2-DAY CONFERENCE April 30-May 1, 2018 | PRE-CONFERENCE WORKSHOPS April 29, 2018
30 Years of Success: TOC & Throughput Improvement At GM
Presented by Jeff Miller & Kevin Kohls
In 1987, GM’s new Detroit Hamtramck assembly plant was struggling to make its demand numbers. Working with GM Research, the Detroit plant control engineers developed an analytical tool called C-Thru to identify and solve the problem using the guiding principles of The Goal. These being:
1): Define the system and its dependencies.
2): Capture variation and perform an analysis to find the bottleneck.
3). Focus resources to improve the bottleneck.
The resulting methodology was coined Throughput Improvement Process (TIP) and the rest is now history.
Today, every GM plant has a Throughput Improvement Engineer, every machine collects data from the day its turned on, and every design change to the plant must go through the simulation process based on TOC. This is the GM story and how TOC remains central to its success even as it moves towards an Industry 4.0 transformatio
Kevin Kohls has spent over 30 years improving manufacturing systems, from working in both machining and automotive assembly plants and implementing the Theory of Constraints. His team combined automatic data collection, bottleneck analysis, Lean, and Red X (a statistical methodology similar to Six Sigma) into TIP – the Throughput Improvement Process. As an executive, his teams helped validate the design of new automotive plants using simulation, Throughput Accounting, Lean, and TOC. His efforts have generated billions of dollars of improved profitability in GM and other companies. This work and those of his peers were recognized by INFORMS, which awarded GM with the prestigious Franz Edelman Award for 2005. He has also been given both the Chairman’s Honors Award and the Boss Kettering Award for Innovation. As a consultant, he has worked with automotive suppliers, Johnson & Johnson, Magna, Dollar/Thrifty Rental Car, Blue Cross Blue Shield of Michigan, the Detroit Medical Center, Spirit AeroSystems, and many other companies.
Kevin now works as the Continuous Improvement Director at Rex Materials Group in Howell, Michigan, where has significantly improved both their Manufacturing and Project Management process.
Kevin received his undergraduate degree in Electrical Engineering from the General Motors Institute (now Kettering University) and a Master’s degree in Electrical Engineering from Purdue University. He has published his first business/comic book, The Conflicted Middle: Lean Accounting and is currently working on his second book, "Addicted to Hopium”
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