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Theory of Constraints

Theory of Constraints. Lean Manufacturing Series. Outline. Introduction to Constraints Five Steps Of Theory of Constraints Drum Buffer Rope Evaporating Cloud Method The Batch Size Problem Chain Analogy Issues with TOC Measurements & Financial Issues. Constraints.

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Theory of Constraints

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  1. Theory of Constraints Lean Manufacturing Series

  2. Outline • Introduction to Constraints • Five Steps Of Theory of Constraints • Drum Buffer Rope • Evaporating Cloud Method • The Batch Size Problem • Chain Analogy • Issues with TOC • Measurements & Financial Issues

  3. Constraints • Any system can produce only as much as its critically constrained resource Constraint 60 units Per day 70 units Per day 40 units Per day 60 units Per day Maximum Throughput = 40 units per day

  4. Issues with TOC • Advantages • Improves capacity decisions in the short-run • Avoids build up of inventory • Aids in process understanding • Avoids local optimization • Improves communication between departments

  5. TOC, TQM and JIT • All 3 methods attempt to reduce variation and recognize the interdependencies. • Statistical process control is emphasized in the quality area to help identify ways to reduce variations. • Cells are used to reduce the dependencies, U cell configurations, where one worker is moving with the processed piece from one machine to another • Predetermined schedules, in TOC, reduce both statistical fluctuation and dependent resources.

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