Page 104 - The Handbook for Quality Management a Complete Guide to Operational Excellence

90 I n t e g r a t e d P l a n n i n g S t r a t e g i c P l a n n i n g 91

110 Profits do
not suffer
significantly. 111 We have 112 Profits remain 113 We have our
[desired effect] our protective solid or go higher protective
capacity back in (more “T” for capacity back over
the short-term. capacity invested). the long term.
[desired effect] [desired effect] [desired effect]
109 Costs
increase
minimally.

105 Injection: Add 106 We need 107 We need a
a second shift/ short-term, quick long-term solution to 108 Injection:
overtime temporarily response preserve protective Raise prices to
(only when necessary). intervention. capacity. control demand.

103 We know one or 104 Multiple
more resources are “red flags” occur
close to losing their more than once.
protective capacity.

MAG

101 Injection: Use 102 Injection: Use
planned load to identify red-line control (more
possible overload on key than one red flag) to
resources. identify stress in the
system.
Figure 5.5 Future Reality Tree—“red-line control” (manufacturing control)
(adapted from Schragenheim and Dettmer, 2000).

• The “Drum.” In a manufacturing or service company, the “drum” is
the schedule for the resource or work center with the most limited
capacity: the Capacity Constrained Resource (CCR). The reason
the CCR is so important is that it determines the maximum possible
output of the entire production system. It also represents the whole
system’s output, since the system can’t produce any more than its
least-capable resource.
• The “buffer” and the “rope” ensure that this resource is neither
starved for work nor overloaded (causing backlogs). In constraint
management, buffers are composed of time, not things.

• The “Buffer.” Starvation can result from upstream process variability,
which might delay the transfer of work-in-process beyond its
expected time. To ensure a CCR is not starved for work, a buffer
time is established to protect against variability. This is a period of
time in advance of the scheduled “start processing” time that a

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