TLS - TOC, Lean & Six Sigma
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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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Theory of Constraints and Lean 2018-2019 training programme by Marris Consulting

Theory of Constraints and Lean 2018-2019 training programme by Marris Consulting | TLS - TOC, Lean & Six Sigma | Scoop.it
Over 1 200 people have been trained by Marris Consulting in the past 6 years including: Aerosud, ArcelorMittal, Areva, Arkema, Ariane Group, Autoliv, Bayer, Bosch, Embraer, Essilor, Danfoss, Fresenius Vial, GSK, Infineon, Ipsen, Jaeger LeCoultre, Lilly, Merial, Novartis, Pierre Fabre, Procter & Gamble, Pyrex, Nexter, Safran, Saint-Gobain, Salzgitter-Mannesmann, Schlumberger, Seb, Siemens, SKF, Thales, Veolia, Visteon, Yves Rocher & Zodiac Aerospace.


Our training sessions are also available as internal in-house training sessions. These sessions can be organized in our premises at the Montparnasse Tower or in your company premises anywhere in the world. You can contact us for rates and conditions regarding internal training sessions and we will get back to you with different options.


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Negotiate the right purchase price with suppliers - online training by Ian Heptinstall - Jan.-Feb. 2019

Negotiate the right purchase price with suppliers - online training by Ian Heptinstall - Jan.-Feb. 2019 | TLS - TOC, Lean & Six Sigma | Scoop.it
An online coaching & training programme for that will help buyers negotiate the right price - Not too high so you leave money on the table, but not too low so you increase risks. Limited places available. Over 15 hours of live and recorded training, plus 2 x 30 minute personal coaching sessions with an experienced procurement professional and coach.
Philip Marris's insight:

Ian Heptinstall has significant experience of purchasing and the Theory Of Constraints. He is the co-author of "The Executive Guide to Breakthrough Project Management: Capital & Construction Projects" [using CCPM/TOC] https://www.amazon.com/Executive-Breakthrough-Project-Management-budget-ebook/dp/B01JK0K3XY/ref=sr_1_1?

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Component commonality: "Runners, Repeaters, and Strangers among Components" -a [clever] post by Michel Baudin

Component commonality: "Runners, Repeaters, and Strangers among Components" -a [clever] post by Michel Baudin | TLS - TOC, Lean & Six Sigma | Scoop.it

In assembly operations, we need a Plan For Every Part (PFEP). For each purchased component, we must specify suppliers, choose order and delivery patterns, organize all actions taken inside the plant to deliver it from the receiving dock to the assembly line.

Setting a plan for each one of the thousands of purchased items is a daunting task. It helps if you can group the items in a handful of categories. Policies by category may not be as fine-tuned as for individual items but they are an improvement over “one-size-fits-all.” [...] We explain how we use this chart to categorize components as Runners, Repeaters, and Strangers. Then we show how we generate it from bills of materials and a product demand. We end with actual examples from several factories and recommendations on communicating these results.

Philip Marris's insight:

I recommend that all those that have an assembly type industry try and draw their Friedman curve. It will most likely be an eye opener.

Another thought provoking article by Michel Baudin.

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5 similar permanent news websites curated by Philip Marris

5 similar permanent news websites curated by Philip Marris | TLS - TOC, Lean & Six Sigma | Scoop.it
Philip Marris manages 5 different permanent news websites:
1) (This one) TLS - TOC + Lean + Six Sigma
2) Theory of Constraints
3) Critical Chain Project Management
4) Théorie des Contraintes (in French)
5) Chaîne Critique (in French)

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[Throughtput Accounting] TOC Measurements - On-line course designed by Rajeev Athavale - $50

[Throughtput Accounting] TOC Measurements - On-line course designed by Rajeev Athavale - $50 | TLS - TOC, Lean & Six Sigma | Scoop.it

This course explains TOC measurements and how to use them in day-to-day decision making. The course has 16 small chapters and quizzes. Every chapter has a video and the PDF containing the screen and text. You can learn at your own pace.

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Theory Of Constraints and Lean Manufacturing | W H Meanor

Theory Of Constraints and Lean Manufacturing | W H Meanor | TLS - TOC, Lean & Six Sigma | Scoop.it

[...] Listed below are some of the strengths of the theory of constraints and lean manufacturing: 1.The theory of constraints provides focus to the student in a world of information overload. 2.The theory of constraints provides its practitioners an opportunity to improve their organization by limiting their focus on very few issues which are the seen constraints to ongoing profitability. 3.The lean manufacturing on the other hand became famous after being derived from the system of the successful Japanese automobile maker Toyota. ...

