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2025年10月4日 星期六

From Products to T-Generators: Redefining the Roles of Operations, Marketing, and R&D

 

From Products to T-Generators: Redefining the Roles of Operations, Marketing, and R&D

One of Eli Schragenheim’s most thought-provoking insights is the distinction between what operations and marketing truly deliver. Operations, he argued, produce products. Marketing, on the other hand, sells t-generators—the tangible or intangible entities that generate throughput.

This distinction opens the door to a deeper rethinking of organizational roles. If marketing is not merely about pushing existing products, but about shaping and selling throughput generators, then the function of R&D cannot remain confined to “product development.” R&D must be integrated into marketing’s mission of designing and evolving t-generators—whether they take the form of products, services, or even innovative business models.

The Redefinition of Roles

  1. Operations: Builders of Capability
    Operations’ role is clear and stable. They are responsible for transforming resources into reliable outputs—whether physical products, digital deliverables, or service executions. Their success lies in efficiency, quality, and dependability. Operations are the foundation on which throughput potential rests.

  2. Marketing (including R&D): Designers and Multipliers of Throughput
    Marketing’s mission is not simply to promote what operations produce. It is to define and develop the t-generatorsthat maximize the organization’s throughput. This means understanding customer needs, market dynamics, and competitive landscapes to identify what kind of t-generators can create sustainable streams of value.

    R&D belongs here, not as a separate silo. Its task is not just to “invent” or “improve” products, but to co-create with marketing new and more effective throughput generators—be they subscription models, service packages, ecosystems, or platforms. This reframing aligns R&D’s creativity with the ultimate economic engine: throughput.

  3. KPI Realignment
    Traditional KPIs often measure marketing by sales volume and R&D by the number of new products launched. This misses the point. If marketing plus R&D is truly about generating throughput, their KPI must reflect the net throughput potential created by the portfolio of t-generators.

    • Not “How many products did we launch?” but “How much throughput capacity have we created?”

    • Not “How many leads were generated?” but “How effectively are our t-generators sustaining throughput growth?”

Why This Matters

Most organizations unintentionally limit R&D by tethering it to operations. The result is incremental product improvements that do not necessarily translate into stronger t-generators. By placing R&D under marketing, innovation becomes market-driven, strategically aligned, and directly linked to throughput.

This redefinition also clarifies the boundaries:

  • Operations excel at execution.

  • Marketing (with R&D) excels at conception and value creation.

  • Together, they form a coherent system where throughput is not left to chance but is deliberately designed and reliably delivered.

Conclusion

Organizations that adopt this perspective will unlock a sharper division of labor, a more focused set of KPIs, and above all, a deeper alignment with the fundamental goal of business: to maximize sustainable throughput.

When marketing and R&D unite around the design of t-generators, and operations delivers them with excellence, the organization as a whole achieves clarity of purpose and strength of execution.


2025年9月24日 星期三

Supercharging Your Warehouse: How to Pick Faster and Smarter

 

Supercharging Your Warehouse: How to Pick Faster and Smarter

In the world of warehousing and distribution, a common bottleneck that slows everything down is picking—the process of retrieving products from shelves to fulfill an order. When picking is the constraint, it doesn't matter how fast everything else is; the entire warehouse's output is limited by how quickly pickers can move. This problem leads to longer lead times, frustrated customers, and a general lack of efficiency.

This is a prime candidate for the Theory of Constraints (TOC), which provides a structured approach to identify and manage the single biggest bottleneck in a system. By applying TOC, a warehouse can transform its picking operation from a slow, chaotic process into a highly efficient, high-speed engine.


The Problem: A Bottleneck in the Aisles

Think of picking as the heart of the warehouse. All other functions—receiving, stocking, shipping—depend on it. When the heart is weak, the entire body suffers. A weak picking operation often looks like this:

  • Picker Delays: Pickers waste time walking long distances to find items, or worse, find empty shelves because replenishment hasn't happened yet.

  • Wasted Space: Poorly organized inventory means slow-moving products take up prime real estate near the packing stations.

  • Inconsistent Flow: The warehouse experiences rushes and lulls, leading to inefficiency and potential overtime costs during peak periods.

The TOC Cure: A Rhythm for the Racks

The solution is to apply TOC's Drum-Buffer-Rope (DBR) model, which focuses on synchronizing the entire warehouse to the pace of the picking process.

  1. Identify Peak Picker Availability as the Drum:

    The "Drum" is the constraint that sets the pace for the entire system. In this case, the peak picker availability—the maximum number of pickers and their most efficient picking speed—is the drum. All other activities must be scheduled around this capacity. Instead of having replenishment teams work independently, their pace is dictated by what the picking team needs, and when they need it.

