TOCICO conference : Quality Control is often the bottleneck in operations

About the conference 


During this conference, it was emphasized that Quality Control (QC) frequently becomes a major hurdle in operational efficiency, a problem that often goes unnoticed. This oversight occurs due to ERP systems not detecting it and a disconnect between operations and quality departments. Furthermore, this issue typically fails to capture the interest of senior management.

Drawing from extensive experience across diverse global industries, it was noted that QC is a significant bottleneck in over half of these organizations, an astonishing revelation.

The overload in QC work is attributed to the growing number and complexity of product quality controls across various sectors, including aeronautics, software development, luxury goods, and food production.

Managing QC performance is challenging, especially in balancing thoroughness with efficiency.

Determining the appropriate number of controllers during budget planning is complex, with management often falling prey to optimistic overestimations regarding future quality improvements, leading to budgetary constraints in this non-value-added area.

This predicament has substantial implications in many industries where quality issues persist. While some organizations like Toyota Motor Manufacturing have achieved remarkably low defect rates, most others experience significantly higher rates of defects without justifiable reasons. It is argued that effectively applying the Theory Of Constraints, similar to Lean principles, can greatly enhance operational quality.

The conference highlighted the severe impact of bottlenecks in QC, pointing out that it is one of the worst areas to experience capacity constraints.

Several strategies were proposed to alleviate these bottlenecks, thereby enhancing the overall throughput of a company.

The conference showcased eight recent case studies from diverse fields such as steel production, luxury watchmaking, aeronautics, paint production, rocket manufacturing, and the nuclear industry.


The conference concludes by emphasizing the frequent yet addressable nature of QC bottlenecks. By effectively tackling these challenges, organizations can achieve notable enhancements in their performance, yielding benefits in both the immediate and extended future.



To enhance your experience, Marris Consulting organizes training sessions on Theory Of Constraints applied to production and projects environments and on Lean Management.


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Marris Consulting, expert in Theory of Constraints & Critical Chain Project Management


Marris Consulting is an expert in the Theory of Constraints (ToC) and Critical Chain Project Management (CCPM). As industry consultants, we are focused on helping process and manufacturing industries reach their highest levels of performance by using Constraints Management  combined with Lean and Six Sigma. We also use Critical Chain Project Management which we sometimes combine with Lean engineering to improve project performance. If you are unsure about the actions which need to be implemented to improve operational efficiency, our industrial management consultants can also conduct a performance audit. Furthermore, our experts host numerous Theory of Constraints (ToC), lean and project management training sessions throughout the year.

Home>Videos>Theory of Constraints in Production>Webinar What if quality control was your bottleneck ?

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.

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