The focus and leverage improvement book: locating and eliminating the constraining factor of your lean six sigma initiative PDF
Preview The focus and leverage improvement book: locating and eliminating the constraining factor of your lean six sigma initiative
The Focus and Leverage Improvement Book Locating and Eliminating the Constraining Factor of Your Lean Six Sigma Initiative The Focus and Leverage Improvement Book Locating and Eliminating the Constraining Factor of Your Lean Six Sigma Initiative By Bob Sproull A PRODUCTIVITY PRESS BOOK First edition published in 2019 by Routledge/Productivity Press 711 Third Avenue New York, NY 10017, USA 2 Park Square, Milton Park, Abingdon, Oxon OX14 4RN, UK © 2019 by Taylor & Francis Group, LLC Routledge/Productivity Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Printed on acid-free paper International Standard Book Number-13: 978-0-367-00111-7 (Hardback) International Standard Book Number-13: 978-0-429-44445-6 (eBook) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, trans- mitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright. com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice : Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging‑ in‑ Publication Data Library of Congress Cataloging-in-Publication Data Names: Sproull, Robert, author. Title: The focus and leverage improvement book : locating and eliminating the constraining factor of your lean six sigma initiative / Bob Sproull. Description: 1 Edition. | New York, NY : Taylor & Francis, [2019] | Includes bibliographical references and index. Identifiers: LCCN 2018026362 (print) | LCCN 2018021253 (ebook) | ISBN 9780367001117 (hardback : alk. paper) | ISBN 9780429444456 (e-Book) Subjects: LCSH: Lean manufacturing. | Six sigma (Quality control standard) Classification: LCC TS155 .S743 2019 (ebook) | LCC TS155 (print) | DDC 658.5/62--dc23 LC record available at https://lccn.loc.gov/2018026362 Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com Dedication Dedication As we go through life, humans continue learning new things. Sometimes we learn through reading books, sometimes it’s through personal experiences and sometimes it’s through someone we’ve met along the way. I can honestly say that I have experienced all three of these learning modes. But having said this, I can say without reservation that much of my learning came about when I met Bruce Nelson. For those of you who’ve never met Bruce, he’s a one–of-a-kind guy. I met Bruce when I worked at the US Army Base, Fort Rucker, Alabama. We were working on improving the maintenance processes on Army helicopters. Bruce worked for another division of the same company, but came to our facility to help us with our improvement efforts. From the very first day I met Bruce, my learnings on the system’s approach accelerated upward and have continued since then. Bruce is just a cut above everyone else I have ever met. His method for explaining new concepts is unlike anyone else I have ever met. He has a gift for making complex subjects simple to understand. Bruce introduced me to systems thinking and Theory of Constraints (TOC) Logical Thinking Processes. I feel honored to have met Bruce Nelson, to have him co-author two books with me and, most importantly, to have him be my friend. I am dedicating this book to Bruce in recognition of everything he has taught me over the years. I can only say, “Thank you Bruce, for all you have done for me and for being my friend.” Contents Contents Preface .................................................................................................xiii Chapter 1 Improvement Efforts ..........................................................1 Introduction ..................................................................................1 A New Type of Accounting .......................................................12 Throughput (T) ......................................................................13 Investment or Inventory (I) ..................................................13 Operating Expense (OE) .......................................................13 Reference ......................................................................................17 Chapter 2 The Ultimate Improvement Cycle ...................................19 Introduction ................................................................................19 Step-by-Step Explanation ..........................................................27 Step 1a ......................................................................................27 Steps 1b and 1c........................................................................29 Step 2a ......................................................................................31 Non-Constraints ........................................................................34 Drum Buffer Rope (DBR) ..........................................................35 Steps 3a, 3b and 3c ................................................................40 Steps 4a, 4b and 4c ................................................................40 References ...................................................................................43 Chapter 3 How to Implement the UIC .............................................45 Introduction ................................................................................45 Ten Prerequisite Beliefs ..............................................................47 Types of Constraints .................................................................56 Resource/Capacity Constraints ..........................................56 Market Constraints ..............................................................56 Material Constraints .............................................................57 Supplier/Vendor Constraints ...............................................58 Financial Constraints ............................................................58 Knowledge/Competence Constraints .................................58 vii viii • Contents Policy Constraints..................................................................58 References ....................................................................................59 Chapter 4 The Goal Tree ...................................................................61 Introduction ................................................................................61 The Goal Tree Structure ............................................................63 The Goal ......................................................................................64 Critical Success Factors and Necessary Conditions ..............65 Constructing a Goal Tree/Intermediate Objectives Map ....66 The Goal Tree Case Study Example .........................................67 The First Meeting .......................................................................68 Using the Goal Tree as an Assessment Tool ...........................77 Performance Metrics ..................................................................82 Reference .....................................................................................86 Chapter 5 The Logical Thinking Process ........................................87 Introduction ................................................................................87 The Logical Thinking Tools .....................................................88 The Current Reality Tree ...........................................................94 Communicating Productively .................................................96 Steps to Construct a CRT .........................................................99 Collecting UDEs .......................................................................101 Constructing the CRT .............................................................102 Conflict Diagrams—Basic Principles ....................................104 Conflict Diagrams—Steps to Construct and Categories ....107 The Steps................................................................................107 Categories of CD .......................................................................108 Future Reality Trees—Basic Principles..................................110 Future Reality Tree Uses ..........................................................112 Future Reality Trees—Steps to Construct .............................113 Step 1—Define the Function of the Future Reality Tree ...113 Step 2—Capture the Idea ....................................................113 Step 3—Make a List of Potential Desirable and Negative Effects ....................................................................113 Step 4—Build the Causal Connections between the Injection and Desirable Effects ..........................................114 Step 5—Strengthen Your Analysis ....................................114 Step 6—Actively Seek Negative Branches ........................115 Contents • ix Prerequisite Trees—Basic Principles ......................................115 The Prerequisite Tree (PRT) ....................................................116 Prerequisite Trees—Steps to Construct .................................118 Step 1—Verbalize Your Objective ......................................118 Step 2—List the Obstacles That Prevent the Attainment or Existence of the Objective ........................119 Step 3—Determine Intermediate Objectives That Eliminate the Obstacles You Have Listed .........................119 Step 4—Find the Time Dependencies between the Intermediate Objectives ......................................................121 Step 5—Check the Prerequisite Tree for Feasibility.......122 Transition Trees—Basic Principles .......................................122 Principles ..................................................................................123 Transition Trees—Steps to Construct ...................................125 Step 1—Define the Situation for Which You Are Preparing the Transition Tree ............................................125 Step 2—Determine Your Objective(s) ...............................125 Step 3—Determine the Actions Are Necessary to Achieve Your Objective(s) ...................................................127 Step 4—Look for Any Undesirable Side Effects ...............130 Step 5—Take Action ............................................................131 Reference ....................................................................................131 Chapter 6 A Simplified Improvement Strategy .............................133 Introduction ..............................................................................133 The Evolution of the Thinking Processes .............................134 The Apparent Problem .............................................................135 The Interference Diagram .......................................................136 Interference Diagram Types....................................................137 Step 1—Define the Goal/Objective ....................................138 Step 2—Define the Interferences .......................................138 Step 3—Quantify the Time Component for ALL Interferences .........................................................................139 Step 4—Alternatives to the Interferences .........................139 Interference Diagram for Strategy .........................................143 Step 1—ID Strategy—Define the Goal/Objective ...........144 Step 2—Define the Obstacles/Interferences .....................144 Step 3—Define the Intermediate Objectives/Injections ...145
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