Showing posts with label TOC. Show all posts
Showing posts with label TOC. Show all posts

Sunday, January 4, 2009

A Process Of On-Going Improvement (POOGI) - Part 32

We are continuing our series based on The Goal by Eliyahu M Goldratt and the Theory of Constraints. {This series was co-written with Brad Stillahn.}

To make managing a complex organization easier, we break organizations into pieces. Many of the current measurements have the purpose of measuring local performance, under the erroneous assumption that the overall performance of the organization will be maximized if each department maximizes its performance.

The role of measurements is to induce the parts to do what’s good for the organization as a whole. What’s good for the organization as a whole is achieving the three objectives stated above.

In previous articles, we’ve referred to some of the measurements used by TOC practitioners:

  • Throughput (T) is rate at which the system generates money through sales.
  • Inventory (I) is the money invested in purchasing things which it intends to sell.
  • Operating Expense (OE) is the money the system spends to turn Inventory into Throughput.

To determine Throughput, subtract truly variable costs (TVC) from Sales dollars. Truly variable costs include raw materials, outsourcing, freight, and sales commission. Throughput is most similar to Gross Profit, except that direct labor is considered an Operating Expense in Theory of Constraints (TOC). It’s not that direct labor does not vary, but it is a period expense and does not necessarily need to vary with sales. Dramatic improvements in Net Profit can be gained when Throughput increases without a proportionate increase in Operating Expense.

...to be continued.

Here's to maximizing YOUR profits!
Dr Lisa Lang
(c)Copyright 2008, Dr Lisa, Inc. All rights reserved.

Thursday, December 18, 2008

A Process Of On-Going Improvement (POOGI) - Part 30

We are continuing our series based on The Goal by Eliyahu M Goldratt and the Theory of Constraints.

Measurements (Not Incentives)

“Tell me how you measure me, and I will tell you how I will behave. If you measure me in an illogical way…do not complain about illogical behavior”.

This quote by Dr. Eli Goldratt, the father of the Theory of Constraints (TOC), speaks directly to the cause and effect power of measurements, and to the general misuse of measurements.

We business managers often struggle to determine what to measure and control, and how to motivate employees. Some of us measure many, many things, while others of us don’t measure much at all.

Think about these questions:
· What problems are we trying to solve by using measurements?
· What and how are we measuring now?
· What problems do we cause by the way we measure now?
· Is there a better way? That is, what should we be measuring and how?

First, let’s set a context for our discussion of measurements by agreeing on the overall objectives of our organization:

  1. Make more money now as well as in the future,
  2. Provide a secure and satisfying environment for employees now as well as in the future, and
  3. Provide satisfaction to the market now as well as in the future.

The challenge is to accomplish all three objectives simultaneously.

One approach to doing so is called “balanced scorecard”. This proposed solution falls into the trap of trying to measure many, many things. It violates the second objective above in that when we measure many things, there will be some things that will look good and others that look bad. Depending upon the management style of the people involved, management can always find something to find fault with employees.

With TOC, we’re interested in ongoing improvement. We aren’t interested in measuring what is going well as much as we are interested in measuring what can be improved.

...to be continued.

Here's to maximizing YOUR profits!
Dr Lisa Lang
(c)Copyright 2008, Dr Lisa, Inc. All rights reserved.

Next Maximizing Profitability Events:
  • January 20, 2009 from 1 pm to 5 pm
  • February 3, 2009 from 1 pm to 5 pm

We now have 2 viewing options:

  1. On-site in Denver
  2. Live streaming video -- watch from you desk

Are you a Vistage/TEC member who would like your team to hear my Maximizing Profitability speech? You and/or you empolyees can attend in Denver at no charge or the LIVE STREAMING VIDEO is only $147 per company. More information at http://theoryofconstraints.eventbrite.com/

First GROUP Boot Camp of the year: February 4, 5, 6, 2009 in Denver. More information at www.MafiaOffers.com. Limited to the first 5 companies!

PRIVATE and On-line Mafia Offer Boot Camps are also available. On-line boot camps are done at YOUR time schedule and PRIVATEs are scheduled at a mutally agreed time.

