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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"Good Lean Bad Lean" online on demand training by former Vice-President of Production of Toyota

"Good Lean Bad Lean" online on demand training by former Vice-President of Production of Toyota | TLS - TOC, Lean & Six Sigma | Scoop.it

“Good Lean” is presented by Reynald Debaut-Henocque, ex-VP Production of Toyota Motor Manufacturing France. 20 years with Toyota. Vast and recent (2000 to 2021) experience of doing good Lean outside of Japan.

“Bad Lean” is presented by Philip Marris, CEO of Marris Consulting, +30 years of applying Lean worldwide in +300 organisations in all kinds of industries.

This course is designed to provide you with the tools and strategies needed to achieve successful “Good Lean” outcomes and avoid the traps of Bad Lean.

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Theory of Constraints & Goldrattism - 11 mins. summary by Philip Marris

Theory of Constraints & Goldrattism - 11 mins. summary by Philip Marris | TLS - TOC, Lean & Six Sigma | Scoop.it

In this video, Philip Marris presents the different components developed by Eliyahu Goldratt.

Eliyahu Goldratt is best known for his novel The Goal, explaining the basics of the Theory of Constraints (TOC) applied to operations. However, his work covers a lot of other topics. Some of them are related to constraints and bottlenecks in several fields of expertise. Eliyahu Goldratt also wanted to "teach the World to think", this is also known as the Logical Thinking Process. As this last part does not deal with constraints, Philip Marris separates the "Theory of Constraints" from "Logical Thinking", both of them being part of "Goldrattism".

00:00 Introduction
01:41 Operation: Drum Buffer Rope
02:36 Projects: Critical Chain Project Management
03:51 Supply Chain: DDMRP
04:39 Marketing & Sales
05:59 Throughput Accounting
07:08 TOC in services
08:18 Logical Thinking Process
10:00 Conclusion

Several of our videos develop these components of the Theory of Constraints. Here is a short sample:
- Operations: https://www.youtube.com/watch?v=y7N2PU-vBpg
- Project Management: https://www.youtube.com/watch?v=SwVYAM5J0_8
- Supply Chain: https://www.youtube.com/watch?v=8XqnD6C5NuE
- Sales: https://www.youtube.com/watch?v=KDTwKqH3HB4
- Throughput Accounting: https://www.youtube.com/watch?v=RSFjYQpRV8o
- TOC in services: https://www.youtube.com/watch?v=lP-R47tnUXo
- Logical Thinking: https://www.youtube.com/watch?v=uKej3ntsItM

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Comparing Lean, Six Sigma, and Theory of Constraints by Mark DeLuzio

1h47 webinar recording. Mark DeLuzio compares the three approaches and makes a recommendation as to how to incorporate these concepts into your business transformation.

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The Evolution of Automotive Assembly Line—Part 2 - Post by Christoph Roser | AllAboutLean.com

The Evolution of Automotive Assembly Line—Part 2 - Post by Christoph Roser | AllAboutLean.com | TLS - TOC, Lean & Six Sigma | Scoop.it

[...] in automotive assembly, you also need to work underneath the car. While I have seen truck assembly lines where the entire undercarriage is flipped on its back, in automotive, this is usually done while the car is hanging. Let’s have a look how this is done, and then I’ll wrap up this post with the last bit of the assembly line where the car stands on its own wheels. ... [+ Variable Takt + etc.]

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How to combine Lean and Theory Of Constraints to boost performance - Video summary by Philip Marris

Philip Marris, a leading authority in the fields of Lean / Toyota Way and the Theory of Constraints (TOC) describes how and why he combines these 2 approaches. With decades of experience and a track record of success, Philip shares invaluable insights into the powerful synergy between the Toyota Way and TOC methodologies. He talks not only about production, but also [...] Critical Chain Project Management and the Logical Thinking Process or Toyota's long term development of partnerships with suppliers. [...] He illustrates how TOC's laser focus on identifying and eliminating constraints complements Lean's waste reduction efforts, resulting in accelerated performance improvements and sustainable growth.

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Variable Takt time - Post by Christoph Roser

Variable Takt time - Post by Christoph Roser | TLS - TOC, Lean & Six Sigma | Scoop.it

In this post I will look at how the tractor maker Fendt handles variability in its plant in Marktoberdorf, Germany. In my view, Fendt is one of the benchmark plants in the world in handling variability. In my previous post I looked at reasons why you may (or may not) leave one part empty on an assembly line with a part normally at every fixed interval. In this post I would like to expand on the idea of playing with the distance between parts to handle such variations in the cycle time, but with a focus on assembly lines where the interval between products can vary. We will look at how Fendt uses this to wrangle its variability.

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TLS: TOC + Lean + Six Sigma - 12 minute conference summary

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 ...

