Sproull B., Nelson B. A Novel on Unifying Theory of Constraints, Lean, and Six Sigma

2nd ed. — Productivity Press, 2015. — 414 p. — ISBN: 149871420X, 9781498714204.Updating the tools, principles, and methods presented in the bestselling first edition, this updated edition explains how to implement the authors’ proven improvement methodology that unifies the Theory of Constraints with Lean and Six Sigma. The bookuses a compelling novel format to demonstrate how to achieve superior on-time delivery along with unprecedented levels of profitability.
Besides explaining how to implement the authors’ unified improvement methodology, the book arms readers with a proven method for convincing management that using the improvement methodology outlined in the text will lead to significantly higher levels of profitability.
This edition has been updated with an expanded appendix that includes more in-depth discussions of the tools covered in the first edition. This edition also sheds more light on the reasoning behind why the very best improvement results can be achieved by the unification of the Theory of Constraints, Lean, and Six Sigma (TLS). The appendix also provides additional detail about how the concepts covered in the book can be applied to your organization.
The primary theme throughout this book is the focus on the unity and enhancement of improvement tools and methods. The book includes an appendix that allows readers to explore, in much more detail, the principles, tools, and techniques presented in the novel portion of the book.
The authors detail a pioneering pathway for significant gains in profitability and market share for any company choosing to implement the methodologies that are presented. Some of the concepts, tools, and principles presented may seem counterintuitive to many readers, but if the principles are understood and followed, the exceptional results are sure to follow.
Epiphanized: A Novel on Unifying Theory of Constraints, Lean, and Six Sigma is a very important book for any organization sincerely interested in doing more with the same, or even fewer, resources. Doing so is the essence of increasing productivity. Too many view increasing productivity as squeezing more out of an oppressed workforce. Nothing could be farther from the truth. There is a clear, long-term connection between increased productivity and an overall increase in both the standard of living and the amount of wealth in our world. Those who argue that too many of these benefits are now going to the rich at the expense of the working class simply ignore history. The gap between these groups has risen and fallen unevenly over time. In the eras of dictators, royalty, and peons, the gap was enormous. It shrank dramatically during the reign of the Vanderbilts, Rockefellers, and other tycoons. Despite today’s economic problems, the gap has continued to shrink. The connection between the standard of living of the average person and increasing productivity is etched in stone. As productivity increases, people live better, have more freedoms, live longer, and have more fulfilling lives. To me that sounds like progress.Foreword.
Preface.
Joe’s First Day.
Joe’s Second Day.
Joe’s Meeting with Connor.
Joe’s Meeting with the Vice President of Operations.
Sam and Connor Meet.
The Strategy Session at Jonah’s.
The Second Meeting with Connor.
The Interference Diagram.
The Meeting with Jerry.
Becky Meets Connor.
Another Meeting at Jonah’s.
The Parts Issue.
Fabrics-R-Us.
Training Fabrics and Greg.
Performance Metrics.
CCPM: Part 1.
CCPM: Part 2.
Joe and Sam’s Trip to Corporate.
The Corporate Purchasing Team.
Connor Goes to Simco.
The Finale.
Appendixes.
TLS Overview.
The Systems Thinking Tools.
Performance Metrics Using Cost Accounting (CA) and Throughput Accounting (TA).
TOC Distribution and Replenish Model.
Drum–Buffer–Rope (DBR).
Critical Path Method (CPM) versus Critical Chain Project Management (CCPM).
The Interference Diagram (ID)/Intermediate Objectives (IO) Map.
Systems Analysis.
Supplemental Thinking Tools.
About the Authors.