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Book Review of "Goal"
@Dai Haotian, 1999
Email:no1skyhorse@yahoo.com
1. What is the problem?
Alex Rogo was a plant manager at the Barrington Plant of Uniware, a division of UniCo. One day Bill Peach, division vice president visited his plant and found that there were lots of problems with schedule arrangement, quality, cost & inventory control in his plant. These problems had already made the organization lose money. At last Bill gave Alex three months to improve, otherwise, the plant would be closed.
Three months?! That was all Alex Rogo was able to think about. Alex had to start to consider what was the goal of the manufacturing organization.
What on earth was the GOAL of the manufacturing organization? Was it better customer service? Larger market share? Lower cost? High quality? just survival? Alex was always trying to find the answer. Finally he got the idea that the GOAL of a manufacturing organization was to make money.
Next step for Alex was to find a way to measure if the manufacturing organization makes money or not. One way was Bottom Line Measurement, which was submitted by Mr. Lou, the plant controller. The bottom line measurement contains three components. They are Net Profit, Return on Investment (ROI) and Cash Flow. Net profit is absolute value the organization earns. ROI is a ratio, which can tell the relationship between return and investment. And organization can not survive without enough cash flow. To make money is to increase net profit, while simultaneously increase ROI and cash flow. The other measurement was developed by Jonah, who once taught Alex mathematical models when Alex was a student. This measurement is also composed by three elements, which are Throughout, Inventory and Operational Expense. Throughput is the rate at the system generates money through sales. Inventory is all the money that system has invested in purchasing things which it intends to sell. Operational expense is all the money the system spends in order to turn inventory into throughput. The goal for making money is improving throughput, also decreasing operational expense and inventory at the same time.
To make it simpler and clear, the relationship between Throughput, Inventory and Operating Expense can be compared with the situation of hike, in which Alex and his son, Dave, participated. Alex let Ron lead the column in moderate pace. Ron can be regarded as consuming raw material, the trail between Ron and the rest is Inventory. If the distance between Ron and the last one is expanding, it can only mean that inventory is increasing. Throughput is the pace rate of last person's walking. So as the slower than average fluctuations accumulate, they work their way back to the last person, which means the last person had to slow down. Which also means that, relative to the growth of inventory, throughput for the system goes down. In terms of the hike, operational expense is the energy for everyone used. It is increasing any time they hurry to catch up, because they expend more energy than they otherwise would. Then what would happen to the plant in this analogy? ----Inventory was going up, throughput was going down, and operational expense was probably increasing.
2. What caused the problem?
What caused such phenomenon? Alex had to turn to Jonah for help. Jonah just gave him two pieces of golden advice:
1. Distinguishing the bottleneck resource and non bottleneck resource
2. Balancing the flow of product through the plant with demand from the market rather than balance the capacity.
The bottleneck determined the effective capacity of the plant, just like Hebie who had the least capacity and actually determined how fast the troop as a whole could move. Identifying "Hebie" in the plant was no easy job. After Alex and his colleague analysized the plant resources, "Hebie" turned out to be NCX-10, which was the one of the most efficient machine with lowest cost and highest rate to produce the parts. Why such a good machine became a bottleneck? Because workflow were always bottlenecked here and expeditors were always waiting for parts from this machine. Another "Hebie" was heat-treatment department, which was just like a barbershop, taking a number, standing in line, waiting heat treatment. These two bottlenecks constrained the whole process.
Alex and his colleagues were happy to identify two "Hebie"s, NCX-10 and Heat Treatment Department, which bottlenecked a flow sufficient to meet demand and make money. So the only thing to do was to find more capacity. To increase the capacity of the plant was to increase the capacity of only the bottlenecks. To increase the capacity of bottlenecks did not mean to install new machine, but to find the hidden capacity. With the help of Jonah, Alex found the NCX-10 had 1-hour idle time, as the union contract stipulated that there must be a half-hour break after every four hours work. The hours lost in the breaks of NCX-10 were enormously expensive because the throughput for the entire plant had been lowered by the bottleneck. The problem of the second "Hebie", heat treat, was that they didn't make the bottleneck work on the parts contributed to throughput and many products were unable to be shipped without the parts in pile for treatment. What was more, they only did most inspections prior to final assembly but never inspected the parts before bottleneck. It easily let defects go through bottleneck and lost time in the bottleneck could not be recovered. The cost of one hour lost in these two bottlenecks is the cost of an hour lost in the system, which is computed as the total expense of the system divided by the number of hours the bottlenecks produced. Here it was $2.735 per hour.
