LENGTH: One Hour
Most manufacturing professionals are familiar with variation in product characteristics, and this is the focus of quality tools such as control charts and process performance indices. Variation in processing and material transfer times is equally important in production control, and it is largely responsible for long cycle times and accumulation of inventory. This kind of variation is also, incidentally, why traffic jams appear out of nowhere.
This presentation takes the participant beyond the Theory of Constraints by addressing the variation (in processing and material transfer times) that Goldratt and Cox simulate in The Goal. The matchsticks and dice exercise show why it is impossible to run a balanced factory at close to 100 percent capacity, but removal of variation from processing and material transfer times CAN allow operation at close to 100 percent capacity. Henry Ford achieved this through innovative process design techniques.
What You Will Learn
- Understand the role of variation in processing and material transfer times (in contrast to variation in quality characteristics) in limiting the throughput of a manufacturing process or service operation.
- Understand the role of the constraint or capacity-constraining resource (CCR), and its similarity to an activity on the critical path of a project.
- Gain awareness of techniques such as observation of inventory and also linear programming in recognizing the constraint.
- Understand the performance measurements (throughput, inventory, and operating expense) of Goldratt's Theory of Constraints, and their role in plant management.
- Understand the role of pull production systems such as drum-buffer-rope (DBR) in reducing inventory, and thereby reducing cycle time.
- Learn techniques such as task subdivision, small-lot or single-unit processing, and work slides and conveyor belts that reduce variation and improve overall performance. These techniques as introduced or deployed by Henry Ford take the attendee beyond the Theory of Constraints to learn how it is indeed possible to run a balanced factory at close to 100 percent capacity.
Viewers of the On-Demand webinar get:
- Unlimited viewing of the webinar for one full year, including any updated versions
William A. Levinson, P.E., is an ASQ Fellow, Certified Quality Engineer, Quality Auditor, Quality Manager, Reliability Engineer, and Six Sigma Black Belt. He is the author of several books on quality, productivity, and management. Henry Ford's Lean Vision is a comprehensive overview of the lean manufacturing and organizational management methods that Ford employed to achieve unprecedented bottom line results, and Beyond the Theory of Constraints describes how Ford's elimination of variation from material transfer and processing times allowed him to come close to running a balanced factory at full capacity. Statistical Process Control for Real-World Applications shows what to do when the process doesn't conform to the traditional bell curve assumption.
HOW DOES THIS ALL WORK?
After you register for this webinar, you will receive a confirmation e-mail containing a PDF file, which contains a link to view the session and other information. You will also receive an e-mail with a link to access the webinar.
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