Kyemon Aung for interviewing me for the journal, 'Healthcare: The Journal of Delivery Science and[..]
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Lean Product and Process Development Exchange conference - Sept. 14-16, 2015 Texas, USA

Lean Product and Process Development Exchange conference - Sept. 14-16, 2015 Texas, USA | TLS - TOC, Lean & Six Sigma | Scoop.it

LPPDE stands for the Lean Product and Process Development EXCHANGE, and that's exactly what happens at our annual conference. If you long for an open EXCHANGE of ideas, best practices, challenges, and solutions, you won't want to miss LPPDE-North America on September 14-16, 2015 in Austin

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What Toyota Production System is Really About? - 5 pages | M. H. Ahmed Soliman

What Toyota Production System is Really About? - 5 pages | M. H. Ahmed Soliman | TLS - TOC, Lean & Six Sigma | Scoop.it

... From my several years of experience in using TPS and leading improvement projects in various industries and businesses, testing what works and what doesn't, talking with professionals like Jeff K Liker, [...] I can confidently say that TPS is not what many do think it is. So what is TPS?

 

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TOC + Lean in Manufacturing - Vilnius Lithuania 2013 - 44 mins

Conference in Vilnius, Lithuania April 2013 […] Part 1 is a brief presentation of the concepts of the Theory of Constraints and Part 2 presents two case studies. […] The first case is an automotive OEM supplier in Mexico. It involves injecting Theory Of Constraints (TOC) into a very Lean system to very rapidly improve the factory’s performance. […] The second is a luxury perfume bottle manufacturer in France that rapidly boosted its performance by using a combination of TOC, Lean and Six Sigma. It is probably one of the first full implementations of “TLS” (TOC + Lean + Six Sigma). The presentation (in English) is by Philip Marris, the founder and CEO of Marris Consulting.

 

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The one thing Lean Six Sigma got wrong about Lean | E. van Der Koogh

The one thing Lean Six Sigma got wrong about Lean | E. van Der Koogh | TLS - TOC, Lean & Six Sigma | Scoop.it

Today's post is a guest post by Erwin van der Koogh, who comes to us from Australia. [...] The one thing that Lean Six Sigma got wrong can be summarized in three words: “Pretty Much Everything.“

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Rajeev Athavale's 9 eBooks about the Theory Of Constraints [Recommended]

Rajeev Athavale's 9 eBooks about the Theory Of Constraints [Recommended] | TLS - TOC, Lean & Six Sigma | Scoop.it

I am a TOC consultant. I teach and implement TOC. I have been studying and trying TOC over a decade.

 

Theory of Constraints - Do It Yourself Kit for Small & Medium Size Enterprises for Manufacturing

Theory of Constraints - Do It Yourself Kit for Small & Medium Size Enterprises for Distribution

Theory of Constraints - Do It Yourself Kit for Small & Medium Size Enterprises for Projects

The Echoes of Theory of Constraints (TOC) - Volume 1

The Echoes of Theory of Constraints (TOC) - Volume 2

Theory of Constraints (TOC) Basic Concepts and Decision Making

Theory of Constraints (TOC) - Application for Manufacturing

Theory of Constraints (TOC) - Application for Projects

Theory of Constraints (TOC) - Application for Distribution

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Moving from “Visuals” to “Visual Management” and to Broader Lean Thinking | Mark Graban

Moving from “Visuals” to “Visual Management” and to Broader Lean Thinking | Mark Graban | TLS - TOC, Lean & Six Sigma | Scoop.it

To me, the core of visual management is captured in this statement from Fujio Cho, now the honorary chairman of Toyota:

“Know normal from abnormal… right now!”

If the “visual” isn’t helping accomplish that goal, it’s probably not visual management. Visual management has two parts – the visual (something you see) and the management (the action you take based on the visual). Why do we have to manage the visual abnormality? To get better results.

 

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Theory of Constraints (TOC) iPhone & iPad App $2.99 | iosnoops.com

Theory of Constraints (TOC) iPhone & iPad App $2.99 | iosnoops.com | TLS - TOC, Lean & Six Sigma | Scoop.it

This is the all-inclusive tool to study Theory of Constraints (TOC). We aim to provide the comprehensive guide and help you fast grasp the essentials of this topic that would take other people many years to learn.
* We have included the theory, diagrams, thinking process, examples and practical solutions in intuitive learning cheat sheets. You may easily refer these cheat sheets from your iphone or ipad, or you may print them out and nail on the wall as daily heads-up.
* We carefully selected the experts video lessons for more real case study, and deeper understanding of the topic.
* We have collected the specialised vocabularies on this topic to help you master the languages. We also have fun flashcards for easy remember. No internet required, offline dictionary.
It is perfect for management professionals and students, project managers, and people who want to understand more of Business Management knowledge and mindset.

 

Philip Marris's insight:

Disclaimer: I have not tested this App.

