theory of constraint and drum buffer rope
TRANSCRIPT
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A p p r o a c h T o H i g h V e l o c i t y M a n u f a c t u r i n g S y s t e m
Theory of Constraints andDrum-Buffer-Rope:
Presented by-
Wagh Sandeep Baburao
MTech 2nd Sem
Industrial Management
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The Theory of Constraints is based onthe premise that
Every real system, such as a business, must have
within it at least one constraint. If this were not the
case then the system could produce unlimited amounts
of whatever it was striving for, profit in the case of a
business..
Dr E Goldratt
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Constraints determine systemperformance
y A business having no constraintswould have infinite profit.
y Constraints may be-
Market
Capacity
Resources
Suppliers
Finance
Knowledge Or Competence
Policy
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Continue .
y Aconstraint is anything that prevents a system from
achieving higher performance relative to its goal (which for
a business is to make more money).
y Apolicy constraint is a policy, procedure, or even mindset
that prevents a company from making more money.
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Examples of Policy Constraints
y Salaries paid to workers are so low that the company cant keep
qualified workers.
y Buying raw materials strictly on the basis ofprice prevent getting
consistent good quality materials
y Repair of large portion ofHigh Way Road, the actual constraint
is Government acquisition policy - contract goes to lowest
bidder.
Policy constraints should be eliminated.
Drum-Buffer-Rope (DBR) applies to Market
and Resource Constraints.
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Finding the Constraint
y
What happens if A produces 5 per hour?
y What happens if A produces 1 per hour?
y So constraint is the weakest link in the system
WorkStation
A - 5B - 4 C - 3 D - 4
Market
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Finding the Resource Constraint(Assume the market exceeds productive capacity).
A- - - -
Constraint
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Identifying the Drum
A - 5 B - 4 C - 3 D - 4
Drum
C should be used as a drumbeating out a pace of
3 units per hour for the line to follow.
the physical constraint or the weakest link, which
will set the timing for the rest of the system may
called as a Capacity constraint resource (CCR).
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Locating the Buffers
A - 5 B - 4 C - 3 D - 4
DrumMaterial
(time) Buffer
SpaceBuffer
aterial release uration.he uffer rotects the ru , y ensuring that the
or -in- rocess arrives at the ell efore it is
sche ule to e rocesse .
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Tying the Rope from the Constraint toMaterial Release
Rope is the term used for the communication feedback to
the resources before the Drum, so that each of them
produces only the amount of inventory that the Drum can
complete.
A - 5 B - 4 C - 3 D - 4
DrumMaterial
(time) Buffer
SpaceBuffer
Rope
Shippingbuffer
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Materialrelease
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What if there is no Resource Constraint?
(The market demand is less than capacity)11
A - 5 B - 4 C - 3 D - 4
Rope Demand
Market- 2
Materialrelease
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TOC ProcessFive Focusing Steps
1. Identifythe constraint to the system.
2. Decide how to exploit the constraint to the system.
3. Subordinate all other resources to the constraint.
4. Elevate the system constraint.
5. If in any step, the constraint is broken, go to step 1. Don'tlet inertia set in.
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Identifythe Constraint to the system.
y Consider what is limiting the performance of the system,
whether the restraint is inside or outside the system
(resource, policy, market)
A - 5 B - 4 C - 3 D - 4
Constraint
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Decide how to exploit the constraint to thesystem.
y Exploit means to get most from the constraining element
without additional investment
y Find out the different possible ways to get maximum
benefit from constraint.
A - 5 B - 4 C - 3 D - 4
Drumt ri l
(tim ) Buff r
Sp cBuff r
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Subordinate all other resources to the constraint.
Local efficiency measures must be eliminated and
replaced by performance to schedule.
A - 5 B - 4 C - 3 D - 4
DrumMaterial
(time)Buffer
SpaceBuffer
Rope
Shippingbuffer
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Materialrelease
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Elevate the system constraint.
This might be a new worker or machine or it might be
offloading work to an existing machine.
A - 5 B - 4 C - 3 D - 4
DrumMaterial
(time)
Buffer
SpaceBuffer
Rope
Shipping buffer
C 3.5
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Materialrelease
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If in any step, the constraint is broken, go to step1. Don't let inertia set in.
y For example, change in market demand for a product, after
elevating the constraint one must not become complacent with
their action as there is an environmental (surrounding) change.
A - 5 B - 4 C 3.5 D - 4
DrumMaterial
(time)Buffer
SpaceBuffer
pe
Shipping buffer
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Materialrelease
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Conclusion
y TOC and DBR is helpful for identifying the core problem of
a complex system.
y TOC addresses the entire system as a chain or grid ofinterlinked chains.
y Result in continual improvement of the performance of the
entire system.
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THANK YOU
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