Theory of Constraints

TOC systematically focus efforts, energy, and attention on the “system constraint.” This constraint, or bottleneck, restricts the output of the entire system and at the same time represents the primary leverage point for improving it. TOC adopts the common idiom “a chain is no stronger than its weakest link”. This means that processes, organizations, etc., are vulnerable because the weakest processor part can always damage or break them or at least adversely affect the outcome.

THEORY OF CONSTRAINTS

Course Objective

There are three questions that TOC philosophy empowers you to answer for any constraint:

  1. What to change?
  2. What to change to?
  3. How to change?

Who Should Attend

Senior Management

Middle Management

Process Owner

QC Managers

Operation Manager

Team Leaders

Project Managers

Benefits of Attending

TOC’s key processes are focused on removing barriers that prevent each part from working together as an integrated whole. TOC takes the analytical and diagnostic process and lays it out into a step-by-step procedure. It is a way to galvanize efforts and energies and to focus attention on a single aspect of the process with the intention of correcting a clear problem to arrive at a clear solution.

TOC means identifying  constraints  and managing them, resulting in:

  • On-Time In-Full (OTIF) delivery to customers.
  • Elimination of stock-outs across the supply chain.
  • Better control over operations and far less fire fighting.
  • Reduced cycle times and therefore inventories.
  • Rapid response culture and fewer chronic conflicts between team members.
  • Exposing additional production capacity without any investment.
  • Higher Net Profit, ROCE & Free Cash Flow.

Workshop Agenda

Introduction To TOC

Understand TOC Focus, Market Constraints, Strategy, and tactic trees, Learn about new frontiers.

Project Management with Critical Chain

Understand problem with classical Project management, How critical chain is redefining project management, Learn to get durable results with critical chain, Sustainability in project management, Role of Lean and Six Sigma in project management.

Drum-Buffer-Rope, Buffer Management, and VATI Flow

Understand the DBR system, Managing flow through DBR, Learn to do classification scheme in the complex production environment, Understand VATI flow.

Managing Supply Chain TOC way

Learn managing Make to Stock, Learn problems in Make to Stock, Why shift to MTS to MTA is required, Monitoring the target levels with Dynamic Buffer, Understand Push and Pull behaviour, Changing the distribution and replenishment through TOC,Managing Seasonality  in TOC distribution, Testing TOC solution on smaller scale, Managing integrated Supply chain through TOC, Understand current MRP conflicts and compromises, How to move  out of MRP conflict using TOC.

Managing Performance through TOC

Understanding Traditional performance measures, Applying the TOC approach to Planning Control and sensitivity analysis, Resolving measurement and performance dilemma, Understanding local and global matrix.

Continuous Improvement and Auditing through TOC

Understand Why to change-What to change and to What to change-How to cause change through TOC way, Using Toc to focus and accelerate Lean and Six Sigma initiatives.

Case Studies.

From DBR to simplified DBR for Make-To-Order

Understand five focusing steps of operation plan, Understand challenges of traditional DBR methodology, Learn to outline the direction of solutions( Time Buffer, Lead controls, Capacity reservation, Slacks), Where to use S-DBR.

Making TOC Way of Life

Using Toc for strategy, Marketing and sales, Applying To to Thinking Process, Doing DWM with TOC, Using TOC in Service management, Using TOC in Professional services, Using TOC in Customer support services, Using TOC for Personal Productivity.

Training Deliverables

Feedback From Past Participants

“Being in a service industry this workshop helped me to structure a constraint-free operation.”

“Our production line is now ready for next level of improvement as now my team can identify and eliminate constraints easily”

The TOC  poses a breakthrough in the scope of knowledge and practice related to projects management.

“This workshop guided us to make TOC  as a way of life.

Know Your Trainer

B tech from NIT Rourkela, PGDM  from IIM Calcutta with 14+ yrs of intensive experience in various sector. He is a certified coach for Manufacturing Management and System Development

He has helped companies turn-around by implementing Manufacturing Excellence through Lean, Statistical Quality Control, Six Sigma, Strategy Management

He is a passionate reader and have inclination to solve complex business problems within very short span of time.

@Tetrahedron Manufacturing Services Pvt Ltd

Phone : +91 7042140046         Email: training@tetrahedron.in

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