About this Presentation
The presentation goal is to share the details involved in adapting the TOC replenishment solution to improve parts availability and inventory turns when the traditional 3 X 1/3 zones approach to stock buffer design is not sufficient. Key learning points are: 1. Developing a replenishment policy matrix for make-to-stock / make-to-stock (MTS / MTO) connected to purchase-to-stock / purchase-to-order (PTS / PTO) provides a strong focus on results for any replenishment implementation. 2. Changes to the traditional 1/3, 1/3, 1/3 red, yellow and green zones are required to provide better visibility of long lead time items as well as buffer re-sizing based on consumption changes versus buffer zone penetration. 3. How the replenishment concepts can be used to better manage the on-order pipeline for long lead time items – predicting the timing of future shortages. (i.e. the zones tell you if the on-hand is sufficient / healthy, but how do you know if the timing and frequency of the multiple purchase orders in the on-order is sufficient / healthy?) 4. Collaborating with key suppliers on replenishment significantly improves responsiveness while reducing on-order liability. Three benefits are: 1. See the Standing on the Shoulders of Giants (SOSG) process applied to the traditional TOC replenishment solution. 2. Hear Teledyne DALSA talk about the ‘leap of faith’ required to abandon the forecast and migrate to replenishment when there was a 16 week gap (due to long lead times). 3. Specific methodologies, approaches and formulas are provided.
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)
Paul Balmforth
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.