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7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
1/19
21st International Conference of the
TOC Practitioners Alliance - TOCPA
www.tocpractice.com 11 November 2015 !"
Using diagonal buffer
for better managerial decisions
in production and operations
Jelena Fedurko,
TOC Strategic Solutions, Estonia
11 November, 2015
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
2/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
Jelena Fedurko is a Co-Founder and Co-President ofTOC Practitioners Alliance TOCPA, InternationalDirector of TOC Strategic Solutions, TOC expert in
tocExpert.
Jelena has been involved in TOC since 1999. She is aTOC expert, trainer and consultant, and providesTOC implementation support in production, supplychain and project management. Jelena has worked
in various countries all over the world, includingJapan, Poland, Germany, Switzerland, Turkey, Italy,Russia, Ukraine, India, China, Chile, Colombia,Mexico.
Jelena is the author of the books Behind the Cloud,Through Clouds to Solutions, Typical mistakes inworking with TOC Logical Tools. Together with OdedCohen Jelena has co-authored the book Theory ofConstraints Fundamentals.She has contributed to anumber of books on TOC, and has manypublications. Jelena is the translator and editor ofmany books on TOC.
jelenafedurko.gs@gmail.comwww.tocexperet.com
www.toc-strategicsolutions.com
www.tocpractice.com
Jelena Fedurko
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
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21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
The #$%!&A# P#O'!CTION (!))$# for plannin* an+ e,ection control is measre+ onl in time
its si/e is preset for it to wor properl the si/e of the #e+ /one shol+ be NOT &$ than the cmlative
TO!C TI3$ nee+e+ to process the wor or+er it serves 4 obectives on +ifferent sta*es of han+lin* a cstomer or+er6
718 to chec an+ +etermine what completion +ate can be promise+ to the client 7A&$ an+P#O'!CTION P&ANNIN%8
728 to +etermine the wor or+er 79O8 release +ate 7P#O'!CTION P&ANNIN%8
748 to *ive pro+ction mana*ement :earl warnin* si*nals; abot the ris that a 9O ma benot complete+ on time an+ to prompt for corrective actions 7$
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
4/19
21st International Conference of the
TOC Practitioners Alliance - TOCPA
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
5/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
There are certain conditions in the reality of production environment that can
pose questions whether the use of the Time Buffer would be effective or at
all possible:(1) the touch time is a significant part of the elapsed time that the work
order spends in production often the touch time (including different kinds
of maturing! time like cooling when no machine time is used) is close to "#$
of the current %&T' thus the requirement of setting the sie of the ed to be not less than the
touch time immediately cases the planne+ P&T to increase which
does not bring enthusiasm to %%* people and often is truly not
needed if there is no progress (or not enough progress) on the +, in the
-reen one' the loss of time can not be recovere+ later in the process
due to a very long touch time
#h$ !iagonal Buffer for
Production (%)
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
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21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
There are certain conditions in the reality of production
environment that can pose questions whether the use of the
Time Buffer would be effective or at all possible:
(") the orders for the same ./0 are sporadic in time and hugely
vary in quantities' thus it makes no sense to hold a stock buffer for this ./0 to
work in the replenishment mode (as there is no regularity of
consumption)'
it is not possible to preset the production buffer sie (as theorder sie varies hugely and unpredictably)
#h$ !iagonal Buffer for
Production (&)
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
7/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
There are certain conditions in the reality of production
environment that can pose questions whether the use of theTime Buffer would be effective or at all possible:
($) the production is very fleible with capacity' and can quickly
and significantly increase the capacity for any work order
through assigning additional molds' knitting machines' workers in
assembling operations' etc2' thus
the %%* people argue that in their conditions it is notpractical to have preset buffer sies
#h$ !iagonal Buffer for
Production (')
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
8/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
The three issues in the reality of production environment that pose
questions whether the use of the Time Buffer would be effective or at all
possible:(1) the touch time is a significant part of the elapsed time
(") the orders for the same ./0 are sporadic in time and hugely vary in
quantities
($) the production is very fleible with capacity' and can quickly andsignificantly increase the capacity for any work order
,ut of these three issues' the most critical is issue (1):
the ed one is not enough to do all the work on the +, if there is no progress (or not enough progress) on the +, in the -reen
one' the loss of time can not be recovered later in the process due to a
very long touch time
#h$ !iagonal Buffer for
Production
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
9/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
the #e+ /one is not eno*h to +o all the wor on the 9O
if there is no pro*ress 7or not eno*h pro*ress8 on the 9O in the %reen /one the loss
of time can not be recovere+ later in the process +e to a ver lon* toch time
This brin*s the nee+ to measre not onl the CON!3PTION O) TI3$ allowe+ for the
wor or+er 7how mch time has alrea+ passe+ from the allowe+ release8
bt also the P#O%#$ O) T$ 9O#" O#'$# CO3P&$TIONin terms of its content.