3. How to solve the problem?
Again, Johan, figured out some principle guidelines to tackle the bottleneck
Problems.
1. Make sure that the bottleneck time is not wasted by eliminating idle time during lunch break.
2. Put Quality Control in front of bottleneck.
3. Make the bottlenecks work only on what will contribute to throughput today.
Alex was inspired by these principles. He and his colleagues rescheduled and re-structured the production process.
a. Checking parts going the bottlenecks, NCX-10 and heat treat, to ensure no defects pass bottlenecks
b. Setting up new rules for lunch time to eliminate idle time on NCX-10 machine
c. Listing orders according to overdue priorities from most day overdue to least day overdue; scheduling the bottlenecks to start working on the parts for the latest order first, the next latest and so on.
d. Showing priority. All work-in-process on the plant would be marked by tag with a number on it and the tag would be colored red and green. A red tag marker meant the work attached to it had first priority, which were to be processed by a bottleneck. The green one meant it should give way to red one and should be processed after red one if there was a choice between them. In addition, they decided to extend the capacity of bottlenecks by activating an old machine, adding a foreman and two workers at the heat treat furnaces, putting set-up crew of two person on NCS-10 and having some piled parts sent out to the vendors across the town. The purpose was to reduce the efficiency of some operations and make the entire plant more productive.
With these changes, remarkable results appeared. This month, they shipped 57 orders with a value of $3 million compared with the best historic record 31 orders with a value of $2 million. The work-in-process inventory declined by 12%. Cheers for the success! However, the good news did not last long enough before a new problem occurred. New bottlenecks appeared. The bottleneck parts were still in short supply and so were the non-bottleneck parts. A list of parts was queued for final assembly. Alex was puzzled with this problem. Why new bottleneck occurred? He could do nothing but turn to Jonah for help again. Jonah pointed out that it was not a problem of bottleneck but a problem of the relationship between bottleneck and non-bottleneck. They ran non-bottlenecks for ‘efficiency’ and built inventory far excesses demand. The constraint now was not production but market ability to sell. They were trying to optimize every resource in the system. The cause of the problem was the milling machine processed materials faster than the bottleneck can process it. Yes, it was a problem of pace.
All the departments should process at the same rate just like the scout troop. A time buffer and a communication rope solve the problem.
The rope is a signal to link the bottlenecks with the release of materials schedule. As each batch leaves the bottleneck, they can update the information, calculate a date when more red tag material should be released and also determine a schedule for final assembly. Once the time of bottleneck parts would reach the final assembly is known, the release of the non-bottleneck materials can be calculated backwards and determined and so can the release of the non-bottleneck materials along each of their routes. In this way, the bottlenecks will determine the release of all the material in the plant. The time buffer is a three-day-stock of work-in-process in front of each bottleneck as well as a buffer in front of assembly. With these efforts, Alex directed the plant to the right track. But Bill Peach wanted to see big improvement. He demanded Alex to give him 15% profits on the bottom line. A tough job for Alex!
To make money means to get cash back fast and put products through market fast. Alex and his co-workers decided to shorten lead-time by cutting batch size half, which reduced delivery time from 8 weeks to 4 weeks. Customers responded to the change with satisfaction. Throughputs improved accordingly.
In the last month, throughput had doubled; inventories were about 40 % of what they were three months ago. With more business and more parts over which spreading the costs, operating expense went down. They were making money--- the goal of business was reached. Alex Rogo now had a new goal of making more money for the company as he was promoted as the division manager.
4. Recap Theory of Constraint
The process of Theory of Constraint is as below.
1. Identify the system constraints:
NCX-10 and Heat Treat are the bottlenecks of the plant.
2. Decide how to exploit the system constraints:
Realizing that NCX-10 should not take a lunch break.
3. Subordinating everything else to the above decision:
Making sure that everything marches to the tune of the constraint. The red and green tags.
4. Elevate the system constraints:
Bring back the old machine, switching back to old, less "effective" routings.
