8 - emanuele_strada_23 tocpa_usa_21-22 march 2016 v8a

8/18/2019 8 - Emanuele_Strada_23 TOCPA_USA_21-22 March 2016 v8a

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23rd International Conference of the

TOC Practitioners Alliance - TOCPA

www.tocpractice.com 21-22 March, 201, Tennessee, !"A

"harin# e$perience on step 2

%ecide how to e$ploit the s&stem's constraint

Emanuele Strada

Thinking-Solutons, Italy

March, 2016


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23rd International Conference of the TOC Practitioners Alliance - TOCPAwww.tocpractice.com

Your logo

Emanuele Strada

Emanuele Strada is a thought leader on business

process transformation at Thinking Solutions. He is an

expert in supply chain re-engineering and dynamicprocess modelling with over 20 years’ experience. He

has worked for some of the top manufacturing

companies in the world - setting corporate strategy,

holding various senior positions with a focus on re-

engineering and creating systems and structures todeliver substantial improvements in companies.

Emanuele is a well-respected expert in leading

business change. He has proven capabilities in

managing complex turnaround projects at an

international level and has earned many awards forthem. [email protected]

Place for the photo of the

presenter


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Your logo

Agenda

• the challenge• customer expectations

• gap analysis

• key learning


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Your logoThe customer expectations

• !!" up#to#schedule shipping performance

•$ero off#lines or production losses due to supplier failure

• !!" %uality parts& 'ero shipping discrepancies

• (anufacturing fle)ibility for une)pected plant

shortagesre%uirements

• +rror#proof processes

• aily shipments• -ccurate pac.aging and e)ecution

• +lectronic communication capability and e)ecution

• -dvance problem notification and %uic. resolution

• Internal training procedureprocess

• /o supplier constraints• …


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Your logoAt least the “what” is clear…

…today, the process performance

is far below the e)pectations


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Your logo…a step back: gap analysis

0asting1ps

(illing1ps

01/234-I/3

cont5line

ownstream1ps 6

istribution

07231(+4

1ps

1. IDENTIFY the system's constraint(s).

2. Decide how to EXPLOIT the system's constraint(s).3. SUBORDINATE everything else to the above decision.

4. ELEVATE the system's constraint(s).

5. WARNING!!!! If in the previous steps a constraint has been broken, go back to step 1, but do not

allow INERTIA to cause a system's constraint


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Your logoFrom S!s to "oils

0ustomer production Plan

81(

297s re%uirement

0oils re%uirement

0oil

01/234-I/3

emand

I/P73


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Your logo#es… $!T

0asting1ps

(illing1ps

01/234-I/3

cont5line

ownstream1ps 6

istribution

07231(+4

1ps


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Your logo

0oils re%uirement

From S!s to %other "oil

297 !!! 297 n297 !!!: 297 m

0ustomer production Plan

81(

297s re%uirement

(arriage logic

*;irst challenge< I/P73 7/I32 = the 01/234-I/3

0oil

01/234-I/3

emand

I/P73

(other

0oil


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Your logo

0asting1ps

(illing1ps

01/234-I/3

cont5line

ownstream1ps 6

istribution

07231(+4

1ps

0oils

&'(!T !'&T o) the "*'ST+A&'T


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Your logo

0asting1ps

(illing1ps

01/234-I/3

cont5line

ownstream1ps 6

istribution

07231(+4

1ps

(other

0oils

&'(!T !'&T o) the "*'ST+A&'T


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Your logoThe challenge ,-

(other 0oil >

? 297

? 297 :

? 297 n

(other 0oil Y

? 297 a

? 297 b

? 297 '

(other 0oil $

? 297 @

? 297 9

(arriage logic

:

*2econd challenge<

(other 0oils

2e%uencing = the01/234-I/3

Atechnical limitations

6 real downstream /13

e%uali'ed needed %uantityB

*

*

01/34-I/3

input


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Your logoThe challenge ,.

