1st Edition

Constraint Management in Manufacturing Optimising the Supply Chain

By Ted Hutchin Copyright 2002

    Focusing on making money out of the supply chain, this book describes how to successfully manage manufacturing companies in today's global context. The text explores how constraint management, with roots in the Theory of Constraints, produces wealth through the development of manufacturers' strengths.

    Constraint Management in Manufacturing: Optimising the Global Supply Chain is for both practitioners and researchers alike. It is an instructional tool for anyone teaching operations management and related subjects, and is a valuable guide for those striving to improve the performance of their own companies. The text addresses the increasing demand for manufacturing approaches that apply constraint management and link it to the creative use of new technologies, including the Internet.

    The text draws on the author's own experiences implementing constraint management within UK manufacturing, using case studies to highlight the key issues that enhance bottom-line performance. It examines the role of new product development, production, distribution, team development, and the strategic focus required to turn the supply chain/revenue chain into a true value stream for any company.

    UNDERSTAND THE PRESSURE TO SUCCEED
    Introduction to the World of Manufacturing
    Key Themes in Manufacturing
    Globalisation of the Supply Chain
    Supply Chain/Network Management
    Chain or Network?
    Lean Thinking
    An Example of Misplaced Focus
    Manufacturing: A Constraint Management Perspective
    Constraint Manufacturing Defined
    The Core Competencies of Constraint Manufacturing

    THE REVENUE CHAIN AND THE IMPACT IT HAS
    Defining the Chain
    Measurements
    The Problem with Problems
    A Quick Snapshot of the Organisation
    The Notion of the Constraint
    Typology of Constraints
    The Five Focusing Steps of TOC Revisited
    The Laws of Constraint Management

    THE FULL ENTERPRISE ANALYSIS METHODOLOGY
    Three Basic Questions
    Analysing Problems
    Gaining Consensus on the Problem
    The Starting Point is the Undesirable Effects (UDEs)
    The Conflict a UDE Creates
    How Bad Can a UDE Go?
    The Application of the UDE Cloud
    Constructing the Composite Cloud
    Developing the Core Solution
    Creating the Full Feature Set of the Solution
    Developing the Implementation Plan
    Making It Happen
    The Impact of Paradigm Lock within Constraint Management
    The Impact of the Paradigm Lock Cloud

    MANAGING NEW PRODUCT DEVELOPMENT
    Background to New Product Development and Project Management
    Typology of Projects
    Critical Chain Introduced
    A Worked Example: Single Projects
    Buffer Management
    Delivering the Project
    The Sequence of Creating a Critical Chain Schedule
    Project Example: Single Project
    Substantial Delay in Start?
    Multi-Project and Critical Chain

    MANAGING PRODUCTION
    Typical Problems in Production
    The Application of DBR Simulations
    Developing the Drum-Buffer-Rope Solution
    Direction of the Solution
    Case Study 1
    Case Study 2
    Developing the Ability to Implement Constraint Manufacturing within the Production Area

    GETTING THE PRODUCT TO THE CUSTOMER
    The Analysis of Distribution
    Developing the Solution
    Replenishment: the Solution

    THE STRATEGIC IMPORTANCE OF MANAGING CHANGE
    Introduction
    The Role of Change and Change Management
    Managing Change
    The Change Agent
    Resistance to Change
    The Politics of Change
    Change/Implementation Models and Conflict Resolution Examined
    Organisational Learning
    An Analysis of Change Control Models
    Linking the Paradigm Lock Cloud to Models of Change
    The Constraint Management Wheel of Change

    PULLING IT ALL TOGETHER: GAINING A TRUE ENTERPRISE FOCUS
    Enterprise Focus Revisited
    Final Thoughts

    Biography

    Ted Hutchin