Showing posts with label TOC. Show all posts
Showing posts with label TOC. Show all posts

Friday, September 18, 2015

Book Review - Purple Curve Effect

Almost finished reading this book. I like it, though I can't think of anyone I'd recommend it to. For the begginers it is way all over the place and would not be a good starting place. For the advanced it is way too simplistic. Still, SKI is very personable and does a good job selling himself.
I liked some of his tips, especialy the idea of making lists from the end goal backwards. I was also very intrigued by the fact that I think he got all his TOC on backwards and still it works very well for him. Goes to show this TOC thing is robust.

Monday, November 14, 2011

How We Communicate is Important

When  was in Kiev (yes, I know you know I went to the conference, but I WAS in Kiev when this happened) I kept thinking of you, the readers of my blog and how I will post this and post that. One thing I thought about was this advertisement clip. The post was clear to me, the subject, the connection to Theory of Constraints, everything. But by the time I got around to digging it up I could not remember what got me going in the first place. It still feels right, though.

I find this clip has a very powerful message about communication and conflict situations. I suggest you watch it first with the audio OFF! Now before you run it again with the audio on, let me tell you these two actresses are doing a great job here. Of course there is a catch, but I won't tell you what it is, turn on the sound and hear for yourself.

{BTW, I noticed a lot of readers view this blog through a translating site, so if English is not for your ears, I've added a transcript below for the translating tool, as the text is relevant}


Here's what I see here, when we find ourselves conflicting with others we many times get into a "fight" mode. Think back about arguments and fights you've had over the years. As soon as the disagreement starts we become entrenched in our own corner, defending our needs or wants or point of view with all our might. This is greatly intensified if, coming into the 'discussion', we predict the other side will not react as planned. We are armed and ready and so we are ready to misinterpret any of her reactions as a declaration of war. Now, as soon as we go into "fight" mode we turn off "communication" mode and thus we stop listening to others and start listening only to our inner voice. We hear only those things that can serve as "ammunition" in the next "round". Do you remember this Magritte painting?



Well, can you agree that an argument is not communication, then?

As stated here, the Theory of Constraints requires change and it requires cooperation from others. To get others to cooperate with the change offered communication must be used to get buy in and commitment. You can't argue your way into convincing them that you understand and that you have a valuable offer.

Sunday, November 13, 2011

The III European TOCICO Conference

I just returned tonight from the conference. My head is still spinning from all the learning and insights I got. It was a very special experience for me and it will probably take me some time to completely process it.
Here are some quick "take away"s I noted down throughout the days:

  • People have the means to live but not a meaning to live for - we are no longer fighting to survive, we are looking for a meaning
  • We each create the meaning for ourselves, so it is our duty not to interfere or hinder or create obstacles to the ability of others to create their meaning (a tad more on meaning can be found here)
  • Success (or failure) do not come from the uniqueness of the product but for the uniqueness of the product
  • "Where there is a tail - there is a dog" (attributed to Eli Goldratt) this means that when all you see is a "tail" - a handful of clients with a special need there is a "dog" you don't see - a real market potential for a new offer
  • Projects fail because time estimates become time commitments
  • Analyze success (better than expected results), not just failure (below expectation results), it holds opportunities you can capitalize on, but only if you can understand them
  • TOC implementation requires a paradigm shift, compromising drastically increases the possibility of failure of the implementation
  • Win Win offers do not sell themselves, especially when the environment is saturated with suspicion and mistrust
  • The conflicts of my clients are my conflicts
  • The reason to really learn a subject matter is for improving it
  • The bigger the base - the bigger the jump
Let me know if you'd like me to elaborate on any of these, or if there is any particular detail you'd like to know about the conference.

