Synchronizing the Flow: Advancing Production Control in Make-to-Order Manufacturing

 

Synchronizing the Flow: Advancing Production Control in Make-to-Order Manufacturing

For a custom-order or small-batch manufacturing business, the "bottleneck" is the heartbeat of the factory. If it skips a beat, the whole system suffers. Recent advancements in TOC methodology focus on the critical third step: Subordinating everything else to the constraint. This ensures that every part of the business—from sales to the shop floor—works in harmony with the plant's actual capacity.

1. The Drum-Buffer-Rope (DBR) Mechanism

The DBR system acts as the "nervous system" of the factory:

• The Drum: The bottleneck or constraint that sets the pace for the entire plant.

• The Buffer: A protection of time or inventory placed in front of the drum to ensure it never stops working due to upstream fluctuations.

• The Rope: The communication mechanism that releases work into the system only when the drum has processed an equivalent amount.

2. The Integration of Sales and Operations (S&OP)

One of the most significant constraints in MTO environments is the gap between what Sales promises and what Operations can deliver. By using TOC, businesses can integrate these two departments. Sales no longer sells "empty slots" but sells "available capacity," ensuring that delivery dates are realistic and lead times are kept short.

3. Introducing Capacity Buffers

In a "Demand-Driven" world, traditional inventory buffers aren't always enough. Modern manufacturing now uses Capacity Buffers. This means intentionally maintaining a certain level of "protective capacity" (extra machine or labor time) to absorb sudden spikes in customer demand without delaying existing orders.

4. Systematic Implementation

The evolution of the TOC process involves moving beyond "firefighting" to a systematic approach. By analyzing real-world case studies, it has been found that the successful implementation of the third TOC step requires:

• Identifying the true constraint in a complex environment.

• Designing an adaptive process that evolves with the market.

• Ensuring that the "Rope" effectively prevents over-production and congestion on the shop floor.