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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TLS: Good TOC + Good Lean + Good Six Sigma - 13 minute conference extract of presentation by Philip Marris | TOCICO Annual conference

TLS: Good TOC + Good Lean + Good Six Sigma - 13 minute conference extract of presentation by Philip Marris | TOCICO Annual conference | TLS - TOC, Lean & Six Sigma | Scoop.it

TLS: Open TOC + Good Lean + Good Six Sigma". Philip Marris explains why he believes TLS allows businesses to improve faster and achieve even higher levels of performance than using just one of these elements.

TOCICO = Theory Of Constraints International Certification Organisation = the global association of the TOC community.


Via Philip Marris
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Hoshin Kanri X-Matrix - Description and criticism by Christoph Roser | AllAboutLean.com

Hoshin Kanri X-Matrix - Description and criticism by Christoph Roser | AllAboutLean.com | TLS - TOC, Lean & Six Sigma | Scoop.it

When googling Hoshin Kanri, you will sooner or later come across an X-Matrix. It is a visually very impressive tool, but I am in serious doubt about its usefulness. It focuses on the creation of the Hoshin items, but to me this approach is overkill, and – even worse – may distract the user from actually following the PDCA, especially the Check and Act parts. While the article is highly critical, I hope reading it and understanding the shortcomings help you better understand how Toyota thinks.

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"The Goal": A Business Graphic Novel by E. M. Goldratt, D. J. Zimmerman, D. Motter - New (2017) graphic edition - Book and eBook

"The Goal": A Business Graphic Novel by E. M. Goldratt, D. J. Zimmerman, D. Motter - New (2017) graphic edition - Book and eBook | TLS - TOC, Lean & Six Sigma | Scoop.it
Visual and fun to read, The Goal: A Business Graphic Novel offers an accessible introduction to the Theory of Constraints concepts presented in The Goal, the business novel on which it was based. The Goal is widely considered to be one of the most influential business books of all time. A bestseller since it was first published in 1984, the business novel has sold over 7 million copies, been translated into 32 languages and is taught in colleges, universities, and business schools around the world. Named to Time magazine’s list of the 25 Most Influential Business Management Books, it is frequently cited by executives as a favorite or must-read title.
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Toyota's long term partnership with its suppliers - Webinar recording by Toyota ex-VP Manufacturing - Sept. 2021

The Toyota Way has revolutionized the industrial world. This approach has often been copied through the deployment of certain principles such as waste reduction, one piece flow, standardization of tasks, 5S, 5 whys, etc. However, the stable long term relationship that Toyota has been able to build with its network of suppliers remains unique. To date this practice is rarely adopted, even in the automotive industry. This is the subject of this webinar recording by Reynald Debaut-Henocque, ex-Vice-President Production of Toyota Motor Manufacturing France (TMMF).
If Toyota does this why don't you?

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Theory Of Constraints applied to an agile task board - 5 min. video by Andrew Rusling

Explains how to apply the Theory of Constraints to your agile/Scrum task board. You will learn how to improve the flow of your work via improved visualisation and most importantly by identifying your constraint and doing something about it.

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5S, 5 Whys and Standardised Work discussed by a Toyota ex-VP of Manufacturing - 8 min. interview by Philip Marris

What does Toyota find the most difficult in applying the Toyota Way!? Reynald Debaut-Henocque, ex-Vice-President of Manufacturing in Toyota Motor Manufacturing France, shares his 20 year experience of the elements he considers required the most efforts to maintain. He underlines 3 elements in particular: 5S, 5 Whys and Standardized Work. He is interviewed by Philip Marris, CEO of Marris Consulting, who has extensive experience in implementing "Good Lean" (Toyota Way) in a wide variety of industries throughout the world.