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When to use Lean Manufacturing, TOC and Six Sigma - Part 4 Six Sigma | Synchrono.com

When to use Lean Manufacturing, TOC and Six Sigma - Part 4 Six Sigma | Synchrono.com | TLS - TOC, Lean & Six Sigma | Scoop.it
What Grade of Sandpaper Will You Use? Part FourHere we are at the final installment of our four-part, Sandpaper blog series about when to use the tools of Lean Manufacturing, the Theory of Constraints (TOC) and Six Sigma to address constraints, drive flow and promote continuous improvement. With regard to sandpaper, I talked a lot about what level of grit you will need to smooth out your processes—and what could happen if you try to start with Six Sigma as a first step in creating continuous improvement momentum. Refine with Six Sigma

Six Sigma is the fine grit sandpaper, best used on a relatively smooth board that you want to make like glass. After TOC has helped with global flow

 

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Are You Really Listening to Your Customer or Just Going Through the Motions? | Mark Graban's Lean Blog

Are You Really Listening to Your Customer or Just Going Through the Motions? | Mark Graban's Lean Blog | TLS - TOC, Lean & Six Sigma | Scoop.it

Today’s guest post is by Rodrigo Bernal, with the first post on this site contributed from Mexico. Rodrigo uses a lunch outing to raise important questions about customer focus and the voice of the customer. If there is a quality problem, does that feedback get back to the source of the problem for root cause analysis and corrective action? If you’re asking customers for feedback, is it superficial or meaningful?

 

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"Product-Market Fit" [Agile + Lean Product Dev.] | Management.about.com

"Product-Market Fit" [Agile + Lean Product Dev.] | Management.about.com | TLS - TOC, Lean & Six Sigma | Scoop.it
Learn the six steps of the Lean Start-up Process, a way to improve the development and commercialization of new products using Lean principles.
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10 Guidelines for Leading Culture Change | aLeanJourney.com

10 Guidelines for Leading Culture Change | aLeanJourney.com | TLS - TOC, Lean & Six Sigma | Scoop.it

Implementing Lean Thinking is a cultural change that requires leadership…because in the end it’s all about people. Here are 10 guidelines your leader can do right now to change the culture:

ONE) Challenge People to Think. If you are not thinking, ....

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TLS: Open TOC + Good Lean + Good Six Sigma TOCICO 2013 - 12 mins | Philip Marris

TLS = Open TOC + Good Lean + Good Six Sigma. Presentation by Philip Marris at the TOCICO annual congress in Frankfurt in June 2013. It is argued that TLS enables companies to improve faster and reach even higher levels of performance than using one of the elements alone.
Each component is redefined:
Good Lean = Toyota = Growth (no downsizing) + Mindset + NPD
Bad Lean = A process of continuous downsizing.
Open TOC = TOC is powerful, it is necessary but not sufficient.
Closed TOC = TOC is the best, TOC is the only way.
Good Six Sigma = Data + VOC + Focused DOE projects.
Bad Six Sigma = A lot of belts, a lot of projects, few results.

 

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Throughput Accounting Workshop by Eli Schragenheim - Oct. 2015 Paris, France - 5 mins

For further information: http://tinyurl.com/p25dtat

 

Unleashing the power of Theory Of Constraints’ Throughput Accounting. Eli Schragenheim – Paris Oct. 2015

Eli Schragenheim addresses 3 key business questions: what to sell, at what price and how much capacity must be maintained. Traditional decision making is based on Management Accounting’s Cost per unit and assumes that the cost is proportional to the number of units. Eli Schragenheim claims, like many other experts such as Kaplan and Ohno, that this traditional and widespread approach is wrong. And he proposes a new solution. [...] He is hosting a 1,5 day workshop in Paris, France on the 15th and 16th of October 2015 to teach this “Throughput Based Decision Making” process (TBDM).

 

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10 Books to read for a Six Sigma Certification | Simplilearn

10 Books to read for a Six Sigma Certification | Simplilearn | TLS - TOC, Lean & Six Sigma | Scoop.it
Here are top 10 books to read when preparing for a Six Sigma certification exam. These books will cover all the important concepts about Six Sigma processes.
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What is TPM? | Steve Borris

What is TPM? | Steve Borris | TLS - TOC, Lean & Six Sigma | Scoop.it

Easy, it is the abbreviation for Total Productive Maintenance... It is how best to maintain equipment.Well, yes, maintaining equipment is a huge part of it but TPM is so much more.I can understand why sometimes there is confusion. I was recently talking to a 6 Sigma black belt that told me TPM was a lean tool, and to be fair, it is...

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German case study shows benefit of Lean Six Sigma method in interventional radiology (IR) | Radiology Business

German case study shows benefit of Lean Six Sigma method in interventional radiology (IR) | Radiology Business | TLS - TOC, Lean & Six Sigma | Scoop.it

A recent case study in the Journal of the American College of Radiology looked at how the Lean Six Sigma methodology can be used to improve the efficiency of an interventional radiology (IR) suite. 

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Official video by Toyota Material Handling - Production From Start to Finish - 3 mins

The Toyota Production System (TPS) is a reference in the world of production. It is based on a Pull system, which means that we only produce what is ordered; Watch behind the scenes of Toyota Material Handling’s supply organisation: this video highlights how a truck is being produced from start to finish. You will learn about the concepts of ‘Heijunka’, Just in time and Jidoka’. You will also be taken through how defects are being managed in order to continuously improve quality for our products.

www.toyota-forklifts.eu
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Overview of Value Stream Mapping Symbols | AllAboutLean.com

Overview of Value Stream Mapping Symbols | AllAboutLean.com | TLS - TOC, Lean & Six Sigma | Scoop.it
Explanation and overview of value stream mapping symbols, also including alternatives and different variants. These are also for download in Microsoft PowerPoint and Microsoft Excel.
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Lean Six Sigma and Minitab book (4th Edition)

Lean Six Sigma and Minitab book (4th Edition) | TLS - TOC, Lean & Six Sigma | Scoop.it

Lean Six Sigma and Minitab (4th Edition): The Complete Toolbox Guide for Business Improvement Offer Price $66.49 ISBN:095468138X Authors Quentin Brook List Price : $69.99 Availablity Usually ships in 24 hours Publisher : OPEX Resources Ltd **Fourth Edition

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