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2015 TOCICO International Conference

Transforming Industries Track


Philip Marris
PHILIP MARRIS
CEO
Marris Consulting

TOC to Boost Aeronautical Manufacturing Performance
September 8, 2015

Three different cases will be presented; three different factories of large well-known actors of the aeronautical industry. In all cases the Theory Of Constraints was the main guiding approach but blended into a Lean or Lean Six Sigma environment.

In factory A, the plant manager had read the Goal and already successfully applied TOC in a previous plant. The 400 person plant suffered from very poor due date performance, quality problems and very poor financial performance. SAP had been used to identify the bottleneck resources; 12 key expensive machines were thought to be the constraints. A 4 hour analysis on the shop floor showed that in fact the bottleneck was elsewhere; in the quality control department. Having identified the constraint it was them exploited. This increased the Throughput and the productivity of the whole factory by over 30% in less than 2 weeks. To reduce the excessive level of WIP the "2 for 1” rule was applied: a new Work Order could only be launched once 2 Work Orders had been completed. This generated a growing list of Work Orders whose launch was overdue. When there were too many, the wait times in the SAP ERP were reduced. The improvement process was to first improve the plant physically and then, afterwards, explain to the ERP what the improvements were. Other actions were: batch sizes were divided by 2, sub-contracted work was reintegrated, the priority system was redefined, the plant was reorganized, the assembly process was re-engineered for one piece flow … The delivery due date performance quickly went from 50% to 85% and the target is now 99%.

In factory B, a manager attended a 2 day course on the Theory Of Constraints in manufacturing and then went away and implemented it alone in his 50 person production unit. The due date performance went from 70% to 100.00% which had a strong impact on obtaining new sales with a major aircraft manufacturer. The production lead times and the work in progress were divided by 2. Many other improvements were also made. The TOC system was then rolled out to the rest of the 300 person factory.

In factory C, TOC was injected into their pre-existing Lean Six Sigma management system. The management thought that they had identified the bottleneck but in fact the bottleneck was elsewhere. Once the real constraint had been identified it was properly exploited. As a result the plant’s Throughput and productivity improved by 10% per month for 4 months in a row. In this period some sub-contractors became bottlenecks and this problem was resolved. A strong monthly hockey-stick phenomenon was eliminated. The "best” plant bottlenecks were then identified and the drum-buffer-rope system was applied to manage the flow of each of the 4 production channels.

To conclude the strengths of the Theory Of Constraints applied to these manufacturing environments will be summarized.


PHILIP MARRIS is CEO of Marris Consulting. Marris Consulting is a management consultancy focused on industrial operations. Over 80% of the firm’s projects are based on TOC. He is the author of the French reference book « Le Management Par les Contraintes en gestion industrielle ». He is involved in the "TOC + Lean” movement and founder of the LinkedIn "TLS - TOC Lean & Six Sigma” group. He has designed, sold and executed over 150 transformation projects. He is a member of the board of the TOCICO French regional group and is active in increasing the awareness of TOC in Europe.

He started his TOC journey in 1986 when he joined Creative Output France and had the honor and pleasure of working with Eli Goldratt and Issi Pazgal.

Philip Marris was in charge of Manufacturing Operations in large consulting firms.

He has over 29 years of experience in industry and in consulting. Philip Marris started his career as a production engineer in the steel industry. He is English and is bilingual and bi-cultural. He lives in Paris, France.

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