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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Advanced Lean training by Toyota ex-VP Manufacturing | Marris Consulting

Advanced Lean training by Toyota ex-VP Manufacturing | Marris Consulting | TLS - TOC, Lean & Six Sigma | Scoop.it

Marris Consulting is honoured to offer an online training session on « advanced » Lean hosted 80% by Reynald Debaut-Henocque, ex-VP Manufacturing of Toyota France 1999-2020 and its 5,000 person factory in northern France. 80% of the 7.5 hours is by ex-VP of Manufacturing Reynald Debaut-Henocque in which he presents the Toyota Way (Good Lean). In the remainder, Philip Marris , CEO of Marris Consulting presents the traps of Lean (Bad Lean). We do NOT present the basics of the Lean tools (5S, 5 whys, etc.). 3 days x 2.5 hours per day. Topics covered include: partnership with suppliers;  Lean product development / Lean Engineering;  Manufacturing management; Quality management; Standardized work; Visual management; the essential growth in turnover ...

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The Power of Process - Book by J. Zayko and M. Ethington

The Power of Process - Book by J. Zayko and M. Ethington | TLS - TOC, Lean & Six Sigma | Scoop.it

Book review by Jeffrey Liker:

Lean Process Design
Those of us who have done lean transformation work at the front lines of manufacturing plants can recall lamenting:  “We spend so much time fixing broken, waste-filled processes.  Why couldn’t they have been designed lean to begin with?”  Matt Zayko and Eric Ethington were in that position two decades ago when they worked as internal lean consultants for Delphi—GM’s in-house parts operation.  They were knocking it out of the park improving every metric for production lines only to find that in a new model launch none of what they were learned was used and the new line became the old line that needed to be transformed—all rework.  Delphi created the best process I have seen for new process design and launch. And Matt and Eric continued to learn over the last two decades.  ...

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History of the Toyota Production System (TPS) - 15 min video

Video from the Toyota Kaikan Exhibition Hall near Nagoya in 2005
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TLS, the Combination of Theory of Constraints, Lean, & Six Sigma - Presentation by Mark Woeppel

What's in the TLS – Theory of Constraints Lean Six Sigma approach to process improvement and how it creates results.

Many organizations struggle with their continuous improvement (CI) efforts; achieving real bottom line results, whether in cost savings or increased revenues, has proven to be difficult. In spite of the widespread implementation of Lean and Six Sigma principles, poor results persist.

The TLS process generates 15-20 times better performance than Lean or Six Sigma. This presentation will show the root causes of poor CI program performance and a systematic framework to create ongoing bottom line results.

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Toyota Way 2nd Edition - series of short videos co-produced by Jeffrey Liker

Toyota Way 2nd Edition - series of short videos co-produced by Jeffrey Liker | TLS - TOC, Lean & Six Sigma | Scoop.it
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Lean in a High-Variability Business: A Graphic Novel about Lean and People at Zingerman’s Mail Order | Book by Lander, Eduardo, Liker, Jeffrey K., Root, Thomas E.

Lean in a High-Variability Business: A Graphic Novel about Lean and People at Zingerman’s Mail Order | Book by Lander, Eduardo, Liker, Jeffrey K., Root, Thomas E. | TLS - TOC, Lean & Six Sigma | Scoop.it

Jeffrey Liker: "Lean Transformation Comic Book: I am excited to announce our graphic novel about the transformation of Zingerman's Mail Order business will be shipping December 1. It tells the story through graphic arts of this company's transformation from large batch to one-piece flow with all the bells and whistles of lean. It has been a journey of over 15 years guided by my former Doctoral Student, Eduardo Lander. You will get to feel what an organic transformation of learning is about in very different circumstances than a Toyota assembly plant. I think you will enjoy it and even want to share it...maybe with your family."

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The Theory Of Constraints: to accelerate your Lean program and generate growth | Medium Article by Philip Marris

The Theory Of Constraints: to accelerate your Lean program and generate growth | Medium Article by Philip Marris | TLS - TOC, Lean & Six Sigma | Scoop.it

... "By focusing Lean initiatives in the right places within the company, [TOC] leads to much faster improvements in performance. By identifying what limits sales, TOC enables organizations to renew with growth and avoid downsizing." ...

