Increase the production of Ariane 5 tanks by applying the Theory of Constraints

Context

  • Initially the production rate was 6 rocket reservoirs per year ...

  • … for a demand that increased to up to 8 tanks per year.

  • The site doesn't honour client delivery dates, and shifts constantly its delivery commitments.

  • Big technical problems aggravated the situation.

 

Approach

 

Theory of Constraints, CCPM and Lean: a winning combination

  • Identification of the bottleneck: the welding machine. A key, unique and complex piece of equipment.

  • Scheduling of the bottleneck work with Critical Chain Project Management rules (focused durations, buffer to protect the lead time, monitoring using a Fever Chart ...)

  • Reduction in the number of Work Orders with the 2 for 1 Rule

  • Suppression of silos between services to improve the performance of the quality control reception using controllers from other areas

photo illustrative des réservoirs Ariane 5

Results:

  • The lead time of quality control at reception was reduced by 85%.

  • The level of work in progress and the cycle times of the lines (critical accessories) dropped by60%.

  • Financial results: from chronic losses to profits in 3 months

  • The tank production throughput has increased by around 30%.

Find the process and the results obtained in video

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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 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.

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33, avenue du Maine - 75755 PARIS cedex 15

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