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Mazaaki Imai discusses the early history of Lean - 40 mins | Gemba Academy

Mazaaki Imai discusses the early history of Lean - 40 mins | Gemba Academy | TLS - TOC, Lean & Six Sigma | Scoop.it

Ron Pereira sits down for more than 40 minutes and talks with Mr. Masaaki Imai who is known the world over as the original “Lean Guru” and the father of Continuous Improvement. Mr. Imai has been a pioneer and leader in spreading the kaizen philosophy all over the world. His firsthand account of the history of lean based on his close associations and travels with such legendary giants as Shoichiro Toyoda and Taichi Ohno...

Jean-Guy Frenette's curator insight, July 26, 2014 10:17 PM

Un guru à connaître!

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Lean Enterprise Institute article about Theory Of Constraints "compared" to Lean

Lean Enterprise Institute article about Theory Of Constraints "compared" to Lean | TLS - TOC, Lean & Six Sigma | Scoop.it

[...] Combining Lean Thinking with the Theory of Constraints. Can the Theory of Constraints be used as a catalyst for lean implementation? This author says yes! TOC methods fit nicely into the lean thinking five-step change framework, between steps two and three. Using TOC can help lean change agents to improve performance in processes where it is infeasible to eliminate bottlenecks. Specifically, after creating the ideal future value stream map, how do you achieve it? As you divide your value stream into loops and determine improvement objectives for each, as described in Learning to See, incorporating TOC methods can give the following benefits:
• Determining Where to Begin ...

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The Theory Of Constraints' growing pertinence - Point of view by Philip Marris

The Theory Of Constraints' growing pertinence - Point of view by Philip Marris | TLS - TOC, Lean & Six Sigma | Scoop.it

The Theory Of Constraints is more and more pertinent in today's world of volatile uncertain demand in which it is not possible to distribute the work evenly throughout an organization. One resource will necessarily have a greater workload than the others; it will become the capacity constraint of the system. We must therefore identify the constraints and manage them accordingly. This video by Philip Marris, is a short extract of one of his one day training courses.

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Perspectives on Standard Work – Article by Michel Baudin + numerous contributions from various experts

Perspectives on Standard Work – Article by Michel Baudin + numerous contributions from various experts | TLS - TOC, Lean & Six Sigma | Scoop.it

“What do we mean by ‘Standard Work’?” […] I saw it as whatever you do to ensure that same work is done the same way every time, regardless of time of day, production line, or factory; 96 comments later, my perspective has changed somewhat. Ensuring consistency is, of course, essential but the tool to do it is Job Instruction (JI) rather than Standard Work. […] Standard Work builds on these instructions by specifying how these tasks are sequenced and combined to make effective use of people and equipment. The main contributors to this post and ensuing discussion are : Sid Joynson, […] The discussion also cited publications by Mike Rother, Art Smalley, John Shook, and Taiichi Ohno. If you want to see the whole discussion, please check it out on LinkedIn. This post is a synthesis , organized by topic and with illustrations added.

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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 curates 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)

Via Philip Marris
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EOQ Versus JIT Explained Through Coffee Beans and Raspberries | Michel Baudin

EOQ Versus JIT Explained Through Coffee Beans and Raspberries | Michel Baudin | TLS - TOC, Lean & Six Sigma | Scoop.it
The “Plan for Every Food” in my household involves different policies for buying coffee beans and fresh raspberries. These simple examples show that  thinking in terms of Economic Order Quantity (EOQ) isn’t always wrong, and Just-In-Time (JIT) isn’t always right.  You need to set appropriate policies for screws, steel bars, engines, microchips, and all other items […]
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Offshoring discussed by a Toyota ex-Vice-President of Manufacturing

For low labour costs reasons, most industries choose to offshore their operations. Invited by Philip Marris, Founder and CEO of Marris Consulting, Reynald Debaut-Henocque, ex-Vice-President of Manufacturing at Toyota Motor Manufacturing France, presents his point of view on this topic.
He explains how Toyota successfully built a Toyota car assembly factory in expensive France in 1999. Currently, in 2021, the factory has 5,000 employees, they produce one third of all cars in France, it is a small low margin Segment-B car (Yaris), it won the car of the year award in 2021, etc.
Excuses for why companies do off-shoring are numerous. Few people talk about the counter examples that prove that you can compensate for high labour costs in many ways.