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Combining TOC and Lean – Free webinar by expert Philip Marris – 4th April 2024

Combining TOC and Lean – Free webinar by expert Philip Marris – 4th April 2024 | TLS - TOC, Lean & Six Sigma | Scoop.it

Discover the Power of Integrating Lean and Theory of Constraints (TOC). When Lean principles and Theory of Constraints are seamlessly combined […] faster improvements and substantial increases in sales become the norm. Lean excels at eliminating wasteful practices, while TOC helps pinpoint constraints that, when addressed, increase turnover. Together, they create a powerful synergy, propelling your company into a continuous cycle of effectiveness and growth. […] insightful webinar on April 4th at 4pm (CET Time) …

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Process Control and Gaussians | Article by Michel Baudin

Process Control and Gaussians | Article by Michel Baudin | TLS - TOC, Lean & Six Sigma | Scoop.it
The statistical quality profession has a love/hate relationship with the Gaussian distribution. In SPC, it treats it like an embarrassing spouse. It uses the Gaussian distribution as the basis for all its control limits while claiming it doesn’t matter. In 2024, what role, if any, should this distribution play in the setting of action limits for quality characteristics?
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Toyota management basics: Trying is better than doing nothing - From 2 shifts to 3 shifts

In this video, Reynald Debaut-Henocque, former Vice-President of Manufacturing at Toyota Motor Manufacturing France in Onnaing, details a significant milestone achieved by Toyota Motor Manufacturing France (TMMF).
He explains the transition from a conventional two-shift per day to an audacious three-shift operation, a first in the history of Toyota's global manufacturing practices and a world first in the automotive industry for a vehicle assembly plant.

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A song about Toyota and Lean management | Bob Emiliani

A song about Toyota and Lean management | Bob Emiliani | TLS - TOC, Lean & Six Sigma | Scoop.it

A song about Toyota and Lean management.
(Verse 1)
Oh Toyota, king of the road, your cars reliable, your work showed us the code
You built a system, a perfect flow, kaizen forever, let the good times grow
(Chorus)
Respect for people, that’s the key, continuous improvement, constantly
But the West came knockin’, got it all wrong, took your TPS, called it Lean, made it cheap not strong
(Verse 2)
Just-in-time, a beautiful dance, eliminate waste, always take a chance
But Lean became slashin’, cuttin’ to the bone, forgot the workers, left them all alone
(Chorus)
Respect for people, that’s the key, continuous improvement, constantly
But the West

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The 3 types of Constraints explained in 2 minutes by Philip Marris

Description by Philip Marris, CEO and founder of Marris Consulting, of the 3 types of constraints you can find in an organization:
1) The bottleneck that prevents from making more money in the short term
2) The constraint that prevents from making more money in the future
3) The meta constraint of "Management Attention"

 

Philip Marris started his Theory Of Constraints journey in 1985 when he started working with Eliyahu Goldratt. He has implemented these ideas over 300 times in all sorts of organisations worldwide.

tdollar's curator insight, March 11, 5:45 PM

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How to Pace Your Assembly Line | All About Lean / Christoph Roser

How to Pace Your Assembly Line | All About Lean / Christoph Roser | TLS - TOC, Lean & Six Sigma | Scoop.it
An assembly line is a manufacturing process in which a product is built in a step-by-step sequence. One of many decisions when installing an assembly line has to do with its pacing. When should you use a pulsed line? When a continuously moving line? And when is an unstructured timing best? This post will look at the pros and cons of these options.
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Working with Machines - Michel Baudin

Working with Machines - Michel Baudin | TLS - TOC, Lean & Six Sigma | Scoop.it
In Working with Machines: The Nuts and Bolts of Lean Operations With Jidoka, author Michel Baudin explains how performance differences that can be observed from one factory to the next are due to the way people use the machines -- from the human interfaces of individual machines to the linking of machines into cells, the management of monuments and common services, automation, maintenance, and production control.

 

When automating production, you do not replace direct labor with nothing but with indirect labor. Instead of having humans work with their hands or with machines, you have them program, troubleshoot, and maintain equipment.

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Boeing quality crisis - Article by John Shook | Lean.org

Boeing quality crisis - Article by John Shook | Lean.org | TLS - TOC, Lean & Six Sigma | Scoop.it

[...] But will adding inspectors and inspections fix the problem? What if, rather than adding inspectors (whether from the outside, from the FAA, or inside) at the end of the process, each of the 12,000 operators in the factory could be an inspector? Upstream, what if each engineer (software or hardware) were responsible for ensuring that quality is built in at each step? ...

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Critical Thinking or Scientific Thinking? | Bob Emiliani

Critical Thinking or Scientific Thinking? | Bob Emiliani | TLS - TOC, Lean & Six Sigma | Scoop.it
Critical thinking or scientific thinking. What is the difference? And which should you practice?Let's begin with definitions of these two cognitive skills:...
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Toyota times | Official Toyota website

Toyota times | Official Toyota website | TLS - TOC, Lean & Six Sigma | Scoop.it
Toyota Times offers a unique, unprecedented inside view of Toyota not seen before. Through this site, Toyota shows how it is transforming into a mobility company and shares the thoughts of its top leadership, including Akio Toyoda. Join us for this behind-the-scenes view of Toyota.
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Maintenance the Toyota Way – Webinar by former Toyota VP – 22nd May 2024

Maintenance, a competitive edge at Toyota Motor Manufacturing France. Hosted by Former Vice-President of Production of Toyota TMMF Reynald Debaut-Henocque.

