Theory of Constraints Handbook - James Cox Iii [485]
The Process of Consolidating Process Outline
1. Select three UDEs from the area under investigation.
2. Build the individual UDE Cloud for each UDE using Steps 2 through 5 (write story lines, construct Cloud and checks, and surface assumptions) of the UDE Cloud process.
3. Consolidate the three Clouds into one Cloud.
4. Check and upgrade the Consolidated Cloud.
5. Surface the assumptions underlying the Consolidated Cloud.
6. Construct the solution and check it for win-win.
7. Communicate the solution.
Step 1: Select three UDEs from the area under investigation.
Example: A list of UDEs of a Production Manager in a make-to-order (MTO) environment.
UDE #1—We often do not have sufficient capacity to meet all demands.
UDE #2—Production priorities change too frequently.
UDE #3—We have too many engineering changes.
Step 2: Build the individual UDE Clouds.
In building the Clouds, recall you (the Production Manager, in this case) are always on the CD′ side and the Clouds are always written from your perspective (the Production Manager, in this case).
For each UDE, build a Cloud and surface the assumptions following Steps 2 through 5 (write story line, construct Cloud and checks, and surface assumptions) of the UDE Cloud process. These Clouds are shown in Fig, 24-l0a, b, c.
Step 3: Consolidate the three Clouds.
Write a generic statement in each box A, B, C, D, and D′.
Write down each statement from the same box of each of your three Clouds. You may organize them in a small table: A statements, B statements, etc.
Examine the statements from the same box (A, B, C, D, and D′) and write a generic statement that describes all of them. Each specific statement from the same box should be an example/manifestation of the generic statement that you verbalize.
Example:
Consolidating B:
B-1: Meet our production schedules.
B-2: Effective use of resources.
B-3: Meet our cost targets.
Generic B: Meet our department performance measurements (on time and within budget).
FIGURE 24-10 Examples of UDE Clouds of the production manager.
Consolidating D:
D-1: Not accept all customer orders without considering capacity.
D-2: Follow the established production schedule priorities.
D-3: Introduce engineering changes only with regard to schedule and capacity.
Generic D: Not accommodate all customer demands for schedule changes and new product introduction.
Consolidating C:
C-1: Satisfy customers’ increasing demands.
C-2: Meet customers’ changing requirements.
C-3: Instantly provide customers with the latest designs.
Generic C: Provide customers with flexible, fast, reliable service with the latest designs. Consolidating D′:
D′-1: Accept all customer orders regardless of capacity.
D′-2: Change the established production schedule priorities.
D′-3: Introduce engineering changes without regard to schedule and capacity.
Generic D′: Accommodate all customer demands for schedule changes and new product introduction.
Consolidating A:
A-1: Have successful operations.
A-2: Satisfy the business objectives.
A-3: Achieve our business goals.
Generic A: Achieve our business objectives.
The Consolidated Cloud is shown in Fig. 24-11.
Flipping Clouds
In the process of consolidating the statements of each box, you may feel as if one of the three Clouds is “flipped.” In other words, as if the B-D statements and C-D′ statements from this Cloud should swap their places to “match” the pattern we observe in the other two Clouds. If this has happened, then, for consolidation, just “flip back” these B-D sides and C-D′ sides to add them to their matching group of statements.
FIGURE 24-11 The Consolidated Cloud of the production manager.
Why does “flipping” happen?
The UDE Cloud is written from the point of view of