Copyright Information 4
This book is dedicated to 5
Preface 6
I am thankful to… 8
What is Synchronized Manufacturing? 9
What are the Basic Rules of Manufacturing? 11
Types of Plants12
“V” type Plants12
“A” type Plants14
“T” type Plants 15
“I” Type Plants 16
The Vicious Cycle 17
The common Undesirable Effects (UDEs) 18
The Conflict 21
A resource standing idle is a major waste 23
The Work Ethics 28
Drum-Buffer-Rope (DBR) – An Analogy29
Drum-Buffer-Rope System 32
Drum-Buffer-Rope (DBR) More Details 37
Identify the Constraint 37
Choosing the Constraint 37
Factors for Choosing the Best Location for the Constraint 38
Choosing the Constraint for Control Purposes 38
Choosing Constraint for the “V” Type Plant 38
Choosing Constraint for the “A” Type Plant 38
Choosing Constraint for the “T” Type Plant 39
Choosing Constraint for Hybrids “X” and “Diamonds” Plant 39
Choosing the Buffer size 40
How should the tasks at non-constraints be prioritized? 40
How should the tasks of Support Functions be prioritized? 40
When is it necessary to expedite work? 41
Rules for monitoring the Buffer size 41
Buffer Management 42
Holes in Buffer Zones 42
Managing Holes in Constraint Buffer 43
Managing Holes in Assembly Buffer 43
Managing Holes in Shipping Buffer 43
Simplified-Drum-Buffer-Rope (SDBR) 46
How to Reverse the Vicious Cycle – The Solution 47
Capacity 48
Types of Capacity 48
Productive Capacity 48
Protective Capacity 48
Excess Capacity49
Capacity of Non-constraint 50
Idle Capacity 50
Balanced Plant 50
Cost of Capacity 50
TOC View on Batch Size and Setups 53
A Game to Show the Impact of Batching 54
MTS, MTA and MTO (From TOCICO dictionary) 56
Make-To-Stock (MTS) 56
Make-To-Order (MTO) 56
Make-To-Availability (MTA) 57
Measurements59
Self-Defeating Success 60
The Success 60
The Danger 60
The Defeat 60
The Way Out 60
Impact of Inventory on Competitive Edge 61
Impact of Inventory on Managing Quality 61
Impact of Inventory on Engineering Changes 62
Impact of Inventory on Margins 63
Impact of Inventory on Investment per Unit 64
Impact of Inventory on Due Date Performance 64
Impact of Inventory on Quoted Lead Times 65
How much Raw Material Inventory should we hold? 66
Summary 67
Self-assessment questions 70
eBooks published by Rajeev Athavale 74
Learner’s Guides 74
Article Repository 75
TOC Applications: Implementation Guidance for Small and Medium Size Enterprises 76
Bibliography 77