Tuesday, July 26, 2011

Great Theory of Constraints resource - YouTube

I'm interrupting my shop floor series to share with you another grate resource - the TOCexpert channel on YouTube.
Hope you enjoy

Monday, April 25, 2011

TOC hiring logic from Bill Rhind

Bill Rhind (see profile on linkedIn) of P3 Consulting has kindly prepared this overview of utilizing the Theory of Constraints logic in the employee recruitment process. I found it very clear if you think of a constrained resource group, but Bill pointed out to me that this logic stands for any hiring, not just within a constrained group.  In fact, he feels the real value is in the non-constraint since there are many more non-constrained resources than constrained resources and one often doesn't think of “exploiting” a non-constraint. To top it all off he even included a small and very thought provoking case review.

Thanks Bill!

"What intrigues me is that many HR decisions are still made utilizing "local" thinking. Each hiring decision is generally made in isolation… on an individual, functional, or divisional case by case based and on the merit of each request. In addition, the decision to hire (elevating the system) is often done prior to identifying the constraint, to exploiting the constraint or subordinating to the constraint.

Why do I believe this is generally the case within most organizations? Organizations which I have been part of or visited (and have not implemented TOC) have a FULL list of personnel requests with all functional managers stating that theirs is the most important, and the managers do not have a clear way to accept or reject them. Managers don’t have a value based way to determine the priority or explain why one group was able to hire while another may not (or they hire based upon “local” efficiencies and don’t realize they are actually hurting the system’s overall performance).

I would like to inject that hiring must be considered holistically. Looking at all requests in an organization and prioritizing them based on T, I and OE (T, or Throughput, is the money or goal units generated by the system, I, or Inventory, is the money invested in the system in order to generate T and OE, or Operating Expenses, is the money the system is working on in order to transform in to T) from a systems perspective. There truly can only be one (or very few) most important hire.

In order to tackle this question, I suggest breaking the answer into three parts

1. decision on hiring
2. who (which skill) should ultimately be hired
3. the hiring process

Decision on Hiring

One necessary condition in order to know what is the most important hire is the company knows their system’s constraint (the only true way to know the impact on T). If the constraint for a system is not known, the best one can hope for is impacting delta I and delta OE (which are also often from a local perspective). Of course there may be situations where this is not the case (e.g., a key skill is missing or lost, and without it, even if the position is a non-constraint, T goes to “0”).

I think a key faulty assumption made or a missing process step in hiring is the assumption that a company truly needs another person within the constrained resource group to add capacity. A step that I believe is fundamentally missing in most hiring processes is the step to ensure that we have fully exploited the current capacity of the skill prior to moving to the elevate step. I can think of a few observations/checks which can be made to test the current state:

- What is the level of bad multitasking occurring within the group?
- What percentage of the constrained group’s capacity is the constraint (or CCR) performing the task which only they can perform (e.g., have they off loaded Herbie)?
- Are they working on the most valuable work to the business?

Prior to even considering the hiring of any additional personnel (and adding OE), I would want to ensure that we have, at a minimum, fully exploited the current capacity (it is important to make sure that the measure is not activity based but truly value based, focused on measuring only the amount of capacity where the constraint is doing only the specific work that the resource/skill can provide) and subordinated all else to ensure that the company was not wasting any of it. As all of you know, these steps alone can bring significant increase of flow (25%...50%...or more) within an organization while having a very positive impact on all of the people.

Who (Which Skill) Should Ultimately be Hired

If it is determined that the currently available constrained resources have capacity which is being stolen doing “other” work (work which does not add value from the customers perspective), then I would suggest hiring a person to remove this more general work from constrained resources versus hiring another constrained resource. The benefit of this is many fold:

1. The hired person would cost less OE (I know this is an assumption, but I believe a pretty good one)
2. It would have a much bigger impact on T (and, therefore, NP)
3. Constrained resource generally happier and more satisfied in their work

Take for example a sales group. We have seen instances where a company was interested in increasing throughput and was considering adding additional sales people. It was obvious that the constraint was the market. In which I really mean, the company’s ability to sell more to the market (the market by itself was not the constraint since the company only had about 10% of the market). To check whether hiring sales people was the right decision, we analyzed the sales process and were looking for overall effectiveness. The key here is how does one define effectiveness.

