Constraints Management

What is Constraints Management?

 

The Constraints Management, or the Theory of Constraints, is an approach based on the distinction between the critical resources - the constraints - and  the other non-critical resources of an organization. It became famous thanks to the "industrial thriller" The Goal, written by E. Goldratt and sold at over 7 million copies and translated into 29 languages.

Constraints Management tools

Constraints Management is focused on 2 tools: 

  • The Drum Buffer Rope (DBR).
  • The 5 Focusing Steps, also known as the process of ongoing improvement of the Theory Of Constraints.

Drum Buffer Rope explained in 4 minutes

Results achieved with Constraints Management

An independant study collected results achieved by companies which implemented Theory Of Constraints throughout the world. It estimates that on average results are:

  • a lead time reduction by 70%;

  • a reduction of production lead time by 65%;

  • an improvement of On-Time Delivery by 44%;

  • A Work-In-Progress reduction by 49%;

  • A Throughput improvement by 63%.

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Our Constraints Management case studies 

Find out examples of Marris Consulting assignements on our website.

CASE STUDIES

 

Find out content on Constraints Management and  video client testimonials on our website and Youtube channel.

videos

 

To go further

Philip Marris, CEO at Marris Consulting, is also the author of Management Par les Contraintes en gestion industrielle (available in French)

Learn more

This inquiry puts forward the fact that Constraints Management improves the operationnal performance to the same extent as Just-In-Time approaches, derived from Toyota Production System. The reason is that both of them improve the production flow and strongly reduce the Work-In-Process, and thus create an environment in which one can identify and eliminate the various forms of waste.

However, one of the main characteristics of Constraints Management is its impact on Throughput since it can increase by 63%. It is due to the focus on the elements limiting the company performance (called "constraints") and the emphasis on excess capacity (non-constraint / non-bottleneck) which often can be used to generate more income.

 

This very study shows the large variety of Constraints Management users : small, medium and large series, manufacturing industries and processes, small and large companies.

 

We can estimate that several thousands manufacturers use Theory of Constraints today : 3M, Baxter, Ford Motor Company, General Electric, General Motors, ITT, Johnson Controls, Lucent Technologies, Pratt & Wittney, Procter & Gamble, National Semi-Conductors, Samsonite, United Airlines, Whirlpool...

 

We are recognized experts of this approach, notably in french-speaking countries. Marris Consulting founder published one of the first books on this subject 20 years ago, and led numerous missions to implement Constraints Management. A new edition of this book is to be published soon. These very projects we managed confirm that Constraints Management transforms the operationnal performance and generates impressive economic results.

 

Implementing Constraints Management with Marris Consulting

As Constraints Management experts, Marris Consulting offers consulting and training services, guiding you through the implementation of the Theory of Constraints (TOC) in manufacturing or process industries. With over 25 years of experience, our consultants have a unique knowledge of Management by Constraints and have, to this day, successfully completed over 270 TOC implementation projects around the world.

We start our Constraints Management implementation by carrying out a quick performance diagnosis of your organization: our main objective is to identify the constraint (or “bottleneck” in manufacturing). We then provide you with a detailed roadmap, containing actions that can be implemented in the short, medium and long term, allowing you to achieve your goals through a better use of the constraint

Once the constraint or bottleneck has been identified, our Theory of Constraints consultants are able to support you in the implementation of the actions identified during the performance diagnosis. Our experts can also offer you training in Management by Constraints, helping you understand the fundamental principles of TOC and teaching you how to use Constraints Management in manufacturing for a rapid, significant and sustainable improvement in the performance of your organization. 

By identifying bottlenecks and implementing Theory of Constraints with Marris Consulting, your organization will achieve its goals and develop a determinant and sustainable competitive edge.

Contact Marris Consulting

To learn more about the approach and its results

 

A website dedicated to Philip Marris' book:

(Fr) Management Par les Contraintes

 

References

The World of the Theory of Constraints, V. J. Mabin and S.J. Balderstone, APICS Series on Constraints Management / St. Lucie Press, Etats-Unis, 2000.

Le But ; un processus de progrès permanent, Eliyahu Goldratt & Jeff Cox, AFNOR, France, 1986-2002, or in English The Goal, North River Press, Etats-Unis, 1984-2004.

Management Par les Contraintes, Philip Marris, Editions d'Organisation, France, 1994-2000.


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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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Tour Maine Montparnasse, 27éme étage
33, avenue du Maine - 75755 PARIS cedex 15

Tel. : +33 (0)1 71 19 90 40

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