Theory of Constraints
Basic TOC Information
- Watch the video or read the book “The Goal”
- 5 Step Process of Improvement Used in “The Goal” (CIRAS)
- Why TOC Works
- Intro to TOC-Web Slide Show (CIRAS)
- Resistance layers to change (CIRAS)
More TOC Information
- Key Elements of TOC
- Let’s Help Herbie Win
- Stress Management
- Why Lean, TOC, 6 Sigma?
- Why Wait & Constraint Mis-Management
- Basic TOC Training
- Examples using the 5 Step Process of Ongoing Improvement
- 5 Step Form in Excel
Powerpoint Files on TOC Basics
- Intro to TOC by Tim Sullivan, Iowa State Univ (195k-right click to download)
- Intro to TOC (Spanish) (same powerpoint by Tim Sullivan above converted to Spanish
- Into to the TP, Overview of the TOC Thinking Processes
5 Step Process of Ongoing Improvement
- What is the 5 Step Process
- 5 Steps Emphasized
- 5 Step Process used in “The Goal” (CIRAS)
- Examples Using the 5 Step Process
- 5 Step Form (HTML)
- 5 Step Form in Excel
Evaporating (conflict) Clouds
- Explanation of Clouds and Other Thinking Processes (TP)
- Examples of Clouds
- Cloud Form in Excel
- A Simple Example of using the Thinking Process
Other Information, Etc.
- Improvement Initiatives of the Last 20 years
- Using TOC Logic Tools in Public Schools
- The Goal (MAAW web site) Summary of the book “The Goal”
- Theory of Constraints (MAAW web site) Summary of the book “Theory of Constraints”
- TOC Section of the MAAW web site
- W. Edwards Deming Section (MAAW)
Ely Goldratt, author of the book “The Goal”, and originator of the Theory of Constraints training often asks this question of his students, “What are you waiting for?”
You know how to identify waste and substandard performance. You’ve been trained on how to list the cause of constraints. You also know how to list cures and subordinate others to help. But, most of all, you know how good it feels to implement improvement and elevate a constraint. So…why do you wait?
But what if we don’t do anything about our constraints. Sure we can rationalize doing nothing.
This type of behavior is called constraint mis-management.
- Ignore-Pretend the problem doesn’t exist.
- Rationalize-Use insulation layers (excuses such as: it’s not our fault; Our problems are different; Yes, but bad things will happen; We can’t it’s against the policy; We won’t get the support,etc,etc,etc) to justify inaction.
- Dominate-Keep the problem to ourselves, don’t include anyone in resolving it.
- Stagnate-Nothing changes, constraint continues.
- Fail-Unsolved problems breeds failure.
Examples Using the 5 Step Problem Solving Process
- (Get all the necessary people in a meeting and use the format. Examples below include global and local improvements)
- Increase Through-Put
- Improving die cast shots per hour (3rd shift)
- Reducing sort time in finishing
- Other successes using the 5 step form (several examples)
- A machining success story (includes detailed meeting notes)
- 5 Step Successes – eliminate 40% waste (several examples)
- Scrap constraints manufacturing xxxx series hub caps
- TOC and 5S at work at the tap and plug operation
- Breakroom cleanliness constraints
- Scrap constraints manufacturing shd covers
- Mini Kaisen – 5 Step a Tapping Process
- Improve shots per shift on dcm#14
- Hydraulic fluid budget constraints
- Wrong part numbers set-up in multiple part tools
- Wrong part numbers set-up (cont.) Matrix Meeting
- Running out of critical office supplies
- 50% scrap on a transfer tool
- Cracked parts
- Organizing WIP at the vibratory/machining areas
- Using TOC During Tooling Rebuilds
- Providing operator tools increases throughput (TOC & Lean)
Examples above provided by: Texas Die Casting
EXAMPLES OF EVAPORATING (CONFLICT) CLOUDS
What are clouds? Learn more about clouds.(Explanation of Evaporating Cloud and Other Thinking Processes)
Time cloud How do you focus your time? (Note: This cloud diagram includes assumptions, etc)
(Note: The clouds below are diagrams only)
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OTHER EXAMPLES OF CONFLICT CLOUDS
(Note: These links are to files in powerpoint)
- Teenager needs to go to bed at 11:00 during school nights
- What to do on vacation
- Add new programs in addition to others?
- Driving forklifts too fast
- Get a new car
- To keep or not keep an old truck
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MANY EXAMPLES OF USING THE TOC LOGIC TOOLS IN SCHOOLS
(Note: These links take you to the tocforeducation.com web site)
- Target Tree – Behavior
- Target Tree – Curriculum content
- Cloud – Behavior
- Cloud – Curriculum content
- Branch – Behavior
- Branch – Curriculum content