Sunday, April 6, 2008

Free Goldratt Theory of Constraints Videos and Audios

I just completed a redesign of part of my website and added several free videos and audios. To view this new page, go to FREE Stuff and then down to FREE Videos & Audios. You will need to register to view/listen to them, but registration is free and we will protect your email.

You will find videos on the following topics:

  • Critical Chain Project Management
  • Viable Vision
  • Mafia Offers and Mafia Offer Boot Camps
  • Success Stories
  • Overview of Goldratt's Theory of Constraints
  • more to come!
You will also find a list of written articles, success stories, blog posts, etc under the FREE TOC & VV Articles (Theory of Constraints & Viable Vision). I'm in the process of resigning this page so that the articles can be better searched and allow you to see how many times each has been downloaded, as well as, you can enter and read reviews left by readers.

And, if you click on the FREE Stuff tab directly you will find other items that might be of interest, like:
  • Theory of Constraints games
  • Theory of Constraints software (Thinking Process Software)

Here to maximzing YOUR profits!

Dr Lisa Lang

P.S. We will be continuing with the "Process of On-Going Improvement" series shortly.

Thursday, March 27, 2008

A Process Of On-Going Improvement (POOGI) - Part 9

Normally, Lean and Six Sigma tools provide additional benefits very quickly. For example, it is common that the constraint resource could benefit from set-up reduction. Focusing Lean tools—which cost little to implement—results in additional capacity where it is needed and that has an immediate bottom-line result.

Due-date performance improves because of the reduction in lead-time, the increased capacity, the predictability of the time to process an order has improved, and jobs are prioritized according to due date.

The “Drum” is the schedule for the constraint resource. It sets the pace for the entire operation. In Goldratt's Theory of Constraints, we assume there is one system constraint that is limiting the throughput of the entire business. The drum is the only resource that needs to be scheduled. All other operations have relative excess capacity, meaning that orders can flow through the plant until reaching the constraint resource, and after it.

The “Buffer” is what protects the constraint from going idle from lack of material to process. The buffer needs to be large enough to prevent starvation on the constraint resource. It is really a time buffer, not physical materials, but we’ll explain that at another time.

The “Rope” is the mechanism for release of new material into the operations.

There are conventional cost accounting assumptions that may block you from implementing Drum-Buffer-Rope. Next time, we’ll address those issues, and describe how TOC’s Throughput Accounting concepts will free you to take the needed actions.

...to be continued.

Here's to maximizing YOUR profits!
Dr Lisa Lang(
c)Copyright 2008, Dr Lisa, Inc. All rights reserved.

______________________________________________________________________ About About the co-authors:

Brad Stillahn is a business owner that has successfully implemented TOC methods in his own business and is now helping other business owners do the same. His consulting company, TOC Professionals engages in long-term relationships with companies implementing TOC. His business and personal partner is Dr. Lisa Lang. Brad can be reached at Brad@ScienceofBusiness.com or 303-886-9939.

“Dr. Lisa” Lang is President of the Science of Business. Her speech “Maximizing Profitability” is popular with Vistage groups and as a keynote speech. Recently Dr. Goldratt’s Global Marketing Director, she offers the “Mafia Offer Boot Camp” for companies wanting to develop and implement a Mafia Offer. She can be reached at DrLisa@ScienceofBusiness.com or 303-909-3343.

Sunday, January 6, 2008

Creating your Strategic Plan and Finding your Compass for 2008

Happy New Year! I hope this blog finds you and your business poised for prosperity! This is the time of year when most of us get reflective. We look back and determine what worked, what didn’t, and what changes we are going to make. And many times when we haven’t achieved all that we wanted to we put pressure on ourselves to really achieve our goals THIS year.

Now, many of you probably think that I’m really big on setting goals and to some extent that is true. You need to generally understand what you are trying to achieve with your business whether it’s to generate rapid sustainable growth, to prepare to sell or exit, or to just maximize your profitability with your existing resources. This understanding is essential for determining the current and strategic locations for your constraint and provides the compass that will set your course. However, I’m not a big fan of the traditional SMART goals – Specific, Measurable, Achievable, Results-oriented, and time-based. These are like a detailed map of exactly what you do.

