Rapid Re-Alignment at Baghaw Safety Footwear With TOC Strategy & Tactics

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com
33rd International Conference of the
TOC Practitioners Alliance ‐ TOCPA
www.tocpractice.com 18 ‐ 19 October 2017, Cape Town, South Africa
Rapid Re-Alignment at Baghaw

Safety Footwear with TOC
Strategy & Tactics
Dawid Janse van Rensburg, CargoSolutions

Fayyada van Rooyen, Bagshaw, SA
19 October, 2017
33rd International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Alternative Title
• How do we ensure longevity/sustainability of
our TOC implementations?
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Dawid B Janse van Rensburg
Dawid heads up CargoSolutions, a TOC consulting

business in the Cargo Carriers group.
CargoSolutions is the implementation partner for the
TOC enabling Symphony software in South Africa
for the past decade or so, and has approximately
done 30 implementations of the software to date, as
well as more than 20 dynamic buffer management
simulations.
He is also the IT Director for Cargo Carriers, and
CargoSolutions now operates a demand-driven
warehouse and distribution operation.
Contact info
Dawid B Janse van Rensburg
dawid@cargosolutions.co.za
011 485 8700
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Slide Title
The Longevity Challenge

Historical perspective
Changing of the Guard…
Ramifications
The Re-Alignment Process
After…
Take-outs
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The Longevity Challenge for TOC
Implementations
• After initial, successful implementation:

• Management changes
• The TOC enthusiasm wanes
• From 30 odd implementations:
– Some companies no longer exists
– Some have abandoned TOC principles
– Every company that has a TOC enabling system, still
“practice TOC”
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Bagshaw Footwear
• Based in Port Elizabeth, and company founded in 1860

• Manufactures Safety Footwear – Lemaitre, SISI, Fuel -
Polyurethane injection moulding process
• Some 400 plus factory workers
• Sell to Personal Protective Equipment (PPE) distributors,
mostly in SA
• Huge pioneering work on establishing SMME’s
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TOC Intervention
• Implemented the basic Consumer Goods Strategy &

Tactics Tree
• TOC enabling system
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Bagshaw Footwear Improvements
• LT reduction from 12-16 weeks to 3 days (MTS), and 2-4

weeks on MTO
– Very high availability on fast runners ‐ 96%+
• Much less inventory in system
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Financial Performance
ROI calculated at end ROI Indexed
600Feb of each year
500
400
300
ROI Indexed
200 Linear (ROI Indexed)
100
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Changing of the Guard
• Various executives moving on…

• Systems knowledge gap…
• ERP/Symphony interface compromised with item costing

changes
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Availability Affected
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WIP Affected
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Interventions
• Fix the Data!

• Back to basics…. (S&T Consumer Goods)
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Strategy & Tactics – Consumer
Goods
Source: Harmony Viewer, Goldratt Research Labs
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Availability Correction
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Late Work Reduction
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Overstocking Reduction
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TVD - Lost Sales Indicator
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Footwear Implementation
• Now in 3 of 7 factories – rest to follow in 2018

• Leather supplier now have VMI partnerships with a
number of the factories
• Started with DBM Warehousing & Distribution for all the
factories
• Enabling TOC in 2 new Footwear Retail Stores
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Symphony Enablement
Product Flow
Jordan
RM JDN
WH
Factory WH
RM Watson WAT

WH Factories WH
CT
RM Barker BKR WH
WH Factory WH
Mossops
RM FG Bagshaw
WH WL RM BGW BF
WH Factory JHB
WH FG Retail
WH WH
RM Beier BR
WH Factory FG
RM
WH DBN
WH
WH
RM Frams FR
WH Factory FG
WH
RM Wayne W
WH Factory FG
WH
Data Flow
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Summary
• After a serious supply chain malfunction, Bagshaw

stabilised the key supply chain indicators in a very short
space of time
• The simplicity of the methodology, and a well established
system enabled this
• Today a renewed enthusiasm and commitment to TOC
• Have witnessed/participated in a number of these “TOC
system enabled re-alignments”
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Thank you!

Rapid Re-Alignment at Baghaw Safety Footwear With TOC Strategy & Tactics

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Rapid Re-Alignment at Baghaw

Dawid Janse van Rensburg, CargoSolutions

Dawid B Janse van Rensburg

Dawid heads up CargoSolutions, a TOC consulting

The Longevity Challenge

• After initial, successful implementation:

• Based in Port Elizabeth, and company founded in 1860

• Implemented the basic Consumer Goods Strategy &

• LT reduction from 12-16 weeks to 3 days (MTS), and 2-4

Changing of the Guard

• Various executives moving on…

• ERP/Symphony interface compromised with item costing

• Fix the Data!

Late Work Reduction

TVD - Lost Sales Indicator

• Now in 3 of 7 factories – rest to follow in 2018

RM Watson WAT

• After a serious supply chain malfunction, Bagshaw

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