TOC-Lean Flow Manufacturing for MRO and Production
2-day Workshop
This workshop for manufacturing or Maintain & Repair companies explores the dramatic improvement to
the bottom-line that TOC-Lean can achieve when applied to manufacturing or workshop flow. The workshop
uses computer simulations in order to determine the real
issues that affect manufacturing companies in their desire to achieve the goal – to make money now and
in the future, to satisfy the market in terms of delivery performance, due date and lead time, with
zero defect as a given. The approach is known as TOC-Lean which is a fusion between two powerful and
complementary philosophies with proven track record in companies all around the world.
This approach also requires the alignment of the other functions within the manufacturing environment
such as planning, purchasing, engineering, QA etc in order to achieve 100% on-time, in full deliveries,
in a reducing lead time with zero defect as a given.
Day One
We use simple interactive computer simulations using a simulated production plant to try to manage fast
flow within the operations environment and we analyse why such management is so difficult when using
conventional, non-TOC methods:
Why is the lead time so long?
Why is the Due Date Performance < 70%?
Why are we not making money?
Why are expediting all the time?
Why are we constantly re-scheduling?
Typical results from the first run of the simulated plant:
And this is a fictional plant with no issues related to quality, no issues related to machine breakdowns, the
people work a full eight hour day, five day week, suppliers supply when asked and the market demand is
fixed and known in advance, so what is happening? Why are we making a loss? We analyse this, and
introduce the following:
The response from the perspective of TOC-Lean
Lessons from Dr Goldratt's seminal book 'The Goal'
The Five Focusing Steps
Typical results from this first run under TOC-Lean rules:
Better, although still way short of what is possible within the plant - but at least we are making money!
Now we fully implement the TOC-Lean approach with all the key rules and procedures in place:
This plant is now running at its optimal level – and you will have learned how to do it
for yourselves. The comparisons between the runs shows a process of improvement which works by
focusing on those key aspects of the business that act as the real levers for enhancing performance –
the constraint.
Day Two
This day builds on the lessons of day one in order to work through the process of constructing robust
schedules for any plant configuration.
Learning how to align the other key functions within the company
The importance of mapping the value stream
Assessing the current position through the use of the Lean Scorecard
Working through the necessary steps to implement Drum-Buffer-Rope into your organisation
The fee is £ 600.00 + VAT per person
If you would like further information or wish to arrange a
workshop for your business, please contact us by telephone or e-mail:
TEL: 01664 502860
E-MAIL: dianej@toc-lean.com
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