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The Focus and Leverage Improvement Book - New book by Bob Sproull

The Focus and Leverage Improvement Book - New book by Bob Sproull | TLS - TOC, Lean & Six Sigma | Scoop.it

...The hallmark of this book is how to first locate this constraining factor and then determine the best way to exploit it to generate extreme profits, radically improve on-time delivery of products or services and increase market share by outperforming your competition at rates you never expected possible. How do we do this? By combining Lean and Six Sigma with the Theory of Constraints. This book demonstrates both the basics of improvement (i.e. results) with the "how to" (i.e. the methodology) in a very simple format that everyone within your organization will understand.

Philip Marris's insight:

The author, Bob Sproull, is one of the most experienced "TLS" practitioner / expert in the world. Among other things, he wrote the TLS best seller "Epiphanized". See his website: http://bsproull-flc.wixsite.com/flc-consulting

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Designing the Future - New [2018] book by Morgan and Liker

Designing the Future - New [2018] book by Morgan and Liker | TLS - TOC, Lean & Six Sigma | Scoop.it

“It is a must read for any leader who wants to create lasting value by building not just a great product, but a turbocharged product creating machine.” – from the Foreword by Alan R. Mulally, former CEO of Ford Motor Company and Boeing Commercial Airplanes  [...] In addition to providing a robust new development framework, Designing the Future shares real-world examples from a diverse set of industries including aerospace, energy, software, automotive, healthcare, heavy equipment, and more. [...] globally recognized lean development expert James Morgan teams up with world-renowned lean management guru Jeffrey Liker to explain [...] Lean Product and Process Development (LPPD) [...] Examples in the book show specifically how companies are redesigning product development systems to consistently design and deliver a progression of market-leading products and services.

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Boeing Lean+ approach [=TLS] - 12 page description in Boeing Frontiers Magazine

Boeing Lean+ approach [=TLS] - 12 page description in Boeing Frontiers Magazine | TLS - TOC, Lean & Six Sigma | Scoop.it

So we started working to align and leverage what we had,
creating one overarching continuous improvement approach that
includes strategies, tools and resources like Lean, Employee
Involvement and Engagement, Six Sigma, Process Management,
Theory of Constraints, the Boeing Production System and others.
We simplified, standardized and aligned the best of Boeing so we
can be the best of industry. That’s Lean+.

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Katacon Lean conference - Feb 18-19, 2019 - Georgia, USA

Katacon Lean conference - Feb 18-19, 2019 - Georgia, USA | TLS - TOC, Lean & Six Sigma | Scoop.it

KataCon is the annual gathering place for Toyota Kata Geeks across North America and around the globe. It’s where the “convinced” and the “curious” gather to share what they’re learning, freely and enthusiastically. There is an interesting mix of short keynotes, hands-on breakout sessions, intensive deep dives, and mini-updates from a variety of practitioners, industries, and applications.

The Kata community is known as a sharing community. So come with questions, and if you have them, answers, because at KataCon we’re ALL learners and coaches.

– 5 Years of KataCon
– 10 Years of Toyota Kata
– 15 Years of Jeff Liker’s Toyota Way
– AND 20 Years of Learning to See!

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Theory of Constraints crash course - Marris Consulting

Theory of Constraints crash course - Marris Consulting | TLS - TOC, Lean & Six Sigma | Scoop.it
A video to understand the very basic concepts of Theory of Constraints.

Philip Marris delivered a "crash course on Theory of Constraints" in manufacturing at the opening of the Critical Chain Project Management Training Course, May 2017. The manufacturing analogy makes it easier for beginners to grasp the notions of bottleneck, buffer protection, Throughput... before transposing it to Project Management

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Toyota and long term thinking Thinking by Richard Cushing | RKL eSolutions

Toyota and long term thinking Thinking by Richard Cushing | RKL eSolutions | TLS - TOC, Lean & Six Sigma | Scoop.it
For most of the time since the late-1980s, the market capitalization for Toyota roughly equaled, or exceeded, the sum of the “Big Three” in Detroit. Although wishful thinkers today attribute much of Toyota’s present profitability to currency manipulation of the Japanese yen, in the 1990s, with a depressed yen and an exploding U.S. stock market, …

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Taiichi Ohno talks about TPS and his meeting with Dr. Eli Goldratt and commenting on TOC | Utah Ops conference 2018

[from Kobus van der Zel]

 

Great Utah Ops conference by Goldratt Consulting. The highlight for me so far is this rare video of Taiichi Ohno talking about his meeting with Dr. Eli Goldratt - presented by Toyota Advisor, Mr. Nampachi Hayashi.