(other 0oil >

? 297

? 297 :

? 297 n

(other 0oil Y

? 297 a

? 297 b

? 297 '

(other 0oil $

? 297 @

? 297 9

(arriage logic

*

*

**

**

**

**3hird challenge<

Potential different ;Cs

%uantity and 297s type

due to different

customerproduction plan

D

E (io of vehicles year 6 E!! 297s per vehicle

:

*2econd challenge<

(other 0oils

2e%uencing = the01/234-I/3

Atechnical limitations

6 real downstream /13

e%uali'ed needed %uantityB


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Your logo

0asting1ps

(illing1ps

01/234-I/3

cont5line

ownstream1ps 6

istribution

07231(+4

1ps

(other

0oils

&'(!T !'&T o) the "*'ST+A&'T


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Your logo

01/234-I/3

cont5line

Input 1utput

ummy

0oil F

2everal 0oil types<• -lloy

• 3emper

• 3hic.ness

• Gidth

• pre#treatment• etc…

Y+2

• 204-P

• 0-P-0I3Y H123

/ocal optimal and constraint

/1


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Your logo

01/234-I/3

cont5line

Input 1utput

ummy

0oil F

/1

2everal 0oil types<• -lloy

• 3emper

• 3hic.ness

• Gidth

• pre#treatment• etc…

/ocal optimal and constraint

-re we really e)ploitingthe constraint F

Y+2

4e%uested

0oil F

• /1/ P41703I+

0-P-0I3Y

/1

4+-H 3J417CJP73

Y+2Y+2


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Your logo

as& +estions/

• Jow to e)ploit the constraint F

• Jow to prove robustness of the solution…

• Jow to reduce the ris. of implementation

failure F


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Your logo

as& +estions/

• Ghat is the batch si'e logicF• Jow many 297s should we consider in our

marriage logicF

• Ghat is the “best” 297s se%uence to

consider, not for local optimal, but for the

entire system F


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Your logo

The )est se+ence

• Ghat is “best” F

• Jow can we describe it F

• Ideally every single coil that need to be producedshould be part of this definition, and every single

coil that is not needed for the production plan of

the customer in a short term, should not be

considered5


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Your logo

The )est se+ence

• Is it correctF

• 1., but… what about the technical limitations

by which the dummy coil is neededF

• …and what does it mean “short term”F


22/26


Your logo0ere we are… the F/*1 2

Hoo.ing forward

/ormal ArightB flow speed

/ormal flow speed


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Your logo

The dynamic process model


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Your logo(ro3ect *utcome

*ummy 0oils

K!"

Cood 0oils

K!"

efore After

3-4C+3 LK"

-2#I2 K!"

-0JI++ ELM"

*ummy 0oils

K!"

Cood 0oils

K!"

NO"

Cood coils

ELM"

*ummy 0oil< coil needed by the continuous line but not needed by the downstream operations


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Your logoey learning

ynamic Process (odelling can support you

not only to Identif& the system constraint, but

also to e$ploit it meanwhile validate your

assumptions for a robust solution

Jow F

…you can sim+late the material and decision flow

considering the resources dependencies coupled

with statistical fluctuation


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Your logo

Emanuele Strada

Emanuele Strada is a thought leader on business

process transformation at Thinking Solutions. He is an

expert in supply chain re-engineering and dynamic

process modelling with over 20 years’ experience. He

has worked for some of the top manufacturing

companies in the world - setting corporate strategy,

holding various senior positions with a focus on re-

engineering and creating systems and structures to

deliver substantial improvements in companies.

Emanuele is a well-respected expert in leading

business change. He has proven capabilities in

managing complex turnaround projects at an

international level and has earned many awards for

them. [email protected]

Place for the photo of the

presenter

Thans for &o+r time.

8 - emanuele_strada_23 tocpa_usa_21-22 march 2016 v8a

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