TOC in Production Online Course extract: The 5 Focusing Steps. A Marris Consulting online service.
This course, that we launched one year ago, has been a great success. We continue to add to it continuously by enriching the appendices with more and more recent examples drawn from our unique experience of implementing the Theory Of Constraints in over 350 organisations throughout the world.
The VAT factory types are the Theory Of Constraints’ powerful classification system of the different kinds of industrial manufacturing systems, they determine how plants should be analyzed and how they should be managed. The VAT system was developed in the 1980s at the time of Creative Output when Eliyahu Goldratt and his team were selling a scheduling software system called OPT based on differentiating between bottlenecks and non-bottlenecks.
The letters represent visually the Bill Of Materials but where the flow is from bottom to top (the opposite of most representations of flow). The raw materials and purchased components are at the bottom and the Finished Goods are at the top. Products flow upwards. The V-Plant has very few ...
Economies of Flow: Making the Business Case for FlowEvent hosted by TameFlow Consulting LimitedMarch 18, 2025Online eventPeople on LinkedIn are goingJoinKeep up with Economies of Flow: Making the Business Case for FlowSee who else is going to Economies of Flow: Making the Business Case for Flow, ...
“Lean has failed.” That’s the bold statement James Womack—founder of the Lean Enterprise Institute and MIT researcher whose team introduced the term “lean” to the world—made at a conference where we both recently spoke. It’s a comment that’s stuck with me. Has lean really failed? And, if so, what can we do to course correct? To explore his statement I invited James Womack to Chain of Learning, to share his reflections and experiences over the past 40 years—where his vision for lean management has fallen short, where it’s succeeded, and what we can learn for the future.
Let's cut to the chase - in quality the real signal is in the noise; the real signal is in the noise. How could it be any other way? I can assure you that there is both a deep irony here and more than a little apparent contradiction.
An Ode to Speed introduces a new approach to management decision-making and argues that, by default, we should be optimizing our organizations for speed and not for cost (or efficiency). Most managers appreciate the value of speed but lack the means or the mandate required to use speed as the basis for day-to-day management decisions. This book changes that.
An Ode to Speed introduces a new approach to management decision-making and argues that, by default, we should be optimizing our organizations for speed and not for cost (or efficiency). Most managers appreciate the value of speed but lack the means or the mandate required to use speed as the basis for day-to-day management decisions. This book changes that.
Half a million views of Marris Consulting’s videos. Thank you to all our followers. 10 years of hard work. Thank you to all the team. Videos mostly about Theory Of Constraints and Lean and Lean Six Sigma. Client testimonials, tutorials, presentations, expert interviews, etc.
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Building on Success 2018 Conference. Nampachi Hayashi joined Toyota Motor Company in 1966.
This video features a very senior and well respected member of the highest of inner circles in Toyota, and contains both video and testimony from and about Ohno-san and Goldratt, and makes it self-evident the role both have played.
All About Work Standards is a practical and utilitarian guide to creating, implementing, maintaining, and improving work standards, the key to continuous improvement. It includes examples from a broad range of industries, and explains the difference between work standards and Toyota Standard Work. The book also explores Leader Standard Work, including its purpose, potential, and limitations. This hands-on resource is essential for practitioners, students, and researchers in lean manufacturing.
I am often asked to tell my story of how I increased the performance of a 1,000 person factory in only 15 minutes. The factory was located in the middle of Mexico. It produced alternators for the…
TLSBlue encourages leadership to create their own path, constantly refining and adapting to fit their operational realities while still adhering to the guiding principles of systemic focus and improvement. TLSBlue integrates the best of TOC, Lean, and Six Sigma, with many other tools, for creating and sustaining a Blue Ocean.
Join us for a free webinar with Art Byrne, renowned lean expert and author of the new book The Lean Turnaround Answer Book, on December 12, 12PM-1PM ET. Drawing from over 40 years of lean leadership experience, Art will dive into real-world answers to the most pressing questions around lean transformation and the challenges companies face along the way.
Many projects fail due to unrealistic promises, multitasking overload, and poor workflow management. [...] To address these issues, we propose a three-level control system. - Portfolio management ensures the system is not overwhelmed with too many projects. - Critical Chain Project Management eliminates excessive safety margins by using a shared buffer, improving predictability. - Execution management uses Kanban and Agile techniques for efficiency. ...
Bob Sproull and Bruce Nelson, both Systems Improvement Consultants lay out how they improve the profitability of organizations from all industry types.
