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Filippo Pescara
IFP sas GoldraM Research Labs
Italy
23 March, 2017
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Filippo Pescara
physical constraint
... both Ford and Ohno followed four concepts (from now on well refer to
them as the concepts of ow):
1. Improving ow (or equivalently lead +me) is a primary objec+ve of
opera+ons.
2. This primary objec+ve should be translated into a prac+cal mechanism
that guides the opera+on when not to produce (prevents
overproduc+on). Ford used space; Ohno used inventory.
3. Local eciencies must be abolished.
4. A focusing process to balance ow must be in place. Ford used direct
observa+on. Ohno used the gradual reduc+on of the number of
containers and then gradual reduc+on of parts per container.
Eli GoldraM 2006 Standing on the shoulder of giants
3 fundamental theorems
Theorems
Second theorem
First theorem Third Theorem
(planning):
(op-miza-on): (coordina-on):
balancing capacity,
local op-miza-on detailed schedules
-me, inventories etc.
does not lead to and priority lists
with demand is
global op-mum cannot be followed
impossible
Solu-on guidelines
First theorem Third Theorem
Second theorem
(op-miza-on): (coordina-on):
(planning):
T-I-OE and 5 Focusing WIP Control and Pull
buering
Steps Systems
insights
dont waste
the
nd the
constraints
resource
availability
whose limited
(do what
availability
should be Synchronize
determines
done; the resouces
the increase the
dont do what to facilitate
performance constraints
shouldnt be the
of the system availability
done) exploita>on
growth
1 2 3
4
stability
Iden'fy the Exploit the Subordinate to
Elevate
constraint constraint the exploita'on
5
Go back to 1.
Beware of
iner'a Theres a connec3on between the green
curve (stability) and the stability of the
constraints: we have to avoid the
situa3on in which, a<er the eleva3on, the
constraint moves!
C
Assump&on: when the constraint moves, the new
Tac2c:
exploita&on ad subordina&on increases chaos stabilize the A
INJ: Dene the way to elevate, avoiding that another constraint
B
resource becomes the new constraint
POOGI
C
Dont
Stability A
elevate Tac2c
B
growth
stability
POOGI
Increased level of exploita2on of
the physical constraint
Growth Elevate
basic insights
New poten0al eleva0on
subordinated to stability
SUSTAIN
C
Tac0c:
stabilize A
the
constraint B
CAPITALIZE
C
D C
Tac0c A
A
B
D B
BUILD
the physical constraint
UDE D C
UDE B
A
UDE Increased level of exploita0on of
UDE the physical constraint
D B
1 2 3
4
Iden1fy the Exploit the Subordinate to
Elevate
constraint constraint the exploita1on
5 Avoid if possible!
Go back to 1.
Beware of
iner1a
The Build Capitalize Sustain modies the 5 Focusing Steps sequence! Moreover, the
sequence depends on the constraint perspecEve
From the point of view of managing the system (dynamic logic) the ulEmate constraint is
the Eme available for management aMenEon.
The sequency assumpEons of the S&T nodes are part of the parallel assumpEons
(feasibility) who obey to the dynamic logic, so the implementaEon sequence must be
related to management aMenEon!
Inspiring guidelines: ease and speed of implementa+on!
www.tocprac+ce.com 32nd Interna+onal Conference of the TOC Prac++oners Alliance - TOCPA
5 focusing steps Your logo
Planned load
Alert buer & Slack
1
2
Iden7fy the 3 5
Subordinate to 4
constraint Exploit market Elevate market
market Subordinate to market demand
(market demand demand
demand
demand)
1 5
2 3
Iden-fy the 4 Elevate
Elevate Exploit
constraint Subordinate to management management
management management
(management a,en-on a,en-on
a,en-on a,en-on
a,en-on)
The focusing
In the implementa,on process the Dont waste management In order to facilitate the
mechanism of
rst step is ALWAYS Elevate the aMen,ons availability exploita,on, in other words to
POOGI further
system constraint (REDUCE THE (do what should be done; facilitate the need to follow
reduces the need
NEED FOR MANAGEMENT dont do what shouldnt the priori,es (subordinate), we
for management
ATTENTION)! be done) need to monitor capacity
aMen,on
Required Required
management management
a.en/on a.en/on
WIP WIP
Murphy
The larger the space buer, the more the system is
protected
Blocking for
maximum
build up of
material
between
the phases
buered line
Touch 'me Touch 'me
Probability Accumula'on
Conveyor belt
Touch 'me Touch 'me
Time
In lines, if the products are not too cumbersome, handling systems provide spaces to generate buers
dynamically.