If you are going on a driving vacation and you follow a very detailed map, where’s the room for a fun detour? I find that too much detail and focus on that detail can cause you to miss opportunities that were not planned for. I believe in following a strategic compass, and in creating an implementation plan, but then being opportunistic when appropriate. [Interesting read -- Goal Free Living]

What’s your strategic compass? What are you ultimately trying to achieve? Do you want to sell? Do your want to transition your business to a family member? Do you want to grow? Or, do you just want to maximize your profits with your existing resources?

Now once you answer this question for yourself, then put some parameters around it – like how much and by when. After you have that done, then we need to create a compass. What objectives would need to have been reached for your goal to be realized? Objectives are states of being as opposed to actions. What state(s) or condition(s) will need to been in place?

An alternative way to think about it, and sometimes easier, is to develop a list of obstacles to meeting your goal. What’s keeping you from the goal? Once you have the list of obstacles, you can convert it to objectives. What objective, if met, would overcome the obstacle?

Now write your goal at the top of a blank sheet of paper. Then ask – in order to achieve this goal, I must first achieve …. Put the objective(s) at the top which are closest in time to achieving your goal and work your way down the page. After you have the first objective(s) listed then asked for each of those – In order to achieve that, I must first … And so on, until you have placed all the objectives (and probably discovered a few more). The objectives at the bottom would be the first ones you would start working on.

This process is creating a PRT (that’s Goldratt Theory of Constraints speak for pre-requisite tree). This map of objectives becomes your compass, your implementation plan. You follow this compass, this path, until you have learned something that changes your direction or until an opportunity comes along that allows you to skip several levels or is just better that what your were planning.

For some examples, I recommend two Thinking Process books:
1) http://www.amazon.com/dp/0873897234?tag=thescienceofb-20&camp=14573&creative=327641&linkCode=as1&creativeASIN=0873897234&adid=10FXZAS4Q35XKQ66WZF7&
2) http://www.amazon.com/dp/1574441019?tag=thescienceofb-20&camp=14573&creative=327641&linkCode=as1&creativeASIN=1574441019&adid=0ES9BA8S32F95PYZ7BCG&

Or you can take a Thinking Process (Jonah) course. http://www.scienceofbusiness.com/Default.aspx?tabid=145

If you are struggling to develop the objectives to meet your goal, we typically recommend a Mafia Offer Boot Camp. Your mafia offer will lead you to what operational changes are necessary to support it. And if you can uncover capacity with little or no investment (certainly possible with the TOC tools) and you can then sell that capacity, you will have a dramatic effect on your bottom-line. And whether your goal is to sell your business, hand it off to a relative, or just maximize your profits – a mafia offer will provide you the specific strategy and tactics (compass) to achieve your goals.

Here's to Maximizing YOUR Profits in 2008!
Dr Lisa Lang
(c)Copyright 2007, Dr Lisa, Inc. All rights reserved.

Saturday, September 1, 2007

Theory of Constraints next topic?

I would like your feedback on which topic you would like me to address next, here are the options I’m considering:

  1. Theory of Constraints on Incentive Plans
  2. Most Common Issues when Implementing DBR (Drum-Buffer-Rope)
  3. Theory of Constraints on Sales Commissions

As a thank you for replying you can purchase Achieving a Viable Vision for 50% off. Just send me an email and let me know your vote and if you want to purchase the 3 hour audio plus workbook (recorded from a live workshop) for only $99 with free shipping worldwide.

Feel free to ask any questions or suggest alternative topics.

Here's to Maximizing YOUR Profits!

Dr Lisa Lang

Friday, August 10, 2007

Book Review: Blue Ocean Strategy

Blue Ocean Strategy: How to Create Uncontested Market Space and Make the
Competition Irrelevant
by W. Chan Kim and Renee Mauborgne.


This review will focus on pointing out those things that are consistent with Theory of Constraints (TOC) and my opinions from those things that are not.

