06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web

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 - 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


2/19


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.

[email protected]

www.toc-strategicsolutions.com

www.tocpractice.com

Jelena Fedurko


3/19



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$


4/19


TOC Practitioners Alliance - TOCPA


5/19



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 (%)


6/19



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)


Production (&)


7/19



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


Production (')


8/19



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


Production


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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


10/19



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$




11/19



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


12/19



3ofconsum

ption

of%);.*

)ON$


2 April

By the end of " 9pril

total "4 units were

produced2


content @ "4#"44@143


"#>@5435%

1 9pr

" 9pr




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3ofconsu

mption

of%);.

*)ON$


4 April

By the end of $ 9pril

total 144 units were

produced2


content @ 144#"44@>43

3 of time consumption @$#>@643

5%

1 9pr

" 9pr

$ 9pr




14/19



3ofcons

umption

of%);

.*)ON$


? 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


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




15/19



3ofconsum

ption

of%);.*

)ON$


? 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


7432

75%

1 9pr

" 9pr

$ 9pr

5 9prmorning

5 9prafterovertime




16/19



3ofconsu

mption

of%);.*)ON$


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


14432 1 9pr

" 9pr

$ 9pr

5 9prmorning

5 9prafterovertime

>9pr




17/19



3ofconsum

ption

of%);.*)ON$


&et@s loo at another

scenario? April after overtime

By the end of the overtime

on 5 9pril 9&& "44 good

units produced2


content @ "44#"44@1443


7432 1 9pr

" 9pr

$ 9pr

5 9prmorning

5 9prafterovertime




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The whole pictreat one *lance = the

stats of A&& OP$N

pro+ction wor

or+ers on a certain

+ate.3ofcon

sumption

of%);.*)


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3ofconsum

ption

of%);.*)

Documents

06-JelenaFedurko 21 TOCPA 11 Nov 2015 UK for Web