Factories,
People
& Results
Theory of Constraints, Critical Chain Project Management, Lean : industry consulting & training - Marris Consulting
Manufacturers of aircraft engine blades: Increasing production volumes while controlling work-in-progress levels
Context
To meet a rapidly growing market demand, engine parts suppliers must achieve a new level of productivity and efficiency. Our client has decided to implement the Theory of Constraints on their Fan Blade production line.
Objectives
- The main objective of the factory was to increase weekly production volumes while controlling the work-in-progress level.
Approach
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The five focusing steps of the Theory of Constraints were applied to the Fan Blades production line, with key focus areas including:
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Increasing bottleneck throughput by over 50% through capacity-enhancing measures (such as recruitment and subcontracting) and reducing workload by eliminating non-value-added activities.
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Implementing the Drum Buffer Rope (DBR) system to align production starts with the bottleneck’s pace, thus managing work-in-progress levels on the line.
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Establishing a safety buffer ahead of the bottleneck.
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Enhancing productivity at subsequent bottlenecks.
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Streamlining and simplifying the process for managing non-conformities.
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Results
- The level of work-in-progress has decreased by 30%.
- The bottleneck production level has increased since the start of the intervention (S8), see graph.
- Production volumes have increased by 50% (from 40 blades produced daily to 62 blades).
- Non-conforming parts are monitored continuously, with no accumulation of untreated parts.
- Team motivation has been strengthened.
About Marris Consulting
Marris Consulting is an industry consulting and training company specialized in the Theory of Constraints (ToC) and Critical Chain Project Management. We focus on improving the performance of manufacturing and process industries by using Constraints Management combined with Lean and Six Sigma. To boost project performance, we also use Critical Chain Project Management (CCPM), which we sometimes combine with Lean Engineering. Our 2-day performance audits, our performance consulting services and our project management, Lean, ToC & CCPM training by our industry consultants offer a wide range of solutions to help our clients around the world reach the highest possible levels of performance.