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Theory of Constraints (TOC) and Six Sigma

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Viewing 9 posts - 1 through 9 (of 9 total)
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  • #31811

    Sorour
    Participant

    Has anyone tried to integrate Theory of Constraints (TOC) with Six Sigma (SS) or Lean Sigma?  I am working on increasing inventory turns in a distribution environment and TOC looks like a great first step to look at entire system to ID bottleneck constraints, exploit constraints, which would eventually reduce WIP, etc., then use SS or Lean Sigma to work local optimization projects on constraint identified first by TOC.  Any thoughts on TOC / SS integration or experience with just SS & increasing inventory turns would be much appreciated!
    Paul

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    #84247

    Erik L
    Participant

    Paul,
    I see a definite link to TOC if you are pursuing the DMAIC thought process.  I would propose that TOC should be looked at throughout the process and not simply at the Define phase.  Often in the Improve-phase we need to way various pros-cons for ultimately deciding what we are going to physically change in the process.  TOC integrated with a FMEA/Noise diagram will help to decide what is the impact upstream/downstream for the process improvements you are about to implement.
    Regards,
    Erik

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    #84268

    mcleod
    Member

    I would advise you to use TOC in the six sigma process.  Not in the Define phase, but in Measure.  I believe it is beneficial at the end of the Measure phase when you have learned a little bit about the process and have a good process map to take a look at some obvious and easy things to fix.  Often lean tools like TOC come into play at this point.  I would continue into Analyze and Improve tackling the more difficult issues.  Be careful that any changes you do make in Measure don’t make the analysis you do in Analyze irrelevant.
    This also helps give the teams a bit of a boost to see some improvement early on in DMAIC.

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    #84274

    Sanjeev Verma
    Member

    I would say, some part of TOC concepts (especially the first step “What To Change”) will be needed in the design phase. In fact, as far as my experience goes, I have seen some of my colleagues take wrong Six Sigma improvement projects to start with. e.g. a Six Sigma improvement project on “increasing the probability of finding defects in Testing phase” was launched and was wrapped up a month later as “Unsuccessful” project. After analysis (obviously using TOC) we found out that the pain area was “decreasing the probability of defect occurance at Customer’s end” – which is a radically different problem
    Also, TOC techniques (the cloud breaking techniques) have proved to be of immense help in the Analysis stage of DMAIC and it reduces the analysis time. So, TOC with Six sigma is a winner combo for sure
     

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    #142295

    Adam
    Participant

    In the Navy we have integrated all three concepts under one umbrella that we call AIRSpeed.  As far as supply logistics, I personally believe that TOC’s Market-Demand pull system would be a great first step, as well as identifying your constraints which will lead to true improvements.  The other aspects of TOC (evaporating clouds, what to change…) integrate well with the LEAN and Six Sigma philosophies giving you a larger tool box to work with.  And you get cool shirts from AGI when you complete their courses!

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    #142296

    Adam
    Participant

    Sorry!  I just realized how old this post was.  It was linked from the home page tip of the day.

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    #151062

    Tim
    Member

    No problem, I’m glad you still posted your reply-I am very interested in the subject now also.

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    #154330

    Putri
    Participant

    Im so interest with ur email on this web, but maybe i’am too late, i ‘ve ever read bout this (in journal from Emerald-written by : Ike Ehie and Chwen Sheu)
    this journal integrated six sigma n TOC (they integrated 6 steps in TOC with 5 steps in SS)
    If  you still want to know more, maybe you can find on Emerald, but if you know more, can you give me information, please!!!i need this for my tesis!! 

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    #174710

    andi
    Participant

    Hi
    I would like to know if you found addditional info about the topic. I also need the infomation for my thesis.

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