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27th International Conference of the TOC Practitioners Alliance ‐ TOCPA www.tocpractice.com
August 16‐18, 2016 Johannesburg, South Africa
Integrating CCPM & DBR in a product development company
Galia du Toit, OpsLogik, South Africa 17th – 18th August, 2016
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Galia du Toit & Paul Grobbelaar
Galia du Toit is a partner in OpsLogik, advising businesses on implementing the TOC methodologies and specializes in Critical Chain Project Management using the Sciforma software to implement and execute Critical Chain based projects. Paul Grobbelaar is a qualified Industrial Engineer and employee at Skeg Product Development. He is the CCPM & Sciforma manager at Skeg. With the help of Sciforma he manages CCPM projects using methodologies developed for DBR and CCPM. The software is integrated with Pastel, enabling real time Throughput Accounting measurements to be used in the management of projects.
OpsLogik Solutions Annandale Road, Stellenbosch, Cape Town +27 (0) 83 258 4843
Skeg Product Development, Marconi Road, Montague Gardens, Cape Town +27 (0) 84 205 6130
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Projects vs Manufacturing Let’s compare between Projects and Manufacturing environments. The similarities are much greater than the differences. Manufacturing Operations
Project Operations
Methods that drive Manufacturing Enterprise Resource Planning (ERP, Symphony)
Methods that drive Projects Critical Chain Method (CCM, Sciforma)
From a TOC perspective, the two method comparisons, assumes that safety is localized throughout the respective operations, and that value is measureable throughout the respective operations Safety is localized in queuing of products (WIP)
Safety is localized in each task of project
Touch Time & Variability Touch time is a very small part of the total time spent in the process, there is also little variability in its duration
Touch Time & Variability All the variability in a project appears to be in the touch time of the task
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Projects vs Manufacturing Manufacturing Operations
Project Operations
Lead Time Project Task1 Start
Task2 Task3
Start
Finish
In project environments the touch times is relatively long.
Touch Time We can aggregate the touch time and we can aggregate the queuing time. Safety
Start
Touch Time
Project Buffer Finish
The tasks are large, the variability is therefore magnified. If we can remove safety that is embedded and add it to the end of the project as a buffer, we shorten the duration of the project without endangering the on‐time reliability of the completion date.
Finish
DBR assumes that the touch time is very small (<10%) compared to the current lead time. By aggregating the queuing time we make the total queuing time available to the whole process.
Things in system = Lead Time x Flow rate Things/time unit = Flow rate
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Skeg’s Effectiveness Model Projects
Objective Projects View
New Product Quotation Funnel Projects Report
Prioritization Board Project Funnel
CCPM environment Supported with Sciforma Software Throughput Realization Graph RotoRoute Black Projects Report Report
Fever Chart Report
Project Buffer
PR1
PR 2
PR 3
PR4
PR 5
Manufacturing Orders
PR 6
Maunfacturing Prioritization Board Mnf Job Funnel
Customers
DBR Environment Supported with Pastel BIC MIS Completed Projects & MNF jobs
DBR Status Report
Robot Mill
CNC Mill
3D Print
Decisive Competitive Edge
FB
Working Projects View
Chain Index Report
Reasons for Red & Black:
Etc… POOGI Projects
Pareto Analysis
Reasons for Task Delay Report
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Previous Skeg Business System Excel Interface Quote to Customer (Calculations & Form): • Create Tasks (Scope & Time) • Materials
Project, Job & task information stored to Evolution database
“Workaround” CCPM Project plan
Pastel Evolution Project: • Tasks (Scope & Time) • Materials (Buying)
Smartsheet • Tasks (Scope & Time) • Materials • Information used to plan tasks and run scheduling board
Evolution Database
Excel Interface Reporting: • Tasks (Scope & Time) • Materials
Reports (Time per project, Project revenue, etc) reported in bespoke reports 27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Current Skeg Business System
Sciforma CCPM Objective Project (Workspace): Quote, PT0, PT1, PT2, Manufacturing • Create Tasks (Scope & Time / timesheets) • Materials Sciforma Database
Interfaced between Evolution and Sciforma
Sciforma CCPM
Pastel Evolution Project: • Tasks (Scope & Time) • Materials Evolution Database
Design Office: • Execution Management • Tasks and Priorities
Manufacturing DBR Work Package can be used to manage DBR jobs
Manufacturing Shop: • Execution Management • Job Cards and Priorities
Reports (Time per project, Project revenue, etc) reported in bespoke reports
Reporting Structure Sciforma Reports Excel Reports 27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Measurements Implemented
Release Control Mechanism
Competitive Advantage = 99% Reliability Capacity Control = T/day Projects flow smoothly through shop floor
Local Efficiencies Abolished
Things in system = Lead Time x Flow rate Things/time unit = Flow rate
Primary Objective – Improve flow (NOT Efficiencies)
Execution WIP (Historical)
Sales WIP (Future Planned)
POOGI
Sum of T/day of open Projects
• • • • •
Convert or Release ?