While many manufacturing companies have chosen to outsource the maintenance of their equipment in large proportions with a view to spurious cost reduction, in Onnaing in northern France, the Toyota Motor Manufacturing France (TMMF) has relied heavily on its maintenance to make it one of the pillars of its strategy.

The plant now produces in 3 shifts per day (3 real/full shifts - and they were the first automotive assembly plant to do this in the world). Maintenance therefore has very limited access to equipment and has had to reinvent itself. Reynald will present the ingredients of their maintenance solution inspired by the Formula 1. An approach that is eye opening because it is the opposite of the practices of manufacturers on many points. "You took 17 minutes to fix this robot. The standard is 14 minutes.  You need more training." The equipment has been completely modified so as to make it easy to maintain. Etc.

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Theory of Constraints in production Online Course by Philip Marris

Theory of Constraints in production Online Course by Philip Marris | TLS - TOC, Lean & Six Sigma | Scoop.it
Learn how to use the Theory of Constraints to generate growth, decrease your production cycles and accelerate the Lean program in your factory! You will get access to the videos during 12 months upon purchase.

Via Philip Marris
NotionPlates's comment, January 21, 7:06 PM
good
viravira.co's comment, January 29, 10:19 AM
nice
tdollar's curator insight, March 22, 8:18 PM
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Watching Toyota Production System Live | Blog post by Tomasz Wykowski

Watching Toyota Production System Live | Blog post by Tomasz Wykowski | TLS - TOC, Lean & Six Sigma | Scoop.it

Ever since I read “Toyota Way” by Jeffry Liker almost ten years ago, I was hoping to see Toyota Production System (TPS) live. Finally, my wish come true today during our trip to Japan we’ve visited Toyota city and joined the Takaoka Plant tour.

["Impressed how much you got out of the visit." Jeffrey Liker]

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Logical Thinking Process: various practical examples | Webinar by Thorsteinn Siglaugsson and Bill Dettmer

In this webinar, [...] Thorsteinn Siglaugsson and Bill Dettmer,  explained how the Logical Thinking Process can be applied in real-life situations. They presented examples to illustrate how this approach aids in defining goals, identifying root causes of complex problems, and resolving persistent conflicts. Some cases they discussed:
- A service department losing market share
- Getting back on track with a project management career
- Saving a stalled DDMRP implementation
- Building a world-class IT business in 10 years
During the second 30-minute segment of the video Bill and Thorsteinn responded to questions from the attendees.

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Annual [TOC] Critical Chain Project Management 2024 Global Online Conference 17-18 April 2024 | TOCICO

Annual [TOC] Critical Chain Project Management 2024 Global Online Conference 17-18 April 2024 | TOCICO | TLS - TOC, Lean & Six Sigma | Scoop.it

Registration Now Open! Join us for this 2-day Critical Chain online conference, designed for Project Managers, Portfolio Managers, and practitioners. Delve into the impact of Critical Chain Project Management (CCPM) project timelines, enabling the delivery of more projects—faster, better, and at lower costs. Whether you're an experienced project manager, dedicated practitioner, or influential leader, our conference program caters to all levels, featuring both introductory and advanced sessions with valuable insights. Packed with the latest thinking and practical applications, the conference provides unparalleled opportunities to enhance your CCPM capabilities. Take advantage of early bird pricing and free tickets, Register Now!

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The Logical Thinking Process of the Theory Of Constraints presented by Bill Dettmer - Introduction

Bill Dettmer presents the Logical Thinking Process in six short parts:

- Part 1: the Introduction

- Part 2: the Goal Tree

- Part 3: the Current Reality Tree

- Part 4: the Evaporating Cloud

- Part 5: the Future Reality Tree

- Part 6: the Prerequisite Tree

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What makes manufacturers unhappy about their ERP systems  | Post by Eli Schragenheim

What makes manufacturers unhappy about their ERP systems  | Post by Eli Schragenheim | TLS - TOC, Lean & Six Sigma | Scoop.it

After you’ve invested hundreds of thousands into your own ERP system, it’s clear you wouldn’t want to find out that there’s a much better alternative on the market. Fortunately, it is not easy for an SME to replace their ERP, and large clients hate it even more. But, the reputation of the ERP company is meaningful for new implementations, and for being able to add more value to their existing clients, by adding applications that either add new required capability, or solve a current problem.

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Good Lean in 2 minutes

Reynald Debaut-Henocque, former Vice-President Manufacturing at Toyota Motor Manufacturing France in Onnaing, briefly describes what "good" Lean is.

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Bringing Scientific Thinking to Life - Book by Sylvain Landry reviwed by Jordan Jarnagin

Bringing Scientific Thinking to Life: An Introduction to Toyota Kata for next-generation Business Leaders (and those who would like to be) By Sylvain Landry

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