Blog

Practical lessons from the factories we work in

Each month someone from the team picks a problem they have helped solve, explains what they found and suggests something to check in your own business.

Articles

· Toby Parnell

Most Theory of Constraints work fails at step 3, not at finding the bottleneck

Finding the constraint is the easy part. Getting everything else to serve it is where most Theory of Constraints work fails. Why subordination breaks down, and what to check on your own lines.

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· Toby Parnell

Seven thinking traps, not technical problems, stall most improvement programmes

Improvement programmes stall and factories drift back to old habits, but the cause is rarely technical. Seven thinking traps we look for, and the questions to ask in your own business.

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· Toby Parnell

Four stations at 90% uptime make a one-piece flow line that runs at 65.6%

One-piece flow is often presented as always better than batching. Couple four stations at 90% with no buffers and the line runs at 65.6%. The maths, the assumptions behind flow, and what to check on your own lines.

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· Toby Parnell

Why most OEE systems leave money on the table, and what to do about it

Most manufacturers track OEE, but many systems are set up so the number hides how much more the line could produce. The three set-up mistakes behind it, and what to check on your own lines.

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