Do NOT change the Fundamental Offering – Change the Mode of Operation Focus on Flow (Rather than Efficiency – e.g. measuring ) Make use of a Single Prioritization Mechanism – driven by “being subordinated to the market” Primary Measurement is Throughput = (Sales Revenue – Truly Variable Cost) Effectively Segment the Market – High Throughput segment – Reliable Response – Effective Flex Market – Sell “excess capacity” 27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Projects & Task Drivers in the Project environment, Sciforma is the driver.
Projects Everyday feedback to Sciforma – how many days remaining
Projects consists of Design & Manufacturing Tasks Chain Index Prioritisation Project ID TAK-PT1Lock2892
#
Name
4 Sourcing and Procurement
Chain Index DBR Status 914.11
TAK-PT1Lock2892
15 Graphics User Interface Design
DEB-AUVMnf2836
127 3D Scan - 4.5.1 Front Section Covers
38.00
DEB-AUVMnf2836
60 4.1.6 3D Scan, Verify All Dimensions
672.00 35.54
ENV-PHeadDv2844
9 Cleaning Hardware Procurement
30.63
ENV-PHeadDv2844
5 Procurement
24.93
ENV-PHeadDv2844
15 Beerline Testing
BRU-RelMech2867
46 Import Competitor Analysis into Report
9.66
SKE-Lean5S2798
19 Training & Implementation
7.08
6 Area 1: Phase 1 Planning
6.12
SKE-Lean5S2798
17.71
WMS-TactCat2345
58 Design heaters and control
5.27
WMS-TactCat2345
47 Robot Machining - Stern Block
5.27
WMS-TactCat2345
42 Bag and Mould Seal - Starboard Hull
5.27
WMS-TactCat2345
31 Procurement - Port Hull Mould Materials
5.27
WMS-TactCat2345
30 Finish and Seal - Port Hull Block
5.27
WMS-TactCat2345
18 Tunnel Lay-up
5.27
RDM-01Slide2906 DEB-AUVMnf2836
1 3D Print 161 Bouyancy Foam - Samples
5.00 4.63
NEL-WaterMt2721
15 Application
4.22
ROY-ModCamP2890
25 Outsourced - Lens Manufacture
4.08
ARC-2.1Prot2806
68 Cast 6 Triggers And assemble handles
2.98
WMS-TactCat2345
64 Procurement - Hull Lay-up
2.93
ARC-EoHExpD2834
10 Test Pelton Wheel
RDM-3DPrint2905
2 3D Print
2.90 2.80
TMT-iCam90L2884
54 Machine Tooling inserts
2.67
TMT-iCam90L2884
16 Mould Inserts
2.67
TMT-iCam90L2884
3 Procurement - PX226 Local
2.67
TMT-iCam90L2884
2 Procurement - Tooling Materials
2.67
ARC-EoHExpD2834
13 Customer Review
2.67
PAT-FneAstr2886
31 CE Test Setup
2.64
ROY-ModCamP2890 NEL-WaterMt2721 VWS-Filters2876
9 Design for Demonstration Prototype 18 Java Server 9 Filter Assembly - 5 off
FUL-SntrGun2207
5 Awaiting Customer Confirmation
TAK-PT1Lock2892
5 Concept Design
Project Task Cards are placed on the landing zone of the FloCution Board according to the task Chain Index
2.60 2.19 2.00 1.75 1.25 Printed on Friday, August 5, 2016
An automated DBR Task Card is created and transferred to the Manufacturing Board The Sciforma Buffer status calculated task cards are transferred to the Manufacturing DBR Board
Manufacturing
Everyday feedback to Sciforma – how many days remaining
In the DBR environment, the Scheduling board is the reporter and Sciforma relay the progress information.