5. If, in the previous steps, the constraints have been broken, go back to Step 1.
The Theory of Constraint is a philosophy theory rather than scientific theory. It emphasizes the overall perception, focuses on the balance of the rhythm in movement. The Theory of Constraint can be applied everywhere, not only in production but also in our life. For instance, the constraints of learning are the bottleneck of memory. If five exams were taken in one week, the memory bottleneck would occur. The capacity of the memory is limited, in which the information for the exam of 5 courses can not be input within the one week. We should arrange the 5 exams in 5 weeks, i.e., one week for each. Thus we can balance the rhythm of the memory flow rather than balance the capacity.
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VIDEOS included - Forex trading
"Something Fantastic" happens every day at the same time, to the same stock index... <a href=http://www.metacafe.com/watch/2823224/forex_strategy>forex strategy</a> that will make you rich! <a href=http://video.yahoo.com/watch/5094234/13517091>forex capital market</a>
Karl Dittmann (Germany) - 30 years of trading experience <a href=http://www.dailymotion.com/user/worte6/video/x99u48_forex-signal_tech>forex signal</a> If you learn the one hidden secret which is repeated daily for years, you will make an incredible profit! <a href=http://www.metacafe.com/watch/2838688/forex_dealer>forex dealer</a>
One single stock index trade within 15 minutes of the market pening is all you need! <a href=http://www.youtube.com/watch?v=VXEBlEu9aT8>forex dealer</a> What if you knew a trading secret so simple, yet so powerful, that anyone could use to profit from the Stock market even without experience. All You need is to trade Single Stock Index - 15 minutes at the opening. 30-50 ticks daily can be yours! <a href=http://video.yahoo.com/watch/5072031/13473857>fores trading signals</a> This is Guaranteed! <a href=http://www.dailymotion.com/user/q1q1q1z/video/x9bi89_forex-trades_tech>forex trades</a>
There is no way to lose money! <a href=http://www.dailymotion.com/user/vygtre3/video/x9afml_forex-made-easy_tech>forex made easy</a>
Forget Indicators and stock trading guides! <a href=http://www.youtube.com/watch?v=exWBS32Hl8Q>forex market hours</a>
There is "something" which happens every day at the same time with the same Stock Index...! <a href=http://www.dailymotion.com/user/q1q1q1z/video/x9bi89_forex-trades_tech>forex trades</a> This is when you can make real money! <a href=http://www.metacafe.com/watch/2843144/forex_research>forex research</a>
It is absolutely possible to have 9 or even 10 winning trades out of 10...
All you need is to know the secret and exact trading algorithm. The secret can be used for some other major stocks too! <a href=http://video.yahoo.com/watch/5073081/13476465>forex futures</a>
This Secret Will Completely Change Your Life! <a href=http://video.yahoo.com/watch/5068933/13466376>forex trading couse</a> The System is 100% mechanical and doesn't need any tech indicators or other tech materials... <a href=http://www.youtube.com/watch?v=c2INow1O4D4>easy forex</a> it can be used by anyone... even beginners.
Newbies will like the simplicity while experts will like the ease of use and amazing stock index trading idea .... <a href=http://www.dailymotion.com/user/poledrok/video/x9avt3_forex-information_tech>forex information</a> It is a complete plug and play system can be used by any people even without any experience of Stock indices trading! <a href=http://video.yahoo.com/watch/5084144/13498305>forex directory</a> All You need is the idea and the exact plug-n-play trading algorithm. <a href=http://www.dailymotion.com/user/wortu2/video/x9a4m5_forex-systems_tech>forex systems</a>
Finally, these unbelievable trading secret are available to the public for the first time ever. <a href=http://video.yahoo.com/watch/5072812/13475778>scalping forex</a> This method have the potential to completely change your life. <a href=http://www.metacafe.com/watch/2824090/forex_trading_systems>forex trading systems</a> 100% Mechanical system, which have been hidden for years, known to only a group of Wealthy Trading Elite! <a href=http://video.yahoo.com/watch/5072485/13475001>forex options</a>
Join us know... <a href=http://www.metacafe.com/watch/2823101/forex_day_trading>forex day trading</a> I guarantee once you read and apply for our method - you will never look back, and never want to use any other trading Stock market system! <a href=http://video.yahoo.com/watch/5066962/13461688>day forex</a> <a href=http://www.ug.edu.gh/?page=wow-gold>wow gold</a> <a href=http://www.ug.edu.gh/?page=warcraft-gold>warcraft gold</a>
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forex account fores quotes [url=http://www.dailymotion.com/user/tunalopas1/video/x9bv3
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Public Board -> Features -> Public Digest
Topic: GOAL-Making Money through Bottlenecks