Reynald Debaut-Henocque regularly gives a training course online ""Lean: the keys to Good Lean and traps of Bad Lean" if you wish to learn more: https://www.marris-consulting.com/en/training/lean-good-vs-bad-lean-training-description

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41 page presentation - 15 examples of Theory Of Constraints combined with Lean implementations - Marris Consulting 15th anniversary - Free PDF download

15 examples of Theory Of Constraints. 1 hour video. Presented by Philip Marris, TOC and Lean expert with >250 implementations worldwide over >30 years. Availab…
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Don’t try to copy Toyota, understand it instead - Article by Nate Furuta | Planet-Lean.com

Don’t try to copy Toyota, understand it instead - Article by Nate Furuta | Planet-Lean.com | TLS - TOC, Lean & Six Sigma | Scoop.it

Many executives have chased the Toyota model of success. You may be one whose organization has tried to replicate the Toyota Production System (TPS) and methods, such as just-in-time or jidoka. [...] There is a tendency to try and emulate TPS, rather than understand the thinking that inspired Toyota executives and workforces for decades. The basic thinking is simple: executives cannot solve a problem if they cannot find the problem. [...] everyone in your organization has to be inspired to find problems.

Toyota became successful because its executives were determined to create a culture dedicated to finding Toyota’s problems, then aligning solutions to those problems with Toyota’s vision.  ...

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How to compare Six Sigma, Lean and ToC | 2002 ASQ article by Dave Nave

How to compare Six Sigma, Lean and ToC | 2002 ASQ article by Dave Nave | TLS - TOC, Lean & Six Sigma | Scoop.it
After listening to multiple champions advocate their special methodology, how do you choose what will be best for your situation? What methodology fits the culture of your organization?
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Theory Of Constraints - Drum-Buffer-Rope scheduling - 4 min. summary | Philip Marris

In this short video, Philip Marris explains how to manage the production flow with Drum-Buffer-Rope (DBR). This methodology was created by Eli Goldratt and presented in his best-selling book The Goal.

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What is the Main Purpose for Combining the Theory of Constraints, Lean and Six Sigma? | Lean Insider

What is the Main Purpose for Combining the Theory of Constraints, Lean and Six Sigma? | Lean Insider | TLS - TOC, Lean & Six Sigma | Scoop.it

Back in May, Bob Sproull and Matt Hutcheson published a book entitled The New Beginning: A Business Novel on How to Successfully Implement the Combination of The Theory of Constraints, Lean, and Six Sigma to Drive Profit Margins. Essentially, this book teaches the reader how to successfully combine and implement the Theory of Constraints, Lean, and Six Sigma to produce results that many companies only dream of having. It covers a variety of different company types including manufacturing and healthcare.

When I spoke with Bob in July, I asked him: "What is the main purpose for combining and implementing the Theory of Constraints, Lean, and Six Sigma?" Here is his full answer:

The main purpose for combining and implementing the Theory of Constraints, Lean, and Six Sigma is quite simply to maximize a company’s profitability.  Each of the three individual components serves a completely different purpose, but ...

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Akio Toyoda: “I want to be the most ‘genba-oriented’ president" | ToyotaTimes.jp

Akio Toyoda: “I want to be the most ‘genba-oriented’ president" | ToyotaTimes.jp | TLS - TOC, Lean & Six Sigma | Scoop.it
Does Akio Toyoda just sit in his CEO office and spend time approving documents? No. Most of the time, he is visiting various frontlines or genba, which is in fact how Akio promised to be when becoming president. #TOYOTATIMES
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Free PDF copy of TLS (TOC + Lean + 6Sigma) best seller offered by co-author Bob Sproull - Highly recommended offer

Free PDF copy of TLS (TOC + Lean + 6Sigma) best seller offered by co-author Bob Sproull - Highly recommended offer | TLS - TOC, Lean & Six Sigma | Scoop.it

I am offering a free copy of my book, Epiphanized, to anyone who wants one. Just log onto my website and click the PDF for the book. [It is the 2012 1st Edition of the book. The current version is the 2nd edition]

[...]