[7 mins. reading time]

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Is OEE a Useful KPI? - Article by Jeffrey Liker | TheLeadershipNetwork.com

Is OEE a Useful KPI? - Article by Jeffrey Liker | TheLeadershipNetwork.com | TLS - TOC, Lean & Six Sigma | Scoop.it
Jeff Liker, world-renowned Lean expert, on key performance indicator - OEE - as part of total productive maintenance (TPS). The way OA is used is not for comparing performance or any type of individual reward or punishment system.
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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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Michel Baudin's Blog Site  – Ideas from manufacturing operations. Recommended.

Michel Baudin's Blog Site  – Ideas from manufacturing operations. Recommended. | TLS - TOC, Lean & Six Sigma | Scoop.it

[...] working first as a production engineer, then as a developer/implementer of software to support manufacturing, and finally as a junior partner to Japanese consultant Kei Abe. After 8 years with Kei Abe, I started my own group, which morphed into the Takt Times Group in 2008, involving partners in France, Russia, Spain, and China. [...] appreciate the relentless pragmatism of manufacturing, the camaraderie of factory people, and their ingenuity. [...] Ohio University or as an instructor in continuing education courses as at UC Berkeley extension. I focus on consulting, teaching short courses, and writing.

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Maintenance at Toyota - Interview of ex-VP of Manufacturing Toyota France

Maintenance is seldom mentioned when it comes to increase a plant's productivity. Nevertheless Reynald Debaut-Henoque, ex-Vice-President at Toyota Motor Manufacturing France (TMMF), is convinced that an exceptional maintenance is essential to complete the two outstanding challenges at their factory located in Onnaing: going from a two-shift organization to a 3-shift organization and producing 3 millions of vehicles in only 10 years, replacing the current achievement which is 3 millions of vehicles in 20 years.
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You can also follow the curator of this Scoop it, Philip Marris, on Twitter

You can also follow the curator of this Scoop it, Philip Marris, on Twitter | TLS - TOC, Lean & Six Sigma | Scoop.it

Via Philip Marris
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Carrying cost of inventory: reconciling Lean and traditional accounting points of view - 5 min. video by Philip Marris

Carrying cost of inventory: reconciling Lean and traditional accounting points of view - 5 min. video by Philip Marris | TLS - TOC, Lean & Six Sigma | Scoop.it

In this video, Philip Marris explains why the carrying cost of inventory is often under-estimated by the traditional accounting methods. Among the costs generated by high levels of inventory there is the impact on improving quality and the inertia of long lead times.

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Mining and Theory of Constraints with Arrie Van Niekerk - 2 short videos

Mining and Theory of Constraints with Arrie Van Niekerk - 2 short videos | TLS - TOC, Lean & Six Sigma | Scoop.it

Theory Of Constraints in mining expert Arrie Van Niekerk is interviewed by Philip Marris in Johannesburg, South Africa. Arrie is one of the most experienced people in the world in successfully applying TOC to the mining industry. He has implemented TOC over 90 times in mines all over the world. Arrie is also the creator of the "Oiled Wheels" metaphor of TOC video that is one of the most popular TOC videos.

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A 3 book series "essential reading for all Lean promoters and practitioners" by Bob Emiliani

A 3 book series "essential reading for all Lean promoters and practitioners" by Bob Emiliani | TLS - TOC, Lean & Six Sigma | Scoop.it

Why do most Lean transformations struggle or fail? Why it is so difficult for bosses to accept Lean management? Who no servant leadership? Why does classical management maintain its grip on leaders? Why are CEOs so resistant to change? Why do people get in trouble with bosses for promoting Lean management? Why don’t leaders create safe spaces for experimentation? Why do leaders become disconnected from the work? You can stop wondering. [...] It took a long time, but now it is done. The books are the result of 13 years [...] They are essential reading for all Lean promoters and practitioners [...] Click on the links below to learn more about each book and read the reviews:

Philip Marris's insight:

A relevant quote from the author Bob Emiliani in LinkedIn:

Had Lean management not been so terribly mean to so many people for so many decades (i.e., Fake Lean, lay-offs, weaponized Lean tools, etc.), the tens of millions of workers who participated in the Great Resignation might have demanded the replacement of Classical management with Lean management. Rather than press for change in management system and leadership practice, they instead quit. The failure of the Lean movement to reach workers with a positive message of change has been profound. Too much time and effort has been spent on appealing to senior executives who have near-zero interest in Lean"

