About this Presentation
This presentation explores how TOC operational solutions can be translated from theory into practical implementation across production and distribution environments. Using the evolution from OPT to DBR and S-DBR as a foundation, it shows how organizations can improve flow, reliability, and performance through disciplined use of buffers, release control, replenishment logic, and capacity monitoring.
The session is especially valuable for practitioners who know the concepts but want to understand how to apply them in real operations. It covers the core causes behind common operational problems, the key injections behind TOC solutions, and the implementation details, obstacles, and negative branches that must be addressed to make improvement stick in make-to-order, make-to-stock, and distribution settings
What Will You Learn
To help you get the most value from this session, we’ve highlighted a few key points. These takeaways capture the main ideas and practical insights from the presentation, making it easier for you to review, reflect, and apply what you’ve learned.
This session is built for practitioners who know TOC concepts but still struggle with the implementation leap: how to turn operational theory into workable production and distribution architectures.
A major insight is that TOC operational solutions can be simplified into a repeatable logic of core cause, core injection, and full set of injections - whether for DBR, S-DBR, make-to-order, make-to-stock, or distribution.
The workshop makes implementation unusually concrete, showing that success depends on details such as choking release, buffer-based priorities, daily replenishment, dynamic buffer management, and disciplined capacity monitoring.
It also closes the realism gap by highlighting negative branches and implementation obstacles, reminding attendees that the right solution architecture matters as much as the solution logic itself.
Instructor(s)
Sanjeev Gupta
Most recently, Sanjeev Gupta was the CEO of Vulcan Mozambique, Africa’s largest coal mine. Within the first 90 days, he led impressive improvements in profitability, mining production, and logistics, setting the mine on a path to sustained success. Sanjeev’s journey in turnarounds began early in his career at Xerox, a Fortune 100 company, where, as a junior manager, he turned around its worst-performing factory and made it the best-performing one. This initial success led him to found Throughput Technologies, where his team provided software based on the Theory of Constraints for factories. He worked with companies ranging from $5 million to $5 billion, improving throughput by 20% to 50% and reducing lead times by over 50%.
He later founded Realization Technologies, offering similar software and consulting services for project-based organizations. There, he achieved comparable throughput improvements, with lead time reductions varying between 25% to 75%. His clients included organizations such as ABB, BHP Billiton, Boeing, L & T, Medtronic, Siemens, and the U.S. Armed Forces (Air Force, Army, Marine Corps, and Navy). Sanjeev is a graduate of the Indian Institute of Technology, Delhi, Virginia Tech, and Carnegie Mellon University.