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Delivering on time, in full and in specification in today’s competitive environment is no longer a long term business objective…it’s a ‘MUST have’ in order to compete. If your competitors can deliver products faster then you risk the chance of losing business.
Managing production is vital and your capacity to produce will be based on the capacity of your constraint – your slowest step! In order to maintain flow your production planning and execution system should be linked to your slowest step – it sets the drum beat for your entire production operations and Lean Six Sigma improvement actions must be focused there.
Managing production is not an easy task….any schedule or production plan must be productive, reliable, robust and realistic:
The Theory of Constraints (TOC) Drum Buffer Rope (DBR) logistical system is a finite scheduling mechanism that balances the flow of the production system. DBR controls the flow of materials through the plant in order to produce products in accordance with market demand with a minimum of manufacturing lead time (MLT), inventory and operating expense.
Due date performance has improved from 78 % to 98%. The only late orders have been due to suppliers being caught out with our increased demand. – Kevin Flint, General Manager, Oasis Engineering Tauranga
DBR is based on the Theory of Constraints logistics approach and five powerful focusing steps:
The definitions of DRUM, BUFFER and ROPE are:
Our Implementation Approach:
• Identification of the core problem/s through robust analysis, e.g. business process mapping, and collection of accurate and appropriate data.
• In-depth training in TOC Production planning and execution principles.
• Formulation and implementation of measures aimed at increasing Throughput.
• Coaching/Mentoring and on-going support to forestall/overcome any obstacles that may hinder implementation.
• Retained support to ensure that the Process Of On-Going Improvement (POOGI) can be sustained.