Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
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keita@juntos.co.jp
http://www.juntos.co.jp
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Agenda
Lessons Learned
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Company Profile
Bridge
Business
TOC
Consulting
Business
Tokyo
Osaka
Fukuoka
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Drawing
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Drawing
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Results of Implementation
Bridge Business
Organized
TOC Consulting Business
Implemented CCPM
for Design Department
Implemented CCPM
for Construction Department
2004
2006
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2007
Agenda
Lessons Learned
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CCPM
2006
2007
SDBR
2008
SCM
MT (TP)
2009
2011
with
Realization Technologies
Production - MTO
ETO,IT
MTA
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CCPM
2006
2007
SDBR
SCM
2008
MT (TP)
2009
2011
Keynote Speaker:
Oded Cohen
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CCPM
2006
2007
SDBR
2008
SCM
MT (TP)
2009
2011
with
Realization Technologies
Production - MTO
ETO,IT
MTA
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CCPM
2006
2007
SDBR
2008
SCM
MT (TP)
2009
2011
Daiken
NIKKEI CONSTRUCTION
2010 3.12 P49-P51
CCPM
2006
2007
SDBR
SCM
2008
Public Works Project
MT (TP)
2009
Production - MTO
Kuroiso Seisakusho
2011
Nippon Tungsten
DDP improved from 70% to 98%.
Production lead time reduced
from 26 days to 10.5 days (inhouse products)
Focused control of production
execution.
2006
2007
SDBR
2008
SCM
MT (TP)
2009
Production - MTO
2011
ETO,IT
Asahi Seisakusho
[Production]
Production lead time
reduced by 36%.
DDP improved to 98.7%.
Overtime reduced by 85%.
[Engineering]
Completion rate increased
by 23%.
Engineers overtime reduced
by 35%.
Sales increased by 15%
Achieved record-setting
Profit for the past 60 years.
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CCPM
2006
2007
SDBR
2008
SCM
MT (TP)
2009
Production - MTO
2011
ETO,IT
MTA
Anonymous Company S
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Agenda
Lessons Learned
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Lessons Learned
Our Operational Improvements
CCPM
2006
2007
SDBR
2008
SCM
MT (TP)
2009
2011
Implemented
Solution for Sales
For Sales
Average Cycle Time
27 wks
Before
2007-2009
After
2010-
For Implementation
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Lessons Learned
How to Approach to Customers
The Cycle time for both Sales and Implementation is influenced by the
ability of getting Buy-in from Top management and Gembas managers.
Top Down
Approach
Top
Management
Decision
Gemba
Decision-making may be done in a short period of time, but we will face a lot
of difficulties due to the lack of consensus with Gemba.
As a result,
Too many reworks during the implementation phase
Cycle time for implementations will take longer than expected.
Gemba may stop to use the solution eventually.
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Lessons Learned
How to Approach to Customers
The Cycle time for both Sales and Implementation is influenced by the
ability of getting Buy-in from Top management and Gembas managers.
Decision
Top
Management
Cycle Time for Sales
Bottom Up
Approach
Gemba
Lessons Learned
How to Approach to Customers
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Top Down?
Or
Bottom Up?
Top
Management
Top
Management
Gemba
Gemba
Lessons Learned
How to Make a Linkage Solution Design FK
Top
Management
Gemba
Solution Design
FK
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Management
Workshop
Implementation FK
Pilot Implementation
Roll-out
Lessons Learned
Solution Design FK UDEs
Example IT Company
UDEs Un-Desirable Effects
Inputs are not available when needed
Often resources are not available when needed
Priorities constantly shift
Too much rework
Too much overtime
Managers and resources have too many tasks
Many projects take longer than expected
Existing projects are disrupted by extra work
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Lessons Learned
Solution Design FK Core Cloud
Example IT Company
B
Make in-process
task/project toward
completion
D
Not switch to
another task
A
Manage projects
successfully
C
Resolve
urgent/short woks
immediately
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D
Switch to
another task
Lessons Learned
Solution Design FK Negative Loop
Example IT Company
Need to show progress,
Standing idle is BAD
Fixed Schedule
(Fixed Start and Finished date)
(Fixed Resources)
Wait time
Inputs are not available when
needed
Often resources are not available
when needed
Priorities constantly shift
Rework
Tasks/projects take
much longer
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Multi-tasking
(of Resources/Managers)
High WIP
Lessons Learned
Solution Design FK Injections
Example IT Company
Rule 1 : PIPELINING
Limit WIP and Concentrate Resources / Task Managers
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Lessons Learned
Solution Design FK Negative Loop
Example IT Company
Need to show progress,
Standing
idle2is BAD
Rule
Full Kit
Fixed Schedule
Rule 3
Wait time
Inputs are not available when
needed
Often resources are not available
when needed
Priorities constantly shift
Rework
Tasks/projects take
much longer
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Multi-tasking
(of Resources/Managers)
High WIP
Rule 1
Pipelining
Lessons Learned
How to Make a Linkage Management Workshop
Top
Management
Gemba
Solution Design
FK
Management
Workshop
Implementation FK
Pilot Implementation
Roll-out
Lessons Learned
How to Make a Linkage Implementation FK
Top
Management
Gemba
Solution Design
FK
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Management
Workshop
Implementation FK
Pilot Implementation
Roll-out
Lessons Learned
Implementation FK MTA Game
How to transfer the knowledge Example of MTA
Scenario 1 :
Fixed schedule based on forecast
Introduce a suggested
solution (MTA)
Run MTA Game
(Run 3 Scenarios)
Review results and find
cause & effect
Integrate experience
into solution elements
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Scenario 1
Scenario 2
Scenario 3
Sales (total)
254
263
262
40
43
Availability
84%
84%
99%
320
280
268
6.7
248
232
236
6.2
5.8
5.9
Avg WIP
47
32
23
26
19
23
73
51
46
6.4
6.6
6.6
11.5
7.8
7.0
Scenario 2 :
Release based on consumption
with same frequency of
replenishment
Scenario 3 :
Release based on consumption with
more frequent replenishment
(MTA mode)
Lessons Learned
Implementation FK MTA Game
How to transfer the knowledge Example of MTA
Introduce a suggested
solution (MTA)
Run MTA Game
(Run 3 Scenarios)
Review results and find
cause & effect
Integrate experience
into solution elements
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Lessons Learned
Implementation FK Procedures
Develop procedures/mechanics for the Pilot
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Lessons Learned
How to Make a Linkage Pilot, Roll-out
Top
Management
Gemba
Solution Design
FK
Management
Workshop
Implementation FK
Pilot Implementation
Roll-out