2019 TOCICO International Conference

Embraer and ToC - A Journey of Achievements: E-Jets E2 Program Development

Embraer's E2 Program, defying the typical 7-9 year cycle, delivered the E190-E2 airliner two months early, on budget, and better than competitors by applying the Theory of Constraints and Critical Chain management.

Increasing productivity through use of day-to-day thinking process tools

Course

Do you face obstacles to productivity? This session offers insights and practical tools to be more effective at making decisions, evaluating ideas, determining action, mentoring, and delegating work, with suggestions to implement immediately.

How a Doctor Implemented TOC and Improved His Ophthalmologic Practice over 50% in a Few Weeks

Course

Physician-led TOC implementation in a Brazilian ophthalmology practice. By applying TOC steps, the practice increased appointment slots by 50% and last-minute appointments by 150% in 4 weeks, improving patient flow and quality of care.

Selling blue ocean projects

Course

TOC offers a path to Process of Ongoing Improvement & Blue Ocean strategy. Consulting is key for execution. This workshop details a Strategy & Tactics tree for selling and delivering these holistic projects, covering steps & success factors.

Applying theory of constraints to improve retailers equity for service offer to retailers

Course

Facing online and inventory pressures, brick-and-mortar retailers can cut inventory by 25% by adopting TOC's Demand-Driven supply chain rules. Dr. Barnard suggests a win:win adoption using a dynamic simulation and profit/equity-share model.

Using dynamic buffer management (DBM) to reduce shortages and surpluses in book publishers' supply chain

Course

GRL helped a major book publisher in 2018 improve their supply chain by reducing shortages and surpluses using a model to investigate causes and test a Dynamic Buffer Management (DBM) solution to reduce lost sales and increase profitability.

Re-engineering and creating shareholder value at a diamond mine using theory of constraints (ToC) and activity-based costing (ABC)

Course

An internal team determined an NPV opportunity through a paradigm shift in capacity release for a mining operation, requiring 4 levels of approval. It debates needing external advice. Argyle Diamonds' 1993 business review is discussed.

Fast tracking a new product in finance

Course

An Australian Investment Bank (BT) needed to launch a new Separately Managed Account (SMA) fund in 4 months, against the usual 15–18 months. Using Project Flow and executive support, the team launched the product in 14 weeks.

A new TOC decisive competitive edge

Course

General solution for Aggregating Manufacturers' (A-Plants) raw material shortage problem using a TOC community-developed solution. Market opportunity is $10T in sales, potential fees $50B annually.

Utilizing TOC to improve sub-recipient monitoring at the Texas Workforce Commission

Course

In 2016, TWC's Sub-Recipient Monitoring Department eliminated a year's worth of backlogged reports (79) in 14 months using the TWC Rapid Process Improvement methodology, creating a sustainable, risk-focused monitoring system.

Critical Chain Basics workshop

Course

Critical Chain Project Management workshop introduces foundational concepts, emphasizing Focus, 50/50 estimates, buffers, and fostering a high-trust workplace. It addresses how multitasking harms productivity and extends project durations.

Using the Theory of Constraints to Solve Ill-Structured (wicked, messy) Problems: A Healthcare Example

Course

Intractable problems (e.g., healthcare, education costs) are hard to solve due to conflicting stakeholder goals. A new methodology combining concepts from Simon, Goffman, and Goldratt is proposed for structuring and solving these issues.

The case study of TOC equity partners

Course

The case study of TOC Equity Partners (TOCEP), a TOC-managed organization, is analyzed to understand the limits of TOC success. Despite flourishing, TOCEP did not fully embrace its Transformational Strategy and Tactic Tree (TSTT).

What is blocking the real potential of TOC?

Course

TOC's spread is limited, even for experts, due to a fractured community and lack of collaboration since Dr. Goldratt's passing. The goal is to realize TOC's potential for individual success and ever-flourishing organizations.

TOC consulting best practices, from the client perspective

Course

Manage the conflict between teaching and consulting to improve top management trust in consultants using TOC Thinking Processes. The summary elaborates on conflicts, assumptions, and proposes policies, measurements, and procedures to enhance trust.

Better than before (B2B)

Course

The "Better than Before" principle motivates improvement and is easily accepted. A weekly report focusing on 3-5 key metrics (throughput, investment, operating expenses) facilitates corrective actions and continuous improvement.

Paradigm shift vs. shifting paradigm and its application in implementing DBR

Course

TOC solutions require paradigm shifts, which are challenging due to reliance on intuition and staff turnover. This workshop explores shifting paradigms via a series of certain, chosen changes that lead to the DBR paradigm, without a sudden shift.

