Lean精益生产----13.TheoryofConstraints约束理论

Project Mgmt项目管理
2005 Advanced Manufacturing Consultancy Sdn.Bhd. All Rights reserved on printed material. No replication privileges extended
Step 1 - Constraint Identification 第一步约束的识别 1. Calculate net available capacity by work center 计算每一个工作单元的净可用产能
Organizational Goal 组织的目标 Maximize Shareholder Value (Increase Profits) 最大化股东的价值（增加利润） Maximize Return on Investment ROI 最大化投资回报
Inventory 库存 Quality 质量 Sales 销售 Cost 成本 Assets 资产
Do you know the goal of your system? 你知道你所在系统的目标吗？ Where does your system stand in respect to it’s goal? 相对于目标，你所在的系统所处的位置如何？ What prevents you from achieving the goal? 是什么阻止你达到你的目标？
Theory Of Constraints 约束理论
Thinking Process 工序
Logistical Solutions 后勤
Strategic 战略的
Tactical 战术的
Production产品
Distribution分发 External Constraints Jonah Program 外部约束 Conflict Resolution Communication Implementation Plan 冲突解决沟通 实施计划
Step 1 IDENTIFY THE CONSTRAINT 第一步识别约束 Step 2 DECIDE HOW TO EXPLOIT THE CONSTRAINT 第二步决定怎样开发约束
Step 4 ELEVATE THE CONSTRAINT 第四步，提升约束
Step 3 SUBORDINATE EVERYTHING ELSE TO THE DECISION IN STEP 2 第三步在决定改进以前找出所有可能的方法
The Theory Of Constraints 约束理论
Contents 内容
Objectives目标 The System & System Goal 系统和系统目标 What is the Theory of Constraints 什么是约束理论 Video – The Goal 录像----目标 The 5 Step Approach ５步骤方法 Drum Buffer Rope 鼓库存绳机制
Understand basic concepts of Theory of Constraint 明白约束理论的基本概念 A 5-Step methodological approach to ongoing system improvement ５步骤方法改进运做中的系统． How the Drum Buffer Rope principle helps protect the constraints 鼓库存绳子原理怎样帮助保护约束 How Theory of Constraints helps increase/optimise bottleneck performance while working with lower levels of inventory当运行在低库存下，约束理论怎样帮助提高／优化瓶颈 的表现．
在任何独立的链条中，有一环，只有一环是比其它任何链条都弱，最弱的一环．
The weakest link limits (defines) the maximum performance of the chain 最弱的一环决定整个链条的最大强度． The weakest link is the constraint to the system’s performance 最弱的一环就是整个系统能力的约束．
The Theory of Constraints (TOC) was developed by Dr. Eliyahu M. Goldratt, a Jewish Physicist. TOC suggests that: 约束理论是以色列物理学家Goldratt创立的．ＴＯＣ建议： All systems are similar to chains-or networks of chains 所有系统与链条或网状链条比较相似． Each chain is composed of links which vary in strength and capability 每一个链条由不同强度和产能的链环组成． In any independent chain there is one link - and only one – that is weaker than all the rest: the weakest link
2005 Advanced Manufacturing Consultancy Sdn.Bhd. All Rights reserved on printed material. No replication privileges extended
The Goal 目标
Every system exists for a purpose. The purpose can be considered a goal : the objective or end towards which effort is directed 每一个系统都为了一个目的而存在．这个目的可以被看做目标：目标或最 终走向是一切努力的方向． The first and most important task of anyone who wants to improve a system is to determine or recognise the system’s goal 首先并最重要的任务是如果任何人想提高一个系统，必须决定和认识系统 的目标．
政策＋规则＋测量＋培训
2005 Advanced Manufacturing Consultancy Sdn.Bhd. All Rights reserved on printed material. No replication privileges extended
TOC Body of Knowledge 约束理论的知识体系
Step 5 GO BACK TO STEP 1, BUT AVOID INERTIA 第五步，回到第一步，但是避免反弹．
2005 Advanced Manufacturing Consultancy Sdn.Bhd. All Rights reserved on printed material. No replication privileges extended
A number of connected or interrelated elements that could be seen as working together for the overall objective of the whole. A system also takes inputs of some kind, acts on them in some way, and produces outputs. These outputs are supposed to have greater value than the sum of the inputs, so the system might be said to add value to the inputs as it turns them into outputs. 一组相互连接的或 有相互关系的元素，可以被看做为了一个共同的目标而工作在一起．系统也可以被看做 输入了一些东西或动作，生产出一些输出，这些输出的价值可以被看做远高于所有输入 的总和．所以系统也可以说是在输入上加入了有价值的东西，然后变成输 出． Adapted from: (Thomas H. Athey & William Detmer)
2005 Advanced Manufacturing Consultancy Sdn.Bhd. All Rights reserved on printed material. No replication privileges extended
The System 系统
Any manufacturing business organisation happens to be a complex system任何商业制造组织都被认为是一个复杂的系统． A system for the purposes of expounding the theory of constraints is defined as:一个为了详细解释什么是约束理论的系统定义是这样的：
We exist to make more money !
2005 Advanced Manufacturing Consultancy Sdn.Bhd. All Rights reserved on printed material. No replication privileges extended
Net available capacity 净可用产能 = Planned production time – 计划时间内的产能Losses for changeover, maintenance, yield, etc. 换线,维护,品质坏品等造成的损失
The Theory of Constraints approaches improvement at the system level, rather than individual processes or isolated elements of the system约束理论方法提高的是整个系统的水平，不是单独的某一个工序或 系统的独立元素．
Two Types of Constraints 两种类型的约束
Physical: 物理约束
People + Materials + Machine + Geography
人＋物料＋机器＋位置
ห้องสมุดไป่ตู้
Non-Physical 非物理约束:
Policies + Rules + Measurements + Training
OTD
2005 Advanced Manufacturing Consultancy Sdn.Bhd. All Rights reserved on printed material. No replication privileges extended
The Theory Of Constraints 约束理论
2005 Advanced Manufacturing Consultancy Sdn.Bhd. All Rights reserved on printed material. No replication privileges extended
The 5-Steps Approach ５步骤法
2005 Advanced Manufacturing Consultancy Sdn.Bhd. All Rights reserved on printed material. No replication privileges extended
Objectives 目标 At the end of this training session you should be able to:-本章结束后，你应当能够：