  2. Synchronize Replenishment (Buffer):

    A "Buffer" is a strategic inventory placed in front of the Drum to ensure it never runs out of work. For a picking operation, this means the shelves must always be full. The cure is to implement synchronized replenishment schedules to prevent picker waits. This means replenishment teams are not just stocking shelves; they are filling them just in time for the pickers. Adding temporary buffer zones for fast-moving items can also help ensure pickers always have access to what they need without having to wait.

  3. Subordinate to the Pick Rhythm (Rope):

    The "Rope" is the signal that ties the pace of all other operations to the Drum. This means you subordinate other warehouse functions to align with the pick rhythm. The core of this is better slotting of inventory. By placing fast movers near pick faces, pickers spend less time walking, which directly increases the "drum's" speed. Picking schedules themselves are adjusted to flow orders through the system at a constant, manageable rate that the pickers can handle.

  4. Elevate Capacity (When Necessary):

    Once you've exploited, buffered, and subordinated, if picking is still not fast enough to meet demand, it's time to elevate the constraint. This is where you invest in new capacity, but only where it matters most. This might involve short-term capacity elevation, such as adding temporary picking teams during peak seasons or creating dedicated pick lines for specific product types.

The Result: A Lean, Fast Warehouse

By applying these TOC principles, a warehouse can transform its picking operations from a chaotic mess into a lean, fast-moving system. They stop focusing on simply keeping shelves full and start thinking strategically about how to ensure pickers are always in motion. This leads to reduced labor costs, fewer errors, and a significant boost in overall throughput, proving that by optimizing one key area, you can improve the entire system.


2025年6月4日 星期三

Beyond Scarcity: Why the Theory of Constraints Demands a New Economics Paradigm

Beyond Scarcity: Why the Theory of Constraints Demands a New Economics Paradigm

Understanding the deeper philosophical split between TOC and mainstream economics — and why it explains the failure of widespread TOC adoption


Abstract

The Theory of Constraints (TOC), introduced by Dr. Eliyahu Goldratt, has demonstrated profound impact in operations, supply chains, project management, and business performance. Yet despite the global success of The Goal and the enthusiastic initial reception of TOC tools, widespread adoption across organizations, governments, and educational systems has stalled. While many cite resistance to change, measurement systems, or cost accounting paradigms as barriers, this paper argues that a deeper and more structural conflict exists: TOC's core assumptions are fundamentally incompatible with the dominant worldview of traditional economics, particularly the axiom of scarcity and the logic of tradeoffs. This philosophical clash — rarely acknowledged — may be the most significant and underexplored reason why TOC has not become mainstream. To resolve this, we must go beyond isolated applications and commit to the development of a new economics paradigm — one grounded not in scarcity, but in systemic flow, constraint leverage, and win-win logic.


1. Introduction: A Puzzle Hidden in Plain Sight

More than four decades after its introduction, the Theory of Constraints remains one of the most powerful yet underutilized methodologies in business and systems thinking. It has helped thousands of companies increase throughput, resolve seemingly intractable conflicts, and dramatically improve operational performance. And yet — in stark contrast to its promise and practical effectiveness — TOC remains on the margins of mainstream practice.

Why?

This question, famously posed by Goldratt himself — “Why do so many read my books and so few implement the ideas?” — has been addressed in many ways: inertia, resistance to change, measurement misalignment, cultural factors, or the entrenched power of traditional cost accounting. All of these have some merit.

But they are not sufficient.

This paper argues that the root cause lies deeper, in the foundational assumptions of economic thinking itself — assumptions so deeply internalized by managers, educators, and policymakers that they operate invisibly as mental axioms.

Until we address this core ideological mismatch — TOC's rejection of tradeoffs and traditional economics' worship of them — we will continue to see TOC admired but rarely adopted at scale.


2. The Core Conflict: Scarcity and Tradeoffs vs. Constraints and Flow

At the heart of the divide lies a philosophical and methodological split between two worldviews:

🔹 Traditional Economics:

  • Begins with the axiom of scarcity: resources are limited, desires are infinite.

  • Emphasizes tradeoffs: every choice implies a sacrifice (opportunity cost).

  • Uses marginal analysis to allocate resources efficiently.

  • Aims for equilibrium and balance across actors and systems.

🔹 Theory of Constraints:

  • Begins with the assumption that systems have constraints, but these can be exploited and elevated.

  • Believes that most tradeoffs are false dilemmas, caused by hidden assumptions or poor thinking.

  • Uses logical analysis (e.g., Evaporating Cloud, Five Focusing Steps) to find win-win solutions.

  • Aims not for balance, but for maximum flow of value toward the system’s goal.

These are not small differences. They represent mutually incompatible ontologies — different ways of viewing the world, defining problems, and choosing solutions.