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One of the best Theory Of Constraints websites in the world by Kelvyn Youngman

One of the best Theory Of Constraints websites in the world by Kelvyn Youngman | TLS - TOC, Lean & Six Sigma | Scoop.it

"Kelvyn Youngman has done the organizational world an invaluable – no, indispensable – service with this web site.  This is the first comprehensive, truly system-level look at the Theory of Constraints." One of the website's recommendations by  H. William Dettmer, recognized Expert in TOC, author of 4 bestselling TOC books.


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Philip Marris's comment, August 13, 2013 3:16 PM
This website is regarded by many people as one of the best in quality and quantity concerning the Theory Of Constraints. It is administered by Kelvyn Youngman
Philip Marris's curator insight, August 25, 2013 8:42 PM

To quote from his website: "I spent quite some time living in Japan working within a large corporation that was both a batch manufacturer and a significant supplier to Toyota.  Their batch production mode had always caused them to decline “offers” from Toyota to improve their process and timeliness (but not their products which were in every sense of the word “World Class”).  However, together, we were able through Theory of Constraints to produce very significant improvements within a very short period of time.  Results that were significant enough to be reported in the national business press and also national television.

Let me say that I have deep respect for the fundamental techniques of Japanese kaizen, and of Toyota in particular.  Let me also say that I am not ignorant of Lean nor of its predecessors; World Class Manufacturing, Just-in-time, and so forth.  But there is something that is wrong with Lean (and Six Sigma) and I want to try to explain this. ...."

http://www.dbrmfg.co.nz/Overview%20Preface.htm

Pierre Jaeck's curator insight, January 10, 2016 4:34 PM

Certainly the best web site on TOC and more...

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Understanding and Applying Statistical Process Control (SPC) Part 2 | Bob Sproull

Understanding and Applying Statistical Process Control (SPC) Part 2 | Bob Sproull | TLS - TOC, Lean & Six Sigma | Scoop.it

In my last post, I explained how to implement statistical process control (SPC) in four phases. I introduced the concept of control charts, as a way of studying your SPC process, collecting data, and drawing conclusions as to whether the process variation is consistent. I finished with two basic questions to ask before getting started with SPC.

In this post, we will explore the measurement system evaluation using a gage repeatability and reproducibility study, as well as conducting process potential and process capability studies.

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10 Essential Lean Manufacturing Books | Tulip.co

10 Essential Lean Manufacturing Books | Tulip.co | TLS - TOC, Lean & Six Sigma | Scoop.it
Here are our picks for lean manufacturing books that should be required reading for lean manufacturers. These books range from the classics that were foundational in the evolution of lean manufacturing to books by contemporary lean thinkers.
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Focus and Leverage [TLS] blog by Bob Sproull

Focus and Leverage [TLS] blog by Bob Sproull | TLS - TOC, Lean & Six Sigma | Scoop.it

My blog is focused primarily on the Theory of Constraints and how to use it to maximize the profitability of any company. I also discuss why integrating TOC with Lean and Six Sigma is the most dynamic improvement methodology available today.

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Lean and TOC quotes | EverythingSupplyChain

Lean and TOC quotes | EverythingSupplyChain | TLS - TOC, Lean & Six Sigma | Scoop.it

Lean and Toyota Manufacturing Quotes […] “An hour saved at the non-bottleneck is a mirage.”   ~ Eliyahu M. Goldratt, The Goal  […] “Where there is no Standard there can be no Kaizen.”  ~ Taiichi Ohno  […] “For much of Toyota’s history, we have ensured the quality and reliability of our vehicles by placing a device called an andon cord on every production line – and empowering any team member to halt production if there’s an assembly problem. Only when the problem is resolved does the line begin to move again.”  ~ Akio Toyoda, CEO Toyota Motor Company  […] “I say an hour lost at a bottleneck is an hour out of the entire system. I say an hour saved at a non-bottleneck is worthless. Bottlenecks govern both throughput and inventory.”   ~ Eliyahu M. Goldratt, The Goal  […] “Improvement usually means doing something that we have never done before.” ~ Shigeo Shingo  […] “Many people think that Lean is about cutting heads, reducing the work force or cutting inventory. Lean is really a growth strategy. It is about gaining market share and being prepared to enter in or create new markets.”  ~ Ernie Smith “All we are doing is looking at the time line, from the moment the customer gives us an order to the point when we collect the cash. And we are reducing the time line by reducing the non-value adding wastes.”  ~ Taiichi Ohno, father of Toyota Production System (TPS) […] “A relentless barrage of “why’s” is the best way to prepare your mind to pierce the clouded veil of thinking caused by the status quo.  Use it often.”  ~ Shigeo Shingo  […]