Chain Index Prioritisation Project ID TAK-PT1Lock2892
#
Name
4 Sourcing and Procurement
Chain Index DBR Status 914.11
TAK-PT1Lock2892
15 Graphics User Interface Design
672.00
DEB-AUVMnf2836
127 3D Scan - 4.5.1 Front Section Covers
38.00
DEB-AUVMnf2836
60 4.1.6 3D Scan, Verify All Dimensions
35.54
ENV-PHeadDv2844 ENV-PHeadDv2844
9 Cleaning Hardware Procurement 5 Procurement
ENV-PHeadDv2844
15 Beerline Testing
BRU-RelMech2867
46 Import Competitor Analysis into Report
30.63 24.93 17.71 9.66
SKE-Lean5S2798
19 Training & Implementation
7.08
SKE-Lean5S2798
6 Area 1: Phase 1 Planning
6.12
WMS-TactCat2345
58 Design heaters and control
5.27
WMS-TactCat2345
47 Robot Machining - Stern Block
5.27
WMS-TactCat2345
42 Bag and Mould Seal - Starboard Hull
5.27
WMS-TactCat2345
31 Procurement - Port Hull Mould Materials
5.27
WMS-TactCat2345
30 Finish and Seal - Port Hull Block
5.27
WMS-TactCat2345
18 Tunnel Lay-up
5.27
RDM-01Slide2906
1 3D Print
5.00
DEB-AUVMnf2836
161 Bouyancy Foam - Samples
4.63
NEL-WaterMt2721
15 Application
4.22
ROY-ModCamP2890
25 Outsourced - Lens Manufacture
4.08
ARC-2.1Prot2806
68 Cast 6 Triggers And assemble handles
2.98
WMS-TactCat2345
64 Procurement - Hull Lay-up
2.93
ARC-EoHExpD2834
10 Test Pelton Wheel
2.90
RDM-3DPrint2905
2 3D Print
2.80
TMT-iCam90L2884
54 Machine Tooling inserts
2.67
TMT-iCam90L2884
16 Mould Inserts
2.67
TMT-iCam90L2884
3 Procurement - PX226 Local
2.67
TMT-iCam90L2884
2 Procurement - Tooling Materials
2.67
ARC-EoHExpD2834
13 Customer Review
2.67
PAT-FneAstr2886
31 CE Test Setup
2.64
ROY-ModCamP2890 NEL-WaterMt2721
9 Design for Demonstration Prototype 18 Java Server
VWS-Filters2876
9 Filter Assembly - 5 off
FUL-SntrGun2207
5 Awaiting Customer Confirmation
TAK-PT1Lock2892
5 Concept Design
2.60 2.19 2.00 1.75 1.25 Printed on Friday, August 5, 2016
Identified through a small colored sticker that is placed on the task cards on Manufacturing FloCution Board
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Calculating Buffer Status for Task Execution
Manufacturing Buffer Penetration Calculation: – Buffer Penetration =
(Job duration – (Completion date ‐ (Today()) Job Duration
– i.e. Buffer Penetration = = ((Today() – Start date) Job Duration
Task Duration Baseline Duration
The total duration of the Manufacturing Job is considered to be the “MANUFACTURING TIME BUFFER”
Start Date
Today
Planned Completion Date
Manufacturing buffer status has NO relation to amount of work completed Copyright 2016
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Manufacturing Project – Status Update
Actual Start
Manufacturing Project: Duration for the Design Project
Project Duration
Manufacturing Project: Time Buffer Duration In Planning (Starting condition for “In Tracking” mode): The Design Project Manufacturing task duration is 2/3 of the Manufacturing Project Time Buffer Duration In Execution: When the duration (today + remaining duration) > 2/3 of the Manufacturing Project Time Buffer Duration then = “actual duration” Predicted end date = “Finish” in Sciforma 27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Buffer Status for Task Execution Manufacturing
OP
Tasks are executed according to the rule: “Start ASAP and execute As Fast as possible” – Road Runner ethic.