This edition has been updated with an expanded appendix that includes more in-depth discussions of the tools covered in the first edition. This edition also sheds more light on the reasoning behind why the very best improvement results can be achieved by the unification of the Theory of Constraints, Lean, and Six Sigma (TLS). The appendix also provides additional detail about how the concepts covered in the book can be applied to your organization.

The primary theme throughout this book is the focus on the unity and enhancement of improvement tools and methods. The book includes an appendix that allows readers to explore, in much more detail, the principles, tools, and techniques presented in the novel portion of the book.


Via Philip Marris
Philip Marris's curator insight, July 13, 10:43 AM

FREE PDF copy of book offered by co-author Bob Sproull - Highly recommended offer

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The Back Story  of the book - Better Thinking, Better Results - Post by Bob Emiliani

The Back Story  of the book - Better Thinking, Better Results - Post by Bob Emiliani | TLS - TOC, Lean & Six Sigma | Scoop.it

This is the back story to the award-winning book, Better Thinking, Better Results. […] The Wiremold Company’s Lean transformation was featured the book Lean Thinking (published in 1996). It was one of five short chapters highlighting successful Lean efforts. At that time, Wiremold’s Lean transformation, led by the President and CEO, Art Byrne, was barely five years in the making. […] A second edition of Better Thinking, Better Results was published in 2007 to bring the story up-to-date, as Wiremold underwent a change in ownership and changes in management post-2001. I was criticized by some major figures in the Lean community for producing the second edition because it described how Wiremold’s Lean efforts quickly backslid under its new owner. […] In truth, the second edition is more valuable because it not only teaches leaders how to succeed, but also how to avoid failure.

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The top-ten Dilbert cartoons on lean | Better-operations.com

The top-ten Dilbert cartoons on lean | Better-operations.com | TLS - TOC, Lean & Six Sigma | Scoop.it
Dilbert and lean - Is your organization struggling to implement lean? This post presents the 10 best Dilbert cartoons on lean management.
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The Theory Of Constraints to Boost a Lean Organization - 18 minute extract of a TOCICO conference by Philip Marris

An 18 minute extract of the conference "Using TOC to boost a Lean organization" presented at the TOCICO Annual conference in Chicago by Philip Marris…

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Theory Of Constraints Thinking Processes revisited/updated by Graham Scott - Webinar 5th of August 2021 | ToC Show by Clarke Ching

Theory Of Constraints Thinking Processes revisited/updated by Graham Scott - Webinar 5th of August 2021 | ToC Show by Clarke Ching | TLS - TOC, Lean & Six Sigma | Scoop.it

On The ToC Show hosted by Clarke Ching, Graham Scott will take us on a very fast tour of the modern ToC Thinking Processes - including the Flying Logic Software and James Powell’s Druid Process.

To be blunt: this is not your Grandad’s ToC [Theory Of Constraints]. The way we use Goldratt's Thinking Processes has grown up and evolved a LOT over the years. It's still based on the same ideas you read about in It's Not Luck, in Bill Dettmer's big books, or in Lisa Scheinkopf's book, but we now have software and we've got a few different ways of drawing clouds, and CRTs. Graham Scott teaches and consults with this stuff.

If you want to know how to solve problems that others cannot, don't miss this.

Thursday 5th August 2021 = 9:00 pm GMT = 9:00 am Wellington, New Zealand.

The event will be recorded. To be informed of the recording please register.

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J.K. Fenner (India) Ltd. - 'Pull' / Replenishment example | Vector Consulting

In this video the senior management of J.K. Fenner (India) Ltd, the market leader in mechanical power transmission & sealing solutions, shares the remarkable results they achieved by creating an agile supply chain using the Theory of Constraints principles. J.K. Fenner (India) Ltd, enhanced customer service levels by building a highly responsive "pull" based supply chain that now provides higher availability of its products as well as faster and reliable delivery to its customers. This transformed its operations and gained them a decisive competitive edge in the market.
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