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Theory of Constraints (TOC) - 1
Theory of Constraints (TOC) - 1
OF
CONSTRAINTS
An introduction
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(TOC) - IBKM
Continuous improvement
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By using the ‘ Theory of constraints ’,
a logical five step process can be
followed that will focus our attention
on identifying and improving the
system constraint, resulting in overall
system improvement.
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System constraints
➢ A process is described as a series of continuous
actions that bring about a particular result.
➢ In other words, every system or process is a series
of linked activities or process steps.
➢ These process steps can be illustrated by looking at
a piece of chain.
➢ When visualizing a chain we can visualize a number
of individual links (process steps) interconnected to
form a length of chain (process)
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“A chain can only be as strong as the
weakest link”
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THEORY OF CONSTRAINTS (TOC)
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One basic assumption of TOC is that any
process (like a chain) is controlled by the
weakest link in the process. This weakest
link is the constraint of the system.
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Referring back to the chain model,
what is the benefit of strengthening
any link other than the weakest link.
The chain will fail at the weakest link
regardless of the strength of the
strong links. Improving the other links
by 20%, 40% or 100% will not increase
the strength of the chain.
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In the chain model, it is evident that
improvement to any link other than
the weakest link does not improve the
chain whatsoever.
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•
They are :
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1. Identify the constraint
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2. Exploit the constraint
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Example:
➢ A line that is working three shifts (24 hours/day) seven
days per week -
How can this capacity be exploited any further
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➢Implementation of process controls prior to
the constraint will protect system throughput
while root causes of the most pressing issues
are identified and eliminated.
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3. Subordinate everything to the system
constraint
The rest of the organization is synchronized with
the capabilities of the constraint and decisions
made regarding how to best utilize it.
1. Implement a starved buffer
2. Implement a space buffer
3. Implement QC prior to constraint.
4. Identify defects occurring after the constraint.
5. Identify and eliminate root cause of defects
occurring after the constraint.
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4. Elevate the constraint
➢Over time.
➢Sub-contracting
➢Buying another machine.
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5. Inertia
Once the constraint has been broken, the final step in
the TOC process is to go back to step 1 and start the
process over again.
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Success stories
1. Ford Motor Company, Electronics Division
The following figures are an average for all sites and all
products.
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Success stories
2. Avery Denison
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Your inputs please !
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Thank you and may God bless
you
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