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16th International Conference of the TOC Practitioners Alliance
- TOCPA
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April 23, 2015 Johannesburg, South Africa
16th International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
Production vs Projects
Jaco Laubscher, Realization Africa, South-Africa23rd April,
2015
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16th International Conference of the TOC Practitioners Alliance
- TOCPA
www.tocpractice.com
Jaco Laubscher
[email protected]
+27 83 306 7145
Jaco is a Theory of Constraints1 Solutions Application Expert,
currently involved with various projects in South and Southern
Africa.He has been trained by Realization Inc. as a Critical Chain
Implementation Expert.
Jaco has a B.Eng Mechanical Engineering Degree from the
University of Pretoria. Having spent 9 years in the Food and
Beverage industry, dealing with large and complex multi-discipline
projects, Jaco gained extensive experience in Process Engineering,
Process Automation, Project Management, Contracting and Contract
Management as well as the associated disciplines of System
Engineering, Configuration Management, Quality Management and Risk
Management.
For the past 9 years Jaco has actively implementing Critical
Chain Project Management Systems across a number of industries,
ranging from IT, Construction, Maintenance, Repair and Overhaul as
well as new product development environments.
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16th International Conference of the TOC Practitioners Alliance
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Everything I am presenting here today is my personal opinion,
observations and hypothesis.
These opinions, observations and hypothesis are not those of
Realization Inc, nor has any of these been incorporated in any of
the products or services provided by Realization Inc.
These views have however been shaped during a number of
implementations of Realizations technology.
Legal Disclaimer
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16th International Conference of the TOC Practitioners Alliance
- TOCPA
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A Version of TOC history
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16th International Conference of the TOC Practitioners Alliance
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Challenging inconsistencies
Why do I expect to find a pure project environment or a pure
production environment and not a mixture/hybrid of the two?When you
have a hammer, everything looks like a nail
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Pure Production Environment
Repetitive (have been done before) Touch-time is a small
percentage of lead-time Object based Over-production and
under-production is possible Stock of finished goods is possible
Lead-time can be very short (hours/days) Stock buffers and time
buffers is used
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Pure Project Environment
Non-repetitive (Each project is unique) Touch-time is a
noticeable percentage of lead-time Could be non-object based
(ideas, concepts, designs) Over-production and under-production is
not possible,
when a task is completed, it is completed. Stock of finished
goods is not possible Lead-time is longer (weeks/months/years) Time
buffers is used
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16th International Conference of the TOC Practitioners Alliance
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Reality is different
Have projects with repetitive tasks. (Babcock) Have projects
with tasks, where touch-time is a small
percentage of the lead time. (Centurion Systems DTP) Have
production where touch-time is a large percentage
of total lead-time (SABN) Have logistical elements that needs to
be ready for CC-
task as well as non-CC tasks and thus need feeding buffers for
all tasks. (Babcock)
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The Goal vs Critical Chain DBR/sDBR vs CCPM
Is this also reality?
Project Buffer
Feeding Buffer
Critical Chain
vs
vs
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A unified view?
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Production-Project Mix
It is a maintenance project using CCPM principles, but instead
of as-late-as-possible, we manipulate the feeding buffers so that
every chain starts as soon as possible.
Tasks are production task that needs to be completed at a daily
certain rate, so daily targets is used to report progress and not
remaining duration estimates. Buffers are mostly used for Murphy,
rather that task time variability.
Full-kitting is the most important aspect that is required
Buffer
Buffer
Buffer
Buffer
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Production-Project Mix
Overall the development is driven with CCPM.Most departments
obtain their priorities in this multi-project environment from the
CCPM software.One department is running a job-shop and the project
work is only 5% to 10% of their workload.Our solution: When chain
get to this department, the task itself becomes a buffer.
Buffer
Buffer
Buffer
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Logistics Project mix
Created tasks with 100% feeding buffer to ensure that the
logistical supply is ready when the critical chain task starts, but
how do you deal with the some requirement on a non-critical chain
task? Implemented full-kit points to solve the problem.
A
B
C
Buffer
3 weeks
3 weeks
Buffer
3 weeks
A
B
C
Buffer
3 weeks
3 weeks
Buffer
FK
FK
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Summary
Reality is, that there is very few pure project environments or
pure production environments.
As TOC practitioners, we tend to invent and adapt the principles
to find the best solution for the specific environment.
There is a need to capture these solutions and adaptations in
order to be a learning organisation.
Validation of adaptations should be part of the process of
recording them.
We may actually still be missing some pieces of the puzzle.