Theory of Constraints - Do It Yourself Kit for Small & Medium Size Enterprises for Manufacturing
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Theory of Constraints - Do It Yourself Kit for Small & Medium Size Enterprises for Manufacturing

Step by step guide for Business Owners, Managers, Consultants and TOC Implementers

About the Book

This eBook is an instruction manual for implementing Theory of Constraints' application for Manufacturing.

This eBook is targeted at Business Owners, Managers, Consultants and Implementers.

If you are in the business of manufacturing and you have problems in delivering orders on time, your lead time is increasing over a period of time and you have high inventory on the shop floor, this eBook can certainly help you.

About the Author

Rajeev Athavale
Rajeev Athavale

I am a TOC consultant. I teach and implement TOC. I have been studying and trying TOC over a decade.

I am an ardent fan of ToC. For past few years, reading about TOC has moved me from “I am impressed” to “I like it” to “I want to know more…”. I did not realize when it became a passion for me. Now, I eat, sleep, walk and breath TOC.

By sheer accident, I came across the famous book “The Goal” and that changed my life. I went on reading Goldratt’s next book “Its not luck” and thereafter I read all his books. Fortunately, Internet is a great source of information and it opened up the wealth of knowledge for me.

As I did more and more research on TOC, I felt the need for crystallizing and documenting the knowledge that I gained. I created my own training material and conducted a two-day workshop on TOC in my company. Thanks to Internet, I kept on enriching my Training material.

Apart from my own consulting, I had the opportunity to work on a large TOC implementation called "Viable Vision". The project was implemented by Goldratt Consulting.

As a part of the project, I had undergone training from various experts from Goldratt Schools such as Oded Cohen, Mickey Granot, Philip Wiljoen, Eli Schragenheim, Humberto Baptista, Kiran Kothekar and Martin Powell.

Apart from the training and on the job experience, study of Goldratt’s webcast, Strategy & Tactics Trees, TOC Insights, TOC Simulators (GSIM, MICSS, PM SIM, and Distribution), TOC Games and TOC SLPs have helped me to enrich his TOC related knowledge.

My passion for learning, experimenting, sharing knowledge and achieving results continues...

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Table of Contents

    • Copyright Information
    • This book is dedicated to
    • Preface
    • I am thankful to…
    • Check the Symptoms
    • How to Go About Implementing
    • Overview
      • The Vicious Cycle
      • How to Reverse the Vicious Cycle – The Solution
  • Phase 1 : Set up the basic system
    • Chapter 1 : Gather Data
    • Chapter 2 : Preparation – One Time Actions
    • Chapter 3 : Order Execution
    • Chapter 4 : Maintaining the Workload and Speed of Execution
    • Chapter 5 : Identify the Constraint
    • Chapter 6 : Decide how to get maximum work out of the Constraint
    • Chapter 7 : Create a bank of work in front of the Constraint
    • Chapter 8 : Manage the non-constraints
      • Non-constraints before the Constraint:
      • Non-constraints after the Constraint:
    • Chapter 9 : Do’s and Don’ts
      • Do’s:
      • Don’ts:
    • Chapter 10 : Gather data
  • Phase 2 : Implement Drum-Buffer-Rope (DBR)
    • Chapter 1 : Preparations
    • Chapter 2 : Plan and execute orders.
    • Chapter 3 : Buffer Management
      • Holes in Constraint Buffer
      • Holes in Assembly Buffer
      • Holes in Shipping Buffer
    • Chapter 4 : Gather Data
    • Chapter 5 : Managing Critical Purchased Materials
      • Modes of Purchasing
      • Items Purchased for Customer Orders or Based on Forecast
      • Items Purchased for Stock
    • Chapter 6 : Move to Simplified Drum-Buffer-Rope (SDBR)
      • Brief Description
      • SDBR Steps
      • SDBR Control
        • Red-line Control
        • Planned Load Control
      • SDBR Rules
    • Chapter 7 : Decision Making
  • Phase 3 : Take Next Leap in the Performance
    • Chapter 1 : Check the original Questionnaire, once again
    • Chapter 2 : (Evaluate alternative Ways to) Elevate the Constraint
    • Chapter 3 : What Next?
    • Available Software: (in random order)
    • Appendix A - Overview of Five Focusing Steps
      • Step 1: Identify the Constraint
        • What is Constraint?
        • How do you find the Constraint?
        • Types of Constraints
      • Step 2: Decide How to Exploit the Constraint
      • Step 3: Subordinate Everything Else (to the Above Decision)
        • What is subordination?
        • How easy or difficult is to subordinate?
        • What does subordination practically mean?
      • Step 4: (Evaluate Various Alternatives to) Elevate the Constraint
      • Step 5: Go back to Step 1 (Do not let the inertia to set in).
      • How do you know that you are managing the Constraint?
        • Identifying the Constraint
        • Time Management
        • Customer Service Level
        • Utilization
        • Improvement
        • Inventory
        • Cash flow
    • Appendix B - Bibliography

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