9e can measre the pro*ress of the content in two was6
IN !NIT6 measrin* the nmber of nits complete+ as compare+ to the nmber
of nits in the 9O
IN #$3AININ% TI3$6 estimatin* the remainin* +ration in time ntil the
completion of the 9O 7the same as estimatin* the remainin* completion of the
tas in CCP38
#h$ e suggest !iagonal Buffer
for some specific Production enironments
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
10/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3 of +, content completion
43
"43
543
643
743
1443
1"43
1543
43 "43 543 643 743 1443
istor of two 9Os = +a after +a
43
"43
543
643
743
1443
1"43
1543
43 "43 543 643 743 1443
The illustration is taken from 8atalia
9nisimova' %resentation at 15 T,*%9
*onference in oscow' 8ov "415
3ofconsu
mption
of%);.
*)ON$
#h$ e suggest !iagonal Buffer
for some specific Production enironments
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
11/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3ofconsum
ption
of%);.*)ON$
9hen we nee+ to measre two +imensions for ever wor or+er6
+, 1 is for "44 units and
was given > working days(> 7?hr shifts) %&T Buffer
on the Time 9is with the
release date on 1 9pr2
1 April
By the end of 1 9pril 14
units were produced2
3 of completion of +,
content @ >3
3 of time consumption @
"435%
1 9pr
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
12/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3ofconsum
ption
of%);.*
)ON$
9hen we nee+ to measre two +imensions for ever wor or+er6
2 April
By the end of " 9pril
total "4 units were
produced2
3 of completion of +,
content @ "4#"44@143
3 of time consumption @
"#>@5435%
1 9pr
" 9pr
#h$ e suggest !iagonal Buffer
for some specific Production enironments
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
13/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3ofconsu
mption
of%);.
*)ON$
9hen we nee+ to measre two +imensions for ever wor or+er6
4 April
By the end of $ 9pril
total 144 units were
produced2
3 of completion of +,
content @ 144#"44@>43
3 of time consumption @$#>@643
5%
1 9pr
" 9pr
$ 9pr
#h$ e suggest !iagonal Buffer
for some specific Production enironments
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
14/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3ofcons
umption
of%);
.*)ON$
9hen we nee+ to measre two +imensions for ever wor or+er6
? April mornin*
By the start of the shift on the
morning of 5 9pril productionreceived information from
quality control that out of 144
produced units 54 were faulty
and had to be produced again2
0%=9T;= .T9T0.? Apr mornin*6
3 of completion of +,
content @ (144?54)#"44@$43
3 of time consumption @ 6432
The decision was made to doovertime on 5 9pr2
By the end of the overtime
there were total 1>4 good
units produced2
5%
1 9pr
" 9pr
$ 9pr
5 9pr
morning
#h$ e suggest !iagonal Buffer
for some specific Production enironments
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
15/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3ofconsum
ption
of%);.*
)ON$
9hen we nee+ to measre two +imensions for ever wor or+er6
? April after overtimeBy the end of the overtime
on 5 9pril there were total
1>4 good units produced2
3 of completion of +,content @ 1>4#"44@A>3
3 of time consumption @
7432
75%
1 9pr
" 9pr
$ 9pr
5 9prmorning
5 9prafterovertime
#h$ e suggest !iagonal Buffer
for some specific Production enironments
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
16/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3ofconsu
mption
of%);.*)ON$
9hen we nee+ to measre two +imensions for ever wor or+er6
5 April
By the end of > 9pril all "44
units were produced and
accepted by quality control2
3 of completion of +,content @ "44#"44@1443
3 of time consumption @
14432 1 9pr
" 9pr
$ 9pr
5 9prmorning
5 9prafterovertime
>9pr
#h$ e suggest !iagonal Buffer
for some specific Production enironments
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
17/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3ofconsum
ption
of%);.*)ON$
9hen we nee+ to measre two +imensions for ever wor or+er6
&et@s loo at another
scenario? April after overtime
By the end of the overtime
on 5 9pril 9&& "44 good
units produced2
3 of completion of +,
content @ "44#"44@1443
3 of time consumption @
7432 1 9pr
" 9pr
$ 9pr
5 9prmorning
5 9prafterovertime
#h$ e suggest !iagonal Buffer
for some specific Production enironments
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
18/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3 of +, content completion
The whole pictreat one *lance = the
stats of A&& OP$N
pro+ction wor
or+ers on a certain
+ate.3ofcon
sumption
of%);.*)
7/23/2019 06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web
19/19
21st International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
3 of +, content completion
3ofconsum
ption
of%);.*)
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