About this Presentation
This presentation is based on a DBR implementation inside a factory. The aim of the project was to synchronize flow between suppliers and the machining area. During the current reality tree (CRT) analysis, we shared that the productivity syndrome of large batch sizes was the key UDE driven by the cost per unit thinking. We decided to apply the 5 focusing steps in order to improve the flow of parts to products. Very quickly, we increased the flow parts to delivered products helping the final assembly to increase the throughput of the system. We moved very quickly from 16M$ to 4M$. The main difficulty we faced during the implementation was the idle resources. One of the first actions we did was to give up all the previous key performance indicator (KPI) boards in order to focus the team on the global throughput (T) and not the local measures. Then we tried to transform this negative branch into an opportunity to increase our ROI. That's why, instead of outsourcing part numbers because of the cost per unit comparison, we decided to do massive insourcing in order to use the idle capacity we generated. Consequently the ROI almost tripled in few months because of the increase of the T, reduction of operating expenses, and the reduction of Inventory. However, the overcapacity was so high that we had to decide to explore other opportunities to increase the ROI. In order to do that, we decided to explore new supply chain solutions which were more related to project management implementation.
What Will You Learn
To help you get the most value from this session, we’ve highlighted a few key points. These takeaways capture the main ideas and practical insights from the presentation, making it easier for you to review, reflect, and apply what you’ve learned.
Instructor(s)
Jennifer Eckman
Ms Alka Wadhwa
Alka Wadhwa is an experienced consultant and process improvement expert with over 24 years of expertise in the Theory of Constraints (TOC), Lean Six Sigma, and organizational performance optimization. She has successfully led projects in healthcare, financial services, and manufacturing, driving significant improvements such as a 67% boost in hospital operations and a 140% increase in outpatient visits.
Previously, Alka Wadhwa spent 17+ years at GE Global Research Center, where she led initiatives to enhance various GE businesses through advanced technologies, process redesign, and system optimization. Founder of Better Solutions Consulting, LLC, she specializes in using TOC, Six Sigma, and data analytics to streamline operations and build high-performance teams.
Her work has earned her multiple accolades, including the Empire State Award of Excellence in healthcare.
Dr Gary Wadhwa
Dr. Gary Wadhwa is a Board Certified Oral & Maxillofacial Surgeon with extensive experience in the field. He completed his Oral & Maxillofacial Surgery training at Montefiore Hospital, Albert Einstein College of Medicine in Bronx, NY, and has served as an Attending at prestigious institutions like St. Peters Hospitals, Ellis Hospital, and Beth Israel Hospital in NY. With a career spanning over two decades, he was the former CEO and President of a group specialty practice in NY from 1994 to 2015. Dr. Wadhwa holds an MBA from UT at Knoxville, TN, and has undergone additional training in System Dynamics at MIT, Health System Management at Harvard Business School, and Entrepreneurship and healthcare innovations at Columbia Business School. Committed to expanding access to Oral & Maxillofacial Surgery care, he is currently engaged in a meaningful project to provide healthcare services to underserved populations in inner city and rural areas through non-profit Community Health Centers.