Theory of Constraints Handbook - James Cox Iii [493]
Task 4: Record the IO Map on an Excel file (some people tend to record the IO map on a project plan file as a PERT structure).
Implementing a Solution of Several Injections
When you have a solution that contains more than one injection, you should implement them in logical order according to the internal dependencies between them.
The sequence for creating the IO map:
1. Build the Injection Map.
2. Determine Intermediate Objectives (IOs) for each injection (as per Steps 4 or 5 of the process of addressing obstacles).
3. Sequence the IO map for each injection.
Please note: If the process is done by a group, then task 2 is done by a group check of the dependency between every two IOs as we progress for every Post-It that we introduce with an IO. The PRT is used in the full TP work for capturing the logical connection between the IOs and the obstacles as well as the reasoning for the sequencing.
4. Integration of the individual IO Maps into the Injection Map.
5. Check the integrated map to ensure that it is logically sound and complete.
Injection Map:
When the solution contains several injections, the overall plan is built by combining several IO Maps into the Injection Map of the solution.
We first build an Injection Map stating the sequence we plan to put the injections in reality. Some injections are implemented one after another; some can be implemented in parallel. Examples of an Injection Map, a fully integrated IO Map, and a Multi-Injection IO Map are provided in Fig. 24-21.
The Multi-Injection IO Map can be translated into a project plan. The project plan contains deliverables and tasks.
Deliverables (IOs) are major milestones in the implementation of the injection. They are tangible and can be measured. In the plan to implement the injection, they are the intermediate objectives marking the steps toward the completion of the implementation.
Tasks are all the activities to be taken by the project team in order to achieve the deliverables. They are actions performed by specific resources and estimated time duration.
Example: Injection: Throughput Dollar Days (TDD) is used as the prime measurement for on-time delivery of projects. An example of a mini-project plan for implementing an injection is provided in Fig. 24-22.
We can conclude that the IO Maps provide the manager with a planning tool for the implementation of the solution. Involving relevant people in the process of building the maps can create ownership and enhance the involvement and support in making the solution a reality.
Conclusion—Problem Solving the TOC Way
The TOC approach is based on the managers’ self-commitment to improve the performance under their responsibility. The TOC way is to work systematically by answering the three questions of improvement (what to change, what to change to, and how to cause the change). Not every problem and challenge demands a thorough analysis and developing a breakthrough solution. Managers do make good decisions (and sometimes “pay” for their bad decisions). The purpose of this chapter was to enhance the ability to make decisions by providing tools to handle problems systematically and support in developing the skills to use them. The tools described in this chapter can be added to your personal toolbox. Practice and use them when you feel it is appropriate.
FIGURE 24-21 Example of an Injection Map and Multi-Injection IO Map.
FIGURE 24-22 Example of mini-project plan for implementing an injection.
For addressing a problem systematically and explicitly, we propose the comprehensive process that we have outlined in this chapter. The flow of the process covers the three questions for improvement.
There are two inputs to the planning process:
Necessary deliverables are encountered in the course of the injection implementation and must be achieved to make sure that the injection becomes the reality. These entities are usually