OP
OP
OP
OP
Task DBR Buffer Status OP
Completed Jobs
3
2 11 Copyright 2014
4
12
6
8
9
10
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Buffer Status for Task Execution Manufacturing
Start Date
OP
Tasks Buffer status relate to their individual DBR buffer status.
OP
Example Today
OP
OP
OP 3
Completed Jobs
OP
2
11
4
12
6
8
OP
9
10
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Buffer Status for Task Execution Manufacturing Task completed early
Task Completion Status
OP
OP
OP
OP
OP
4
2
OP
OP OP
Completed Jobs 3 11
OP
12
6
8
OP 9
10
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Chain Index for Task Execution Projects In Projects, we prioritized the tasks to be executed according to their Chain Index Chain Index Prioritisation Project ID TAK-PT1Lock2892
Critical Chain Tasks; (Critical Chain) Chain Index =
% Critical Buffer Incursion % Critical Chain Completion
Non Critical Chain Tasks; (Feeding Chain) Chain Index =
Portfolio Fever Chart % Feeding Buffer Incursion % Feeding Chain Completion
#
Name
4 Sourcing and Procurement
Chain Index DBR Status 914.11
TAK-PT1Lock2892
15 Graphics User Interface Design
672.00
DEB-AUVMnf2836
127 3D Scan - 4.5.1 Front Section Covers
38.00
DEB-AUVMnf2836
60 4.1.6 3D Scan, Verify All Dimensions
35.54
ENV-PHeadDv2844
9 Cleaning Hardware Procurement
30.63
ENV-PHeadDv2844
5 Procurement
24.93
ENV-PHeadDv2844
15 Beerline Testing
BRU-RelMech2867
46 Import Competitor Analysis into Report
9.66
SKE-Lean5S2798
19 Training & Implementation
7.08
SKE-Lean5S2798
6 Area 1: Phase 1 Planning
6.12
WMS-TactCat2345
58 Design heaters and control
5.27
WMS-TactCat2345
47 Robot Machining - Stern Block
5.27
WMS-TactCat2345
42 Bag and Mould Seal - Starboard Hull
5.27
WMS-TactCat2345
31 Procurement - Port Hull Mould Materials
5.27
WMS-TactCat2345
30 Finish and Seal - Port Hull Block
5.27
WMS-TactCat2345
18 Tunnel Lay-up
5.27
RDM-01Slide2906
1 3D Print
17.71
5.00
DEB-AUVMnf2836
161 Bouyancy Foam - Samples
4.63
NEL-WaterMt2721
15 Application
4.22
ROY-ModCamP2890
25 Outsourced - Lens Manufacture
4.08
ARC-2.1Prot2806
68 Cast 6 Triggers And assemble handles
2.98
WMS-TactCat2345
64 Procurement - Hull Lay-up
2.93
ARC-EoHExpD2834
10 Test Pelton Wheel
2.90
RDM-3DPrint2905
2 3D Print
2.80
TMT-iCam90L2884
54 Machine Tooling inserts
2.67
TMT-iCam90L2884
16 Mould Inserts
2.67
TMT-iCam90L2884
3 Procurement - PX226 Local
2.67
TMT-iCam90L2884
2 Procurement - Tooling Materials
2.67
ARC-EoHExpD2834
13 Customer Review
2.67
PAT-FneAstr2886
31 CE Test Setup
2.64
ROY-ModCamP2890 NEL-WaterMt2721
9 Design for Demonstration Prototype 18 Java Server
2.60 2.19
VWS-Filters2876
9 Filter Assembly - 5 off
2.00
FUL-SntrGun2207
5 Awaiting Customer Confirmation
1.75
TAK-PT1Lock2892
5 Concept Design
1.25 Printed on Friday, August 5, 2016
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Daily Management Reports RotoRoute Report
Chain Index Prioritization
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Daily Management Reports Current & Upcoming Tasks
Portfolio Fever Chart
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
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Daily Management Reports
Throughput Realization Graph POOGI Analysis
27th International Conference of the TOC Practitioners Alliance ‐ TOCPA