Cost is not a dirty word: Bringing procurement into the throughput world

Course

Ian Heptinstall discusses how a narrow view of "Cost World" and procurement (only cutting prices) can lead to missed improvement opportunities for TOC implementations. He argues procurement is more than price haggling.

Why-oh-why do so few managers know about TOC?

Course

This Hyde Park session aims to capture why TOC is an also-ran in management methods, despite its power. The discussion focuses on increasing knowledge of TOC methods to boost adoption, a long-standing issue in the community.

New insights on good constraints and bad constraints through the eyes of TOC and the Cynefin Framework

Course

The update compares the Cynefin Framework's constraints, complexity, and simplicity with Theory of Constraints (TOC) concepts. It shows how Cynefin's view on constraints offers new insights into Policy Constraints and the 5 Focusing Steps.

Med Lab Simulation: Applying TOC concepts to a complex hands-on environment

Course

The med lab simulation is a service environment model addressing complaints about simple, manufacturing-focused simulations. It features high uncertainty and limited resources. It uses TOC to improve the situation without financial investment.

Resolving the TOC (balance flow) vs. lean (balance capacity) conflict

Course

TOC, Lean, and Six Sigma are compatible, with TOC focusing Lean/Six Sigma tools. Conflict arises from TOC balancing flow and Lean balancing capacity, which can be resolved by questioning the assumption that TAKT time and capacity must be equal.

How to tame a Dragon! Framing and Delivering a Complex and Highly Volatile Tech Project on Time in a Short Time with CCPM

Course

A TOCICO presentation details a successful CCPM project to separate shared ICT and administration functions between two businesses, avoiding disruption and high-stress situations common in such projects, and dealing with unexpected challenges.

IT2X: Pursuing aggressive improvement at scale

Course

VIVO's CIO, with no prior experience in IT leadership or TOC, shares the strategy for IT2X, an initiative to double project throughput using TOC Thinking Processes, Critical Chain, Agile, and Lean, including challenges.

An introduction to demand-driven concepts

Course

DDMRP is a multi-echelon supply chain planning and execution methodology using strategically placed stock buffers to protect and promote the flow of information and materials. It's part of the DDAE model, driving sustained financial performance.

Using TOC to improve the delivery of chemotherapy for cancer treatments in a large public hospital

Course

A public hospital used Theory of Constraints (TOC) mapping tools to analyze problems, identify solutions, and implement a trial project. Outcomes included dramatically reduced patient wait times, staff overtime, and improved staff morale.

Project management the TOC way: Combining critical chain project management and the 5 focusing steps for extraordinary results

Course

Combining critical chain project management (CCPM) and the theory of constraints yields extraordinary results quickly, boosting productivity 2-3x, reducing project durations by over 40%, and finishing nearly all projects on time.

TOC journey at TAML

Course

Tata Advanced Materials Ltd. (TAML) implemented Theory of Constraints (TOC) after reaching a $10mn loss in 2012-13. The implementation, led by SR Mukherjee in 2014, helped TAML double operational productivity and move from loss to sustained profit.

Japanese and TOC, POOGI start from “harmony building”

Course

Dr. Eli Goldratt’s TOC (Theory of Constraints) principles, likened to Japan’s ‘WA (Harmony)’, resulted in Hitachi’s net profit increasing five-fold from 2002 to 2007, despite raw material price hikes.

Leveraging TOC in Texas government – our productivity journey

Course

Presentation demonstrates the value of using TOC principles to improve government operations and meet increasing demands. It inspires attendees to get involved with local government to introduce and use TOC for global improvement.

Tools and Techniques That Could Enable Your View for Improvement and Overall Operations

Course

Four new tools are introduced to improve government: strategic compassthroughput operating system, journey board capacity model, and standard operating procedures - value stream map. These tools provide effective visual management.

Extreme DBR

Course

This presentation details two manufacturing environments where implementing T-DBR was crucial due to an internal constraint and order sequence importance. This led to Extreme Drum-Buffer-Rope (X-DBR) and the Drum Hours Lost measure.

Baja Electricals Ltd. (consumer products) building a world class distribution highway with TOC

Course

Bajaj Electricals, a $675M Indian company, faced issues like high working capital and poor sales predictability due to forecast-based stock management. The solution was realigning the supply chain, leading to 21% retail sales growth.

Reality engineering and Magic Druids

Course

This presentation introduces "Magic Druids" simple dilemma clouds, a WiseTech Global innovation that rapidly speeds up the Current Reality Tree (CrT) analysis phase of TOC thinking processes, leading to more robust solutions.