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Lillian Evelyn Gilbreth operational excellence pioneer 1878-1972

Lillian Evelyn Gilbreth operational excellence pioneer 1878-1972 | TLS - TOC, Lean & Six Sigma | Scoop.it

Fifty years ago today, Lillian Evelyn Gilbreth (May 24, 1878 – January 2, 1972) passed away. She was an early pioneer in optimizing and streamlining work, which is especially remarkable in a time when women were supposed to be at home in the kitchen instead of pursuing science and engineering. I already wrote briefly about her, her husband, and Frederick Winslow Taylor in my post The Tale of Taylor and Gilbreth. I also have her portrait, among other key people in the history of manufacturing, hanging in my office. Let’s have a look at the life of this very remarkable and outstanding woman!

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Carrying costs of inventory ridiculously underestimated - full 9 minute point of view by Philip Marris

The carrying costs of inventory are often ridiculously underestimated. Why is there a contradiction between the traditional Cost Accounting estimate of the carrying costs of inventory and the Lean way (Toyota Motor Company & al.)? Philip Marris explains why the true cost might be 10 times or 100 times that. The cost of having inventory is not just the storage costs + financial costs + insurance. There are at least 2 other sources of cost that are much more significant: the contribution to the costs of non-quality and the cost of the inertia that inventory creates. If the true carrying cost of inventory was not phenomenal then Toyota would have gone bankrupt a long time ago.

There are 2 versions of this video. This is the longer 9 minute version.

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The Management of Quality at Toyota - Interview of ex-VP Maunfacturing of Toyota France

In this video, Reynald Debaut-Henocque describes how Quality is managed at Toyota and at Toyota Motor Manufacturing France in particular. From initial training to the troubleshooting process, Reynald gives you an insight of how they really do it.

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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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Unique event: « Lean around the clock » 24 hours of free Lean content from the Lean Global Network / Chairman John Shook | TLS - TOC, Lean & Six Sigma | Scoop.it

Unique Lean global event: « Lean around the clock » 24 hours of free Lean content from the Lean Global Network (chairman John Shook). Starting Monday 29th of November 2021, 2pm GMT.

Here are some of the topics:

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When it comes to solving productivity & quality issues you can rush around and panic, or stand still and learn what you really need to fix. Find out more here.
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A chat with author and Lean expert Nate Furuta on exporting Toyota cultures | Planet Lean

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INTERVIEW – PL meets the author of the recently published book Welcome Problems, Find Success, who discusses bringing lean to different cultures and changing managerial behaviors.

[...] PL: Are there any differences in basic management thinking between Japanese leaders and those in North America or Europe?
KNF: I don’t think there are significant management differences between Japan and Western cultures; just between good companies and not-so-good companies! There might be a tendency for Japanese managers to be quite team-oriented and focused on people development, but the same is true for Western companies that we can describe as “high performers”. ...

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Theory Of Constraints, Lean & Six Sigma videos – Marris Consulting’s YouTube channel >400Kviews

Theory Of Constraints, Lean & Six Sigma videos – Marris Consulting’s YouTube channel >400Kviews | TLS - TOC, Lean & Six Sigma | Scoop.it

Over 300 videos. One new video per week. Subscribe now! Focused on Theory Of Constraints, Lean, Six Sigma and Critical Chain Project Management. Client testimonials, tutorials, presentations, expert interviews, etc. Marris Consulting’s YouTube Channel has now reached 400,000 views.

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The Ghost in the Machine - Webinar by John Willis, Global Transformation Office, Red Hat - 21 Oct. 2021

The Ghost in the Machine - Webinar by John Willis, Global Transformation Office, Red Hat - 21 Oct. 2021 | TLS - TOC, Lean & Six Sigma | Scoop.it
Oct 21 2021, 5:00pm CEST | 30 mins.

John Willis, Senior Director ,Global Transformation Office, Red Hat

When we are talking about one of this year's themes for TOCICO being “Standing on the Shoulder of Giants” it makes sense to talk about a common enemy of flow - “Ghost in the Machine”. Whether we are talking about Walter Shewhart, Edwards Deming, Claude Shannon, or Eliyahu Goldratt, the “Ghost” is always non-deterministic noise.…

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