Came across Bob Sproull and Bruce Nelson's book as Systems Improvement Consultants in 2010. They lay out how you too can improve the profitability of organizations of all types of industrial applications. -- I wasn't able to verify if it worked as advertised until I worked at Meggitt (an Aviation, Aerospace & Defense Firm) when I was the Senior Manufacturing Engineer (the only Mfg Engineer) for the Maintenance, Repair & Overhaul (MRO) Shop. -- We implemented and verified its applicability and value add when we used this methodology, along with Don Reinertsen's 2nd Generation Lean Six Sigma Product Flow Practices (another great Product & Process Improvement Book, that I highly recommend), and then we added in TRIZ a Systematic Innovation tools to make sure that we got all the systems, up the S-Curve of Performance, Functionality and at lower operating cost..." Bringing the Magic Together"...Got an annualized $8.16M in ROI for the shop...the MRO manager, Bobby Padilla, and Bernie Watson, the Factory GM, were astounded...It completely overturned the status quo POV of the Corporate Meggitt Continuous Improvement folks, where they considered what we did as a new BKM for Meggitt...Obviously, they had no idea that combining Lean Six Sigma methods could be improved.
The NUMMI (New United Motor Manufacturing, Inc.) experiment remains one of the most remarkable stories in automotive history. As part of Katie Anderson's fantastic Japan Study Trip that I experienced last November, I had the opportunity to ask Isao Yoshino about his experience at NUMMI, where he played a pivotal role as the training manager at the very beginning. His reflections reveal valuable lessons about leadership, learning, and the power of culture change.
[...] caused me to revisit the 7 tools of QC from 50 years ago and ponder how they should be updated with current data science. Data Science for Operators, as a book, remains to be written. If you google this phrase today, what comes up is training courses offering to “change your career” by attending a “data science bootcamp.” TIBCO Spotfire has “Workflow Operators” but these are programs, not people. So the following are tentative answers to questions that haven’t been asked before.
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)
Describing these approaches as “complementary,” as Bozdogan does, avoids controversy, but I don’t believe it is accurate. They really are competitive brands put out by consultants vying for clients in overlapping markets. […]
Exposure to the Toyota Production System (TPS) sparked my interest in manufacturing, in Japan in 1980, but then I immediately went to work in the semiconductor industry, where TPS is not much of a fit. Over the years, I have been exposed to all of the approaches surveyed in the article, and formed opinions about them, that I am sharing here. In particular, I would like to explain why I chose to work under the Lean flag and none of the others.
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Philip Marris's insight:
This is not a recent article (2013) but it is still valid and pertinent.
There’s no doubt about the importance of a people-centric approach in Lean. More to the point, though, it is becoming increasingly evident that Lean tool deployment and people development should operate simultaneously, supporting and reinforcing one another, if you want Lean to work. Specifically this means training your team to think and work scientifically, so they can effectively handle the problems that Lean tools inevitably expose. ...
Listen to this episode from NLG Talks on Spotify. 🚀 Unpacking Business Transformation: Lean, Six Sigma, and the Theory of Constraints Listen to our podcast with Akshat Agrawal and Eshwar Padmanabhan on how do methodologies like Lean, Six Sigma, and the Theory of Constraints (TOC) differ, and how can they work together to drive lasting transformation.
It’s a new era for the internal combustion engine. Each company’s representative engine, like horizontally-opposed or rotary designs, is being reborn for the era of decarbonization. This deep dive covers the new technology and the unusual joint declaration that has thrilled car lovers. Plus, we have information on the Lexus Charging Stations that are now available to all BEV users!
Philip Marris delivers a "Crash Course on the Theory of Constraints". The manufacturing analogy makes it easier for beginners to grasp the notions of bottleneck, buffer protection, Throughput... before transposing it to Project Management.
Acceptance Sampling In The Age Of Low PPM Defectives
Today, some automotive parts manufacturers are able to deliver one million consecutive units without a single defective, and pondering quality management practices appropriate for this level of performance is not idle speculation. Of course, it is only achieved by outstanding suppliers using mature processes in mature industries.
You cannot expect it during new product introduction or in high-technology industries where, if your processes are mature, your products are obsolete. While still taught as part of the quality curriculum, acceptance sampling has been criticized by authors like W. E. Deming and is not part of the Lean approach to quality.
For qualified items from suppliers you trust, you accept shipments with no inspection; for new items or suppliers you do not trust, you inspect 100% of incoming units until the situation improves. Let us examine both what the math tells us about this and possible management actions, with the help of 21st century IT.
The kaizen spirit is part of Toyota’s DNA and has its roots in the Creative Idea Suggestion System. We look at the history and intentions behind the long-running initiative, which also serves as a tool for fostering kaizen talent. #TOYOTATIMES
I had the opportunity to listen to a presentation by Nadja Böhlmann on “Dark Lean.” In order to do good lean, we need to understand why some lean projects are bad. Or, in order for practitioners to reach the light side of lean, they need to understand more about “Dark Lean.” Let’s have a look at the darkness to understand the light…
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