Prescription for growth: Building a sales machine to out-communicate your competitors

Course

The "Prescription for Growth" workshop aims to significantly increase sales activity by eliminating non-selling duties for salespeople. It provides a detailed, step-by-step plan for implementation.

Why management attention can never be the constraint and why constraint and CCR must always be synonymous

Course

The presentation critiques the Theory of Constraints (TOC), specifically challenging "Management Attention is the Ultimate Constraint" and arguing that "Constraint" and "Capacity Constraint Resource" must be synonymous within TOC.

Software development going beyond agile with TOC

Course

A solution to Agile/Scrum limitations (due dates, batches) implements flow principles, limits WIP, and assumes one-piece flow. This led to a 108% productivity increase and a 58% lead time reduction in a Brazilian software company.

Open to buy – friend or foe?

Course

OTB, a budget solution for retail purchasing, has negatives like "use or loose" mentality and poor SKU mix alignment. A new algorithm replaces OTB, preserving its positives (control, NPI refresh) while fully compatible with TOC Distribution.

Jindal Steel - Prescription for growth

Course

An experienced Lean & Six Sigma Master Black Belt, practicing TOC for 15+ years, details TOC's success: turning around Oman operations (EBITDA $1.5Mn to $25Mn/month), increasing Australia mining market cap 100x, and major production boosts.

Introduction to the theory of constraints (TOC) and to drum-buffer-rope (DBR)

Course

This one-day workshop introduces the basic Theory of Constraints (TOC) methodology for supply chains, covering the five focusing steps, DBR, simplified DBR, buffer management, replenishment, and virtual buffers. TOC focuses on leverage points.

Three compelling views coming from three different perspectives of TOC: management attention as the ultimate constraint

Course

Three views on TOC by Eli Schragenheim, Henry Camp, and Rocco Surace, authors of "Throughput Economics." It discusses Goldratt's ultimate constraint (management attention) and how one resource lacking capacity hurts performance.

Mind your mind

Course

The speaker, inspired by "The Choice" (Goldratt) and "Thinking, fast and slow" (Kahneman), will present "Mind Your Mind," a session on why people struggle to Think Clearly, introducing Mindfulness and countermeasures for a more composite view.

Tata: “Octopus for Coke Ovens” - A productivity innovation case for online flue temperature in stamped charged coke oven operations

Course

This case explains applying TOC to improve manpower productivity at Coke Ovens, where manual temperature measurement posed safety and productivity challenges. An innovative, patent-filed solution was found to resolve the manpower deployment conflict.

Improving quantitative reasoning skills one student at a time

Course

Presentation proposing Problem Solving Maps (PSM), graphic organizers developed using TOCFE tools, to enhance students' quantitative reasoning by focusing on inductive thinking, deductive thinking, and analysis skills.

Thriving on the edges of chaos

Course

The DDAE model & DDOM link operations, tactics, and strategy across three ranges (operational, tactical, strategic) to align system flow with market demand, ending forecast distortion & cost/flow conflict, maximizing ROI.

Adapting the demand-driven operating model

Course

DDMRP is founded on the Theory of Constraints and "standing on the shoulders of giants." It uses complexity science to boost ROI by improving system flow with buffers, correct metrics, and software for enhanced visibility.

Advanced throughput accounting workshop: How making money really works

Course

Throughput accounting can achieve a Viable Vision, guiding companies to 20% ROS without real risks. It increases ROS by 10% short-term. Focus is on right sales, covering costs, and high job margins for profit.

Lessons learned from Premier Foods’ Viable Vision journey

Course

Ex-CEO Ian Visser & Dr. Alan Barnard will share insights from Premier Foods' Viable Vision journey. Premier Foods, established in 1852, turned around a record loss using TOC principles, resulting in a 7000% shareholder return.

TOC consultants’ adventure through cashflow quadrant

Course

Three TOC partners developed "THE STRATEGY OF THE MOST PROFITABLE INVESTMENT FUND" after a late event at TOCICO 2017 to escape consulting. Their cash-constrained plant is projected to grow from ¬ 3,5M to ¬ 100M in a few years.

Best marriage, TOC and digital technology

Course

Hitachi identified a communication gap between IT and OT engineers as the cause of digitalization project failures. The TOC Flow application and six technology questions are suggested to bridge this gap, with "Marriage with TOC" being key to success.

Piaget and Goldratt: Structuralism and subordination - making TOC work for you

Course

This presentation links Jean Piaget's structure definition (wholeness, transformation, self-regulation) to the Theory of Constraints (TOC) 5-step process, emphasizing subordinating exploitation for transformative, self-regulating TOC success.