About this Presentation
In the area of exploiting and subordinating to the constraint, companies have throughput increases between 20% and 110% at the constraint within 24 hours. That is after drum buffer rope and buffer management (DBR/BM) have been installed and operating for several days/weeks with all injections implemented and the usual increases in throughput, shorter lead times, reduction in WIP and so on. It took only 2 hours to cause the change. Andrew presents six cases studies with actual figures to substantiate results. The process is replicable and was applied again only 2 weeks ago. Following the 2-hour training session the next day throughput went up by 25%. Today the site is pumping more than 60% more throughput and has to adjust its physical layout to load trucks faster.
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.
Andrew Kay challenges practitioners to look beyond simply installing DBR and Buffer Management. He shows that even when the TOC solution is technically in place, significant Throughput can still be lost if the constraint is not being fully exploited. His practical method focuses attention back on the constraint and asks where valuable minutes are still leaking away.
One of Andrew’s breakthrough insights is the role of trust in constraint performance. He identifies distrust between people and departments as a real obstacle to exploitation and argues that lasting improvement requires management to demonstrate integrity by acting quickly on employee ideas. This turns trust from a “soft” issue into a practical component of the TOC solution.
Andrew puts constraint operators at the center of the improvement process. Rather than management prescribing solutions, he emphasizes that the people working closest to the constraint have the most intimate knowledge of where capacity is being lost: “Don’t tell them, ask them.” Their ideas are then combined with management’s analysis to create immediate, jointly owned improvements.
The results show how quickly small changes at the constraint can create major financial impact. Andrew presents cases where constraint utilization increased substantially, including structural steel fabrication from 63.2% to 75.9%, food-processing ovens from 62.4% to 79.7%, and steel reinforcing benders from 34.4% to 57.3%, translating recovered minutes directly into additional Throughput.
Instructor(s)
Andrew Kay
ANDREW KAY, TOCPC™ , Founder/Owner TOC3 Pty Ltd & Director of TOC for Education Australia
Recognized in Australia as a leading TOC Practitioner, Andrew is the founder of an independent boutique TOC consulting firm TOC3 Pty Limited based in Sydney, serving the Asia Pacific.
With a TOC career spanning nearly 20 years, Andrew has delivered and helped deliver over 85 successful TOC implementations across a multitude of industry sectors in Australia, New Zealand, Singapore, Indonesia, Japan and the USA. Andrew brings a depth of TOC knowledge and implementation experience in guiding organizations to systematically and rapidly achieve their goals Andrew is proficient in all TOC application solution areas including the Logical Thinking Process Tools. He specializes in rapid and visual implementation methods.
Andrew partners with world-class practitioners and is actively engaged in the International TOC Community. He has commenced sharing his experiences and insights through several case studies at TOCICO and other international TOC Conferences.
Andrew is also the Director of TOC for Education Australia working to introduce the TOCFE thinking tools to schools and communities and wishes he could do more.
Andrew is passionate about TOC and what it can deliver to the world.
Before his TOC career, Andrew served as a scientific-systems based professional in strategic planning for Sydney City and the Blue Mountains Region. A pioneer in Integrated Local Government Geographic Information Systems, Andrew held senior management roles in Government Corporate Strategy and Business Planning and later for 5 years, in the private sector with Business Improvement Consulting with clients such as The Sydney Opera House, Phillips, Canberra Hospital, A V Jennings, and Perrigrin Semi-Conductor. In between he helped establish and run Australia's first micro-finance operation based on the Nobel Prize-winning Grameen Bank of Bangladesh.
Andrew holds a BSc Hons in Applied Science (dual major/Magna Cum Laude) from the University NSW, a post-graduate MBA from Macquarie University, and he is certified by TOCICO, and is a qualified Jonah+ and CCPM IC3PM instructor.