This allows to benet from the higher speed of some centers (central part of the distribuEon curve)
which are thus able to recover in part the low performance due to the tails of the distribuEons.
The ow speed is, as a consequence, higher than that which would be obtained in a line that is not
buered. Unfortunately, buering is not possible in all kinds of contexts.
5%
AdopEng a takt Eme less than T can easily lead to chaoEc situaEons. To prevent this it would be
necessary to increase the takt Eme, in other words to decrease the speed of ow.
Even in balanced lines, the balance is never perfect, since there are too many variables that
determine the duraEon of the operaEons for the center, therefore a boMleneck is always in place.
IN A LINE WITHOUT BUFFERS THE SPEED OF FLOW MUST DEPEND ON THE TAILS OF THE
DISTRIBUTIONS.
To idenEfy the real constraint, if the performance depends on the tails, we need to increase the
buers. The room for improvement is greater if the capacity of the line is dictated by the tails! In this
case most of the system capacity is not exploited.
High probability
Low probability
Low probability
High probability
The situa+on in which the probability of the occurrence of emptying and lling is maximised happens
when the posi+on of the space is exactly in the middle of the line: For each lling and emptying cycle
it is recovered some amount of capacity that, without the presence of the space, would be lost.
Build lling
sta8s8cs
Add a space
buer in the
STOP
yes Is the constraint no middle of the
iden8ed?
candidate
sec8on
Add a space
buer in the Build lling
Is there at least
middle of the sta5s5cs of ALL
1 lled buer?
candidate the buers
sec5on
yes no
STOP
Every +me we introduce a new buer, increasing the number of sec+ons, the capacity of the whole
line increases, due to the increased amount of decoupling between the dierent phases. In order to
idenEfy the constraint in the new situaEon we should idenEfy which, among the new secEons, is the
candidate to contain it.
Direc&on of ow
If there are one or more buers lled for most of the +me, the sec+on that contains the
constraint is located downstream the last buer lled
If all buers are empty for most of the +me, the sec+on that contains the constraint is located
upstream all the buers
The constraint buer is not, in this case, a 1me buer, but a stock buer. It would be imprac1cal to Constraint iden.ed
synchronize the release of material to a 1me buer, since the most important reference for The space buer protects the ow from
synchroniza1on is in this case the takt 1me of the line. Managing a 1me buer would entail the downstream disrup6ons. Usually it should be
introduc1on of another reference of synchroniza1on. Adop1ng a 1me buer would lead to the result empty, but when Murphy hits downstream,
of increasing the complexity and to bring the system outside the plateau of the U-shaped curve the constraint is able to con6nue to work
Pitch (control
withdrawal kanban interval)
produc:on kanban Heijunka box
FIFO FIFO
Pacemaker process
FLOW
The roadrunner rule allows to take
Stock buer
advantage of the protec5ve capacity,
mul5ple ropes (due to kanbans and
supermarkets) inhibit the recovery of
performance and the advantage
Rope
stemming from the aggrega5on of the
constraint buer CCR variability
Shipping buer
Rope
Drum
FLOW
Roadrunner rule: everywhere
The use of supermarket buerizes the system, but the kanbans nullify the benets of buering. The
supermarkets, restored according to rigorous pull, do not allow the amounts contained therein to oat.
Only the uctuaEon of the buers allows to recover part of the lost capacity due to the tails of the
distribuEons.
WE MUST CHANGE THE KANBAN MECHANISM
Release to all centers all the Produc'on kanbans release (the total number
kanbans planned in the heijunka contained in the Heijunka box referred to the
analysis interval!)
box referred to a signicant period
of analysis (for example, two days). FLOOD THE FLOW
In that interval, all centers are
enabled to produce
Constraint
iden-ed
Release the job SIMULTANEOUSLY to all centers (cadenced through producEon kanbans according to
pitch intervals) AS IF EVERY CENTER WERE THE PACEMAKER. Maintain, between the various centers,
supermarkets dimensioned as in tradiEonal JIT systems, so that each center can withdraw the upstream
material when it is enabled to produce from a producEon kanban: in this way we are transforming
supermarkets into eec+ve buers
the constraint
Produc0on
release"Ropes"
Time interval
between opera0ons
(connected to takt
In order to protect the ow we need to place 0me)
stock buers at the end of integra8on legs. This Stock buer
is possible when the assembly parts are not
cumbersome otherwise we have to use Space buer
sequenced kanbans
Supermarket
Space buer
Supermarket
3
1 2
Subordinate to
Iden+fy the constraint Exploit the constraint
the exploita+on
Thank You