Project Management
Companies that have implemented TOC:
Below are some chosen success stories worldwide after implementation of TOC.
* Info taken from, The World of TOC: Reference Bank.
Boeing, United States.
Industry: Aerospace
Brief Summary: The PCB shop has achieved a 75% reduction in lead time; a 60% reduction in WIP inventory; and a 150% increase in Throughput and an on-time delivery rate that approaches 100%.
eIRCOM
Division: – , Ireland.
Industry: Telecommunications
Brief Summary: Due date Performance improved to exceed 90% 30 % Reduction In cycle Times eIRCOM is Ireland’s leading provider of telecommunications, Providing a comprehensive range of advanced voice, data and Internet services. • 80% Market share of the fixed line business. • Turnover of Euro 1.7 billion • Most extensive fixed line telecommunications network in Ireland. • offer both retail and wholesale services.
Iscor
Division: Iscor Refractories , South Africa.
Industry: Primary Metals
Brief Summary: Largest rotary kiln unexpectedly went down for major rebuild and repair of support rollers. Using CC, rebuild project completed in record 10 days VS original estimate of 21 days. In production, lead times have been reduced 60%, WIP is down 60%, RM is down 30% and past dues are at all time low.
Rockwell International
Division: Rocketdyne , United States.
Industry: Primary Metals
Sales: $1,000,000,000
Brief Summary: Delta engine program realized a 33% reduction in cycle time and a 25% reduction in costs. Manufacturing discrepancies reduced 31% and material reviews reduced 44%.
Lucent Technologies
Division: Bell Labs , United States.
Industry: Telecom
Brief Summary: For Premise Cable products – 100% of projects completed on-time (Compared to 40% before); 8 projects completed before 50/50 points and New Production Introduction (NPI) lead times reduced 50%. For outside cables – NPI lead times reduced 50% and tripled development capacity (17 projects vs. 5 before, with no staff increase).
Harris Corporation
Division: Semiconductor products , United Kingdom.
Industry: Semiconductor
Brief Summary: Brand new plant including design, erection of building, installation of equipment, hiring and training of employees, and ramp-up to 90% of designed rate delivered in 13 months – compared to typical time frame of 54 months. Ran 4% overbudget, but by speeding time-to-market, payback is running two times plan. Production rate reached 90% of plan, 21 days after start – compared to industry norm of 18 months.
Babcock & Wilcox Canada
Division: Cambridge, Ontario , Canada.
Industry: Energy
Sales: $200,000,000
Brief Summary: The development of the common language and measurement system at BWC has permanently changed the thinking of BWC employees across the country. Since implementing the 4×4 process, improvement projects are becoming even more tightly tied to BWC’s strategic goals. This has helped BWC maintain leadership position in the worldwide nuclear and fossil fuel steam generating business.
Hampton Conservatories Ltd
Division: NA , Ireland.
Industry: Construction
Sales: $4,000,000
Brief Summary: Improved due date performance from 60 to 90% while reduing overall project lead times by over 50%. Throughput has incresed nearly 100%, while projects in progress has dropped from 10 o 3. Project completion dates are now highly predictable and quality has also improved significantly.
LSI Logic
Division: Design Technology Development Group , United States.
Industry: Semiconductor
Sales: $1,800,000,000
Brief Summary: Over 90% of projects in the library development group now finish within 2 weeks of planned dates. Throughput has also increased by more than 10%, despite reduction in total number of resources due to reorganization.
Pharmacia, United States.
Industry: Pharmaceutical
Sales: $13,800,000,000
Brief Summary: In a very short time, Lead time was reduced over 60%, due-date delivery improved to over 90% and throughput increased and package rate was increased from 20 per month to 50 per month (a throughput increase of over150%).
Shea Homes
Division: Phoenix Division , United States.
Industry: Construction
Brief Summary: Cycle times reduction from 91 days to 56 days, a reduction of 38%, saved millions of dollars annually in interest costs alone.
FMC Kongsberg Subsea, United States.
Industry: Industrial equipment/machinery
Sales: $200,000,000
Brief Summary: “The results have been dramatic,” says Richard Meier, Subsea Assembly Manager. “The time required to complete a tree has dropped from 18 weeks to under 10 weeks, and we believe that we will achieve eight weeks as a reliable performance measure in the next two or three trees.”
RexRoto, United States.
Industry: Industrial equipment/machinery
Brief Summary: Throughput has increased by over 50%, primarily because the rework in manufacturing has come down dramatically; also engineering and manufacturing are now completely synchronized, through integrated task priorities.
Zoran Corporation
Division: Zoran Microelectronics , Israel.
Industry: Semiconductor
Sales: $60,000,000
Brief Summary: Based on CEO summary before starting the implementation there where a feeling that projects time table went almost out of control. As a direct result of the implementation results followed quickly. There were clear early warning indicators for up-coming problems. Management could take decisions based on valid data. Projects are finished on schedule.
Emblase Ltd.
Division: Emblaze Semiconductor , Israel.
Industry: Telecom
Brief Summary: Projects are completed on time. Problems are solved way ahead of the time when they can inflict crises. The TOC know-how has become the foundation of project management in the company.
United states Naval Shipyard
Division: Pearl Harbor , United States.
Industry: Industrial equipment/machinery
Brief Summary: Official results from the shipyard show 11 percent more jobs done per upkeep while using five percent less man-hours; a 13 percent increase in job completions. Cycle time reduced by 5.6 days and on-time deliveries have improved from 10% to nearly 98%.
NAVAIR
Division: Cherry Point , United States.
Brief Summary: Throughput – the number of units serviced – has increased by a full 100%.