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This Introduction to Manufacturing focuses students on the issues that matter to practicing industrial engineers and managers. It offers a systems perspective on designing, managing, and improving manufacturing operations. On each topic, it covers the key issues, with pointers on where to dig deeper. 
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Many projects fail due to unrealistic promises, multitasking overload, and poor workflow management. [...] To address these issues, we propose a three-level control system.
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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. Via Philip Marris
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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.
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“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.
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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.
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Developed by the US Government during World War II, Training Within Industry (TWI) is a methodology to quickly train and develop new employees an
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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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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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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…
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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. […]
Philip Marris's insight:
This is not a recent article (2013) but it is still valid and pertinent.
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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.
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"Today’s manufacturing systems have become more automated, data-driven, and sophisticated than ever before. Visit any modern shop floor and you’ll find a plethora of IT systems, HMIs, PLC data streams, machine controllers, engineering support, and other digital initiatives, all vying to improve manufacturing quality and efficiencies. That begs these questions: With all this […]
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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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In the latest issue of The Management Brief, Jeffrey Liker urges the lean community to move beyond tools and templates—because lean is a way of thinking. Lasting transformation requires integrating lean’s technical, social, and scientific dimensions while developing people who can learn their way forward.
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Philip Marris delivers a "Crash Course on the Theory of Constraints". Via Philip Marris
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This thoroughly revised guide offers the current and next generation of supply chain professionals a clear explanation of the fundamentals of planning and MRP systems in today’s volatile and complex supply chains. Long considered the industry standard, Orlicky's Material Requirements Planning is an indispensable tool for manufacturing practitioners and candidates preparing for certification exams including CPIM, CSCP, DDPP and MRPFP.
Philip Marris's curator insight,
September 4, 2024 3:28 AM
Recommended: An updated classic that integrates DDMRP, TOC, Lean and Six Sigma.
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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. Via Philip Marris
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January 10, 2024 9:58 AM
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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.
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In this video, Philip Marris presents the different components developed by Eliyahu Goldratt. Via Philip Marris
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Within the quality profession, a capable process is one with a high Cpk. In the field, process capability is not quite so simple. [...] “Many manufacturers that I know struggle with incapable processes. Intellectually, people understand the concept of capability, but are unable to effectively apply it to an entire process. A single-figure measure for the entire chain would be ideal to better understand and manage it. The challenge is that the chain consists of processes with measurable characteristics, like thickness, substitute characteristics, like leak current to infer dryness, and also visual inspection results like blemishes or scratches. ...
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Eli Schragenheim, dedicated to making Theory of Constraints (#TOC) solutions accessible to SMEs all over the world, explains two big elements that he misses in the vast majority of ERP systems. With rare exceptions, a manufacturer who can't handle the following challenges must be inherently fragile, agree?
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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.
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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. ...
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