The authors have done a nice job of explaining the problems with current strategy and market development techniques. Specifically, I agree that:

  • "... with supply exceeding demand in more industries, competing for a share of contracting markets while necessary, will not be sufficient to sustain high performance." pg 5
  • "The result has been accelerated commoditization of products and services, increasing prices wars, and shrinking profit margins." pg 8
  • "In overcrowded industries, differentiating brands becomes harder in both economic upturns and downturns." pg 8
  • "The trend toward globalization has compounds the situation." pg 8

No question. There is a problem. We can't continue to do things in the same way and expect different results. However, I believe that a couple key assumptions have lead the authors astray.

Here is what I don't agree with:

  • "To seize new profit and growth opportunities, they need to create blue oceans." pg 5

Blue oceans are new products in new markets/industries and I believe that in many cases this is an invalid assumption -- that you MUST create new products and/or new markets/industries to substantially grow profits. I believe that this is invalid because we have experience in creating irresistible market offers that we call Mafia Offers. These Mafia Offers are typically for existing products in existing markets. The reason we focus our Mafia Offers develop on existing products in existing markets can be traced back to the 5 Focusing Steps that were discussed in The Goal by Eliyahu M Goldratt:

  1. IDENTIFY the system's constraint.
  2. Decide how to EXPLOIT the system's constraint.
  3. SUBORDINATE everything else to the above decision.
  4. ELEVATE the system's constraint.
  5. If in the previous step the constraint has been broken, go back to Step 1.

If your system's constraint is the market, then new products or new markets/industries is an ELEVATION step. I believe that before we elevate we should first try to get more (EXPLOIT and SUBORDINATE) out of what we already have.

The authors then address the risk associated with new products in new markets/industries:

  • A systematic process will minimize risk to expanding into new products and/or new markets/industries. I agree with this, but then they go on to imply that it would be no more than the risk of strategies around existing products/markets/industries.

I think the business owner who was investing in the new development would disagree.

In contrast, a good Theory of Constraints Mafia Offer will achieve all the positives of a blue ocean strategy without the risk. Because mafia offers are developed on existing products/markets/industries and with little or no investment, it is an EXPLOIT and SUBORDINATION step.

Okay, now back to more about what I liked:

  • If and when you need to develop new products/markets/industries then I think the process outlined by the authors is very good.

Almost everyone at some point WILL need to develop new products/markets/industries and I liked this approach. I do think it would be difficult to implement the approach just based on what's in the book. But the framework is there.

Here's to maximizing YOUR profits!

"Dr Lisa" Lang

(c)Copyright 2007, Dr Lisa, Inc. All rights reserved.

Need an example of a Mafia Offer? http://www.podcasternews.com/programs/87/better-process-podcast/3574/?A=1

Friday, March 9, 2007

Goldratt Theory of Constraints Articles, News, & Success Stories

I have been collecting Goldratt Theory of Constraints articles since 2004. I post all of them on my website. The articles include TOC implementation success stories, general knowledge articles, and instruction of the use of the various Theory of Constraints tools - Drum Buffer Rope (DBR), Simplified Drum Buffer Rope (S-DBR), Viable Vision, Demand Pull / Replenishment, Critical Chain Project Management, Solutions For Sales, Marketing (Mafia Offer), Throughput Accounting, Strategy, Cash Flow, Cash Velocity, and Cash to Cash Cycle Time.

You will also find a number of book reviews. There are several reviews of The Goal by Eliyahu Goldratt.

In addition, there are several articles on Theory of Constraints with Lean and Six Sigma.

At the end of 2006 I also created a 140 page document containing all the articles from 2006. Look for the document titled: 2006 COMPLETE LIST 140 pages

You will also find a link to a bank of Theory of Constraints implementation data. While there have been 1000s of implementations, the bank has about 80 success stories.

Here is the link to the articles: http://www.scienceofbusiness.com/Default.aspx?tabid=122
You will have to register (which is free) to be able to view and download them.

Here is the link to the database of 80 success stories: https://toc-goldratt.com/index.php?cont=2&ext=9&partner=DR-LISA-partner