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TOC - Constraint Management Consultants
- A scientific, system level approach to resolving business problems.
Constraint Management(CM) or Theory of constraints (TOC) is a process methodology that is especially useful for planning, organizing, evaluating and controlling complex systems. CM cuts through departments, viewing the entire process of interdependent parts with a focus on increasing throughput, decreasing operating expenses, and decreasing inventory. Our TOC constraint management consultants have been helping clients in Florida and the US utilize TOC to improve process flow. A short discussion of the CM techniques our TOC consultants use is described below.
Identify
Exploit
Subordinate
Elevate
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5 steps for continuous improvement
Constraint Management has 5 focusing steps for continuous improvement:
 Identify the constraint.
Exploit the constraint to minimize its impact.
Subordinate everything else to exploiting the constraint.
Elevate the constraint - turn it into a non-constraint. (This may create a new constraint.)
Return to step 1.
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In any process, only a few variables (maybe only one) limit the performance of the system. The most common metaphor used to visualize Constraints Management at work is to compare a business system (process) to a chain. This chain is composed of a series of links and one of them is the weakest (constraint.) Not all constraints are physical. Many things can be a constraint - resources (people, equipment, facilities), the market, policies, knowledge or skills, suppliers, materials, or financial constraints. |
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Logic Tree Diagrams
The CM method utilizes logic tree diagrams to analyze complex systems and clarify cause and effect relationships. This problem-solving methodology is a valuable tool for problem identification, solution testing, and implementation planning. In our opinion, CM logic diagrams are the best root cause analysis tool we have seen.
Drum Buffer Rope (DBR)
Drum Buffer Rope (DBR) is a scheduling technique and control mechanism used in Constraint Management. DBR scheduling can be used by service companies and healthcare as well as manufacturing companies. In CM, nonconstrained resources are scheduled to serve the constrained resource. The schedule is designed to make all the workstations perform at the pace of the constrained resource or Drum. A buffer in front of the constrained resource allows for a continuous flow of products through the system. Below is a comparison of CM to Lean Manufacturing.
System |
Constraint Management |
Lean
Manufacturing |
| Pace |
Drum (The constraint that is used to build the schedule.) |
Takt Time (Maximum time allowed to produce a product in order to meet demand.) |
| Protection Mechanism |
Buffer (A period of time built into schedules, to protect the drum from disruptions. This allows tasks to be released a predetermined amount of time earlier than they are strictly needed.) |
Eliminate Inventory (Ideally achieve a one piece flow.) |
| Communication |
Rope (A schedule that dictates the timing of the release of raw materials, or jobs, into the system.) |
Kanban (Signals to indicate to production operators what products to produce and when to produce them.) |
CM (Constraint Management) integrates well with Lean Manufacturing and Six Sigma. Lean manufacturing's just-in-time production requires the process to be balanced so each task has the same output level, transferring batches of equal size (ideally one piece flow). On the other hand, DBR uses a buffer in front of the constrained resource to achieve an uninterrupted flow of products through the system. DBR readily allows different sized batches, making it especially suitable for use in a job order shop that takes custom orders of differing sizes. Lean can be modified to include this situation as well. The Pull system in both Lean and CM can also be modified to handle the production of seasonal goods that require substantial finished goods for a seasonal peak (i.e. Easter candy).
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HPK Group LLC © 2006 | Lean Manufacturing Consultants |
Based in Orlando, Florida - Consulting in Florida and all 50 states |
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