It became quickly apparent that the sales people were always busy (and one might say efficient); many working non-stop for 50-60 hours per week. Their days were filled with meetings (both internal and external), report writing, following up on sales orders, logging their sales calls, obtaining marketing materials, driving between calls, trainings and, of course, sales calls. Since sales generally are going to be made during sales calls, we asked how much of the day is spent with customers. The general answer for this client (and many others) was 25-50%. As we peel back the activities within the call itself, we asked one more question: “how much time are you spending with the decision makers?” The answer was enlightening, only 5-10%.
Would adding another sales person have an impact…of course, but, in this case, adding a person who’s responsibility would be to provide support to the entire sales organization would be much bigger. In this case, adding one support person provided for an absolute increase of 15% to EACH sales person. This is the equivalent to a doubling or tripling of the SALES FORCE. While I know that there are other possible levers for improving the T, no one of them could deliver more impact on T (while minimizing impact on OE) in the time it took to implement this improvement.

The Hiring Process


A key improvement is to consider the multitude of hiring’s as a multi-project environment. Ensuring that the hiring projects are being released in such a way as to ensure bad multitasking is minimized. Ensuring that Full Kit (strong job description is developed, availability of resources, clear end date, etc.) is fully developed prior to starting the recruiting process. Ensure that the hires are prioritized and released into the hiring process based upon their impact on T, I and OE.

I think by breaking the solution down, a company can now focus and improve the process to deliver value to the business at a global versus a local perspective. The organization can now make much better and quicker decisions on hiring and the hiring will happen at a much faster rate."

10 Places to start Your journey

My dearest darling is very supportive, he even visited this blog. Then he told everyone who would listen that it is not in any language known to man.
If you concur, here are some great places to make your first strides:
  1. The book shelf - read "The Goal" and any other business novel or book by Dr. Goldratt (there may be a new one on the way), add "The Choice" after you've read a few of the others; it is a bit harder, even though it is still an easy read.
  2. Join Dr. Goldratt's basic workshop "TOC for the Ever Flourishing Company" at the Goldratt House, even people who have been around Theory of Constraints concepts for years told me they found value in this workshop. This is not overly expensive as the workshop costs about $250 but you do need to pay for travel and accomodations
  3. Attend a TOCICO event in person in a conference (here is some data on the 2010 conference) or through the web in a webinar. You can also commit to a Theory of Constraints certification process and start taking the exams. Costs start as low as $40 for a webinar, through $100 for an exam to about $2,000 for a conference. Note that some activities require you become a member of the TOCICO which costs about $200 (less for people in academia)
  4. Join the Goldratt Schools program. They offer different programs, some are offered only as a whole and in some you can attend only the sessions you are interested in. From what I understood of their web site joining the whole program costs $10,000 up front + another $10,000 success based fee to be paid only if real life results of X10 the basic fee are achieved (meaning you pay $20,000 for real life results of the scale of $100,000, I think that's quite fair, if you can come up with the $10,000 to begin with)
  5. Use the self learning tools put out by Dr. Goldratt's team such as the TOC Insights self learning program ($80 per subject, $800 for all) or TOC.TV (this has some free content but is mostly pay per view and subscription based)
  6. Use this highly recommended site. I've been referred to this site many times and it always came highly recommended, but I still have to give it a deep scan, so I can't chime in with my point of view at this time.
  7. Visit the "Focus and Leverage" blog, written by Bob Sproull. This is a step by step intro into TOC for people and organizations, with a specific focus for those already involved with Lean and 6 Sigma. Bob has reached step 31 by now and hopefully will continue adding steps soon.
  8. Take a class at the university, or even go the whole way and get a certification or degree. For example, Dr. James Holt holds classes and has a full certification program at WSU, that are also available as web courses. There are other US universities with Theory of Constraints focus, such as the University of Tennessee. Internationally you can find programs in Poland, Ukrain, Colombia, Taiwan, South Africa, India and more. Many other Universities offer only single courses on the subject.
  9. Dr. Goldratt's blog is a great place after you've picked up the basics, full of "golden nuggets" and extensions, it is in Theory of Constraints jargon and a novice could easily get lost. Once you're up to speed, though, it is the place to be.
  10. Goal Systems International, a Theory of Constraints consulting firm with some of the biggest names, has very good topic specific articles in the "papers" section of their web site

Wednesday, March 23, 2011

Road Runner Ethics

Implementing the Theory of Constraints requires everybody behave like the Road Runner (the blue bird). It is either running full speed or standing, there is no other option. It should be the same for all our resources, especially the human one.