Where economics sees limits, TOC sees leverage.
Where economics accepts sacrifice, TOC searches for innovation.
Where economics optimizes parts, TOC focuses on system throughput.


3. How the Scarcity Axiom Became Dogma

To understand the depth of this conflict, we must examine the historical development of economics as a discipline.

The modern definition of economics — most famously articulated by Lionel Robbins in 1932 — is:

“The science which studies human behavior as a relationship between ends and scarce means which have alternative uses.”

This statement elevated scarcity to the level of an axiom — not something to be analyzed or questioned, but something to be accepted and optimized around.

It formalized a worldview in which:

  • Tradeoffs are not just common — they are inescapable.

  • Every decision has an opportunity cost.

  • Efficiency is achieved through proper allocation of limited resources.

Scarcity → Tradeoffs → Rational Allocation → Equilibrium → Efficiency

This became the foundation of economic thinking, and by extension, the mental model of nearly all business education, public policy, and decision-making.


4. The TOC Challenge: Tradeoffs Are Often Illusions

In stark contrast, TOC asserts that most conflicts can be logically resolved without sacrifice. Its core tool, the Evaporating Cloud, is explicitly designed to challenge tradeoffs — not optimize them.

TOC’s logic:

  • Every system has a constraint.

  • Most performance gaps are due to poor management of the constraint, not scarcity.

  • Conflict often arises from invalid assumptions, not from inherent opposition.

  • Focus, leverage, and sequencing — not compromise — are the keys to breakthrough results.

In TOC, the goal is not to distribute limited pie slices, but to expand the pie by removing the constraint. Scarcity becomes a problem to solve, not a condition to accept.

This is not wishful thinking. It’s logic. It’s method. It’s proven.

And it is in direct conflict with the intellectual structure of traditional economics.


5. Why Cost Accounting Was an Easier Battle

Goldratt's attack on cost accounting was powerful and necessary — but it was tactical, not existential.

Cost accounting is a method of measurement. Scarcity and tradeoffs are philosophical first principles.

Replacing cost accounting with Throughput Accounting changed how we make decisions within firms. But challenging scarcity and tradeoffs changes how we think about choice, value, and possibility across all systems — including public policy, education, and health care.

This is not just a better metric. It is a different metaphysics.

And that is a much harder battle.


6. Why This Paradigm Clash Explains the Lack of Adoption

Every TOC implementation eventually runs into a wall. Not a technical wall — but a mental one:

  • “We don’t have the budget for both initiatives.”

  • “We need to optimize each department for efficiency.”

  • “This is the best we can do given our constraints.”

These are not logistical conclusions. They are economic dogmas in disguise.

The vast majority of decision-makers have been trained to think in terms of scarcity and tradeoffs from the first day of their education. Even those who love The Goal unconsciously default to this logic in practice.

Until this paradigm is challenged systematically and structurally, TOC will remain a brilliant set of tools that clash with the dominant economic logic — admired, but sidelined.


7. Toward a New Economics: From Scarcity to Constraints

What we need is a new economic paradigm — one that:

Traditional Economics New TOC-Based Economics
Starts from scarcity Starts from the system goal
Assumes tradeoffs Assumes win-win is possible
Optimizes allocation Focuses on leverage of constraints
Seeks equilibrium Seeks improved flow
Uses marginal analysis Uses logical cause-effect analysis
Maximizes utility Maximizes throughput toward the goal

This new economics — call it Constraint Economics or Flow Economics — would not reject scarcity entirely, but would deprioritize it as the defining lens for decision-making.

It would prioritize:

  • System-level thinking

  • Dynamic leverage over static allocation

  • Conflict resolution logic

  • Breakthrough performance, not marginal gains

And it would offer an alternative foundation for policy, education, and strategy.


8. What Must Happen Next

To make this shift, we need:

  • A clear articulation of the economic philosophy implied by TOC

  • A group of economists and systems thinkers willing to challenge foundational assumptions

  • Formal models that bridge TOC logic with economic theory

  • Case studies, teaching tools, and policy frameworks based on the new paradigm

  • A concerted movement to redefine economic education

This will not happen overnight. But the first step is to name the real problem:

TOC’s greatest obstacle is not culture or resistance.
It is the economic dogma of scarcity and tradeoffs.

Until we face that, TOC will remain powerful — and marginalized.


Conclusion: The Real Constraint Is the Way We Think

Goldratt was right: the ultimate constraint is not the market, or the machine, or the budget.

It is the mental model we use to frame our choices.

Traditional economics begins by telling us we can’t have it all — and so we never try. TOC tells us to find the assumptions we haven't questioned — and so we do.

To fulfill the promise of TOC, we must go deeper than tools and challenge the axioms.

It is time to go beyond scarcity.

It is time to think differently — not just manage differently.