Beyond Lean Manufacturing - Goal Sys（精益生产目标系统）.pdf

Beyond Lean Manufacturing: Combining Lean and the Theory of Constraints for Higher Performance ===================================================================== H. William Dettmer Senior Partner Goal System International Port Angeles, WA, USA 98362 Summary Lean manufacturing (LM) evokes images of efficiency and minimizing unnecessary costs, an attractive value for many companies. But other companies are already as lean as they can be. Does LM have practical limits? This paper demonstrates how the Theory of Constraints (TOC) can take the business performance of those organizations currently pursuing lean to the next level. Keywords Lean thinking, lean production, lean manufacturing, muda, kaizen, 5S, takt, workload balancing, one-piece flow, Theory of Constraints, drum-buffer-rope, five focusing steps, Throughput, Inventory, Operating Expense, systems approach INTRODUCTION See my people, well here’s my theory Of what this country is moving toward. Every worker a cog in motion, Well, that’s the notion of Henry Ford! One man tightens, and one man ratchets, And one man reaches to pull one cord. Car keeps moving in one direction, A genuflection to Henry Ford. Hallelujah! Praise the maker Of the Model T (Speed up the belt, speed up the belt, Sam!) Hallelujah! Hell, I’ll take her! Sure amazin’ how far some fellas can see! (Speed up the belt, speed up the belt, Sam! Speed up the belt, speed up the belt, Sam!) Mass production will sweep the nation, A simple notion the world’s reward. Even people who ain’t too clever Can learn to tighten a nut forever, Attach one pedal or pull one lever For Henry Ford! Grab your goggles and climb aboard! “Henry Ford” From Ragtime‡ MASS PRODUCTION Every so often, commercial business undergoes a paradigm shift: a change in the nature of the game so fundamental tha