Cost world, which demands maximal efficiency at every point, leads people into conflicts - conflicts with fellow workers (that don't want to work their hardest ALL the time but don't want to look "bad" either) and conflicts with the system that requires they achieve opposing goals (no over time, on time delivery AND maximum utilization). These conflicts lead people to slow down their pace of work, make sure they look busy (I once saw a shareware that helps cover up the fact you are not really doing anything?) and often times leads them to make the wrong decisions.

Throughput world focuses on global optima, not local optima, and thus accepts the fact that most resources should have idle time. This means that being active isn't always being productive. But to get the most out of the system we need to have all our protection where we need it - at the constraint. Anywhere else it is wasted as it is not protecting the system. Therefore, even though a resource has over capacity and is not constraining the system, once it there is work to be done - it should be done ASAP. Knowing that working hard is not penalized (=rests are allowed when there is no work) should lead everyone to that direction. So there are no conflicts between fellow workers (no one should feel bad or threatened by co-workers working hard when they are not), no conflicts with the system and the road is paved for making the right decisions.
Meep Meep


Sunday, March 20, 2011

Theory of Constraints - Science or Art? Both

A great case study of Pinnacle Strategies's work in helping BP overcome the oil spill in the Gulf of Mexico.
It shows the principals of the Theory of Constraints are generic and scientific, meaning they can be applied to a wide range of situations, these are not rigid rules. The execution should be custom made and can be viewed as an art.
Thanks to Mark Woeppel for sharing this on LinkedIn's TOC Learning Group

Saturday, March 19, 2011

ABC and Theory of Constraints in a Non Profit Environment

In this thesis done in the Air Force Institute of Technology, ABC costing and Theory of Constraints are reviewed, compared and used in order to improve the performance of an organization that is not for profit. In this case the maintenance unit of the air force (AFMC).
This is a very through report, over 150 pages long, that covers all the basics before it dives in.
First important take away is that for a non-profit organization a primary challenge is to define its purpose in a way that will allow management to measure it. This is done in for-profit organization by the definition "to make money now and in the future" which is measurable  Defining the purpose correctly, so it can be measured, is imperative, as it allows the managers to measure and compare decisions in terms of their impact on the goal.

Wednesday, March 16, 2011

Comparing Theory of Constraints and ABC product mix decision

In an article published in the Int. Journal of Production Economics in 1999, authors Kee and Schmidt compare the product mix decision you get from ABC and from Theory of Constraints and find them both lacking. Their conclusion is that ABC gives the best results when overhead and labor costs are completely discretionary whereas Theory of Constraints gives the best results when these expenses are fixed. They go on to suggest an extended model to cover the middle ground.
This is an academic publication, so ease of reading was probably not a goal for the authors. It is long and the models are translated to mathematical representation. Still, it is quite easy to understand.
Since my knowledge of ABC is non existent (the "know I don't know" quadrant of the Johary window Dettmer talks about in the article in my first post), I'll not go into this. The way Theory of Constraints is represented, though, is very troubling in my opinion. It may be that Theory of Constraints has evolved since that time, I'm not blaming the authors but they presented Theory of Constraints as a rigid system that forces labor and overhead costs be fixed. I do not think this is true. Theory of Constraints looks at cost through a different paradigm and so classifies them differently then the traditional cost accounting systems. Since modern day businesses face labor and overhead costs that are fixed and not negligible at all, the basic Theory of Constraints models make these assumptions but if these are actually true variable costs, at least to some extent, a correct Theory of Constraints implementation will have to adapt to that. So I have to conclude the article is based on incorrect assumptions and therefore leads to incorrect conclusions.