Theory of Constraints

Theory of Constraints

There Have Recently Been Comparisons Made Between Flow and The Theory of Constraints

Team DFT

Theory of Constraints was developed by Eli Goldratt in the 1980s. He is the author of the book The Goal. Dr. Goldratt believed that if you attach the bottlenecks in the manufacturing process and continually reduce the bottlenecks and made more productive that you would eventually transform into a more productive and flow type process. His theory was to attack the ball next eliminate the set up nonproductive time associated to that bottleneck and then move on to the next bottleneck.

It is hard to see an association between the theory of constraints (TOC) and flow Manufacturing or the Toyota production system. DFT, flow manufacturing the material production system and lean all reference the fact that you need to design a flow process as the 1st step and the elimination of waste and non-value-added activity is the 2nd step on the path to process perfection.

Although there is nothing wrong with eliminating unnecessary steps and wasteful activity I think time has proven that you are not going to revolve scheduling and batch Manufacturing into a flow and pull production process. That transformation is revolutionary not evolutionary. The process perfection steps that follow the revolutionary transformation to flow and pull production, our evolutionary as a corporation moves from 20 to 30 and 40 inventory turns with PPM in-process quality, and beyond. Unfortunately, either by misinformation, lack of training or lack of leadership, companies follow the philosophical path with the best of intention that end up with the worst results. Scheduling/batch production will never compete against a demand pull process!  The millions of dollars.

A Recent Comparison Between Flow and Theory of Constraints

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