Theory of Constraints, Critical Chain Project Management, Lean : industry consulting & training - Marris Consulting
A 3-month assignment in one of the Mexican factories of a very Lean automotive Original Equipment Manufacturer.
This company is a recognized global leader in terms of its size, the reputation of its products and its "Leanness" since it is one of the first to have been inspired by the Toyota Production System at the beginning of the 70s.
Constraints Management (Theory Of Constraints / TOC) was combined with their Production System. The goals were:
To increase very significantly the production volumes to meet a big increase in demand
To eliminate the client delivery backlog
To put an end to huge Premium Freight expenses (airplane deliveries)
To restore the client confidence with its clients especially their biggest customer who is one of the largest car manufacturers in the world
An increase in production volumes of more than 20% without investments
Very rapid increases in the productivity of the Autonomous Production Units (APU); in the most spectacular case productivity increased by 17% in 15 minutes
28% increase in average O.E.E. (Overall Equipment Efficiency) of the 20 production units with >50% increases for some production units (APUs)
Backlog eliminated in 9 weeks
Premium Freight Expenses divided by 10 in 3 months
Improved cycle times (units per minute) of all the identified bottlenecks
Redesign and implementation of a new plant layout: machines, WIP, purchased parts, Finished Goods
Implementation of a taylored version of TOC's Drum - Buffer - Rope product flow control mechanism
Reinforced and improved Kanban processes
Significant improvement in quality: improved the PPM (Parts Per Million defects) through numerous shop floor initiatives and reinforcement of updating and using standard procedures
Integration of a Theory Of Constraints module in their internal university training program
Return On Investment of the consulting assignment in less than one month
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.