Philip Marris's insight:

An amusing collection of so called "Lean" quotes. They are in fact a mixture of Lean + TOC + Others.

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Lean Construction by Christoph Roser | AllAboutLean.com

Lean Construction by Christoph Roser | AllAboutLean.com | TLS - TOC, Lean & Six Sigma | Scoop.it
Overview of the challenges of lean construction compared to "normal" manufacturing with different examples. Examples include pull systems, visualization, layout, etc.
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Mike Rother and Jeffrey Liker "What weve learned since writing Learninf to see - 24 slides

On the 20th Anniversary of the book "Learning to See" Mike Rother and Jeff Liker reflect on what they've learned about turning value stream maps into reality. …
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TLS: Combining TOC + Lean + Six Sigma | Point of view presentation by Marris Consulting

TLS: Combining TOC + Lean + Six Sigma | Point of view presentation by Marris Consulting | TLS - TOC, Lean & Six Sigma | Scoop.it
Combining the best of each approach. Concentrate on the 1% of the system that determines 99% of its performance

TLS - Theory of Constraints + Lean + Six Sigma : Combining the best of each approach

 

Theory Of Constraints (TOC )

Focus on improving the system constraints that determine overall performance…and in this way significantly boost the return on investment and success of Lean & Six Sigma programs

Increase profits by increasing sales rather than by cutting costs and hence avoid headcount reductions

Developed by Eliyahu Goldratt in the 1980s

 

Lean Manufacturing / Toyota Way

By far the most widespread approach in industry...

A focus on eliminating all forms of waste

A multi-dimensional approach: management, Just-In-Time, 5S, Lean Engineering, …

Developed by the Toyota Motor Company in the 1950s....

 

Six Sigma

Reduce process variability to 3.4 defects per million occurrences

Mostly implemented [...] Green Belts, Black Belts, …

Includes [....]  (Design Of Experiments / DOE)

Promoted by Motorola & General Electric in the 1980s.

 

 

TLS considers, on the contrary, that we should seek to combine them thereby creating a system that contains the best aspects of each movement. Each school of thought – Lean, Six Sigma & TOC – has proven its effectiveness, otherwise they simply wouldn’t exist. In combination they are formidable.

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Results using the Theory of Constraints | TOCPA Paris conference extract

Results using the Theory of Constraints | TOCPA Paris conference extract | TLS - TOC, Lean & Six Sigma | Scoop.it

Discover the kind of results you can obtain using the Theory of Constraints in this short video of testimonies from the TOCPA Paris March 2018 Conference.

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An interesting collection of Lean Books proposed by Enna.com

An interesting collection of Lean Books proposed by Enna.com | TLS - TOC, Lean & Six Sigma | Scoop.it
Expand your knowledge of Lean leadership, kaizen, and more
Philip Marris's insight:

Enna is a "Lean" Consulting firm that among other things organizes Japan Tour Guides and sells "Lean Products". It is located in Washington state, USA.

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Four Types of Problems (new "Lean") book by Art Smiley

Four Types of Problems (new "Lean") book by Art Smiley | TLS - TOC, Lean & Six Sigma | Scoop.it

Art Smalley is a renowned expert specializing in leadership, problem solving, and operational improvement.

 

  • Troubleshooting: A reactive process of rapidly fixing abnormal conditions by returning things to immediately known standards.
  • Gap-from-standard: A structured problem-solving process that aims more at the root cause [...]
  • Target-state: Continuous improvement (kaizen) that goes beyond existing levels of performance to achieve new and better standards or conditions.
  • Open-ended and Innovation: Unrestricted pursuit through creativity and synthesis of a vision or ideal condition that entail radical improvements and [...]

 

 

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