Building Resilient Manufacturing Operations: A No-Nonsense Guide to Fixing What’s Broken in Your Plant
You asked for it, and here it is – your complete blueprint for transforming chaotic operations into streamlined perfection. Every time. Anchored in the Theory of Constraints (TOC) the guide walks you through a complete transformation of your production environment, step by step.
Imagine it now: Being able to build systems that perform, even under pressure. With Building Resilient Manufacturing Operations, there’s no need to imagine. From $700M crisis recoveries to sustainable plant transformation, the Theory of Constraints aligns every part of your system to drive real improvement over time.
“I’ve never seen continuous improvement explained this clearly. Embracing change isn’t just a slogan here - it’s a survival strategy.”
“The real-world throughput math blew me away. I’ve never seen product mix strategy broken down so clearly. It’s eye-opening.”
What Makes This Book Different?
Building Resilient Manufacturing Operations is the only book of its kind that provides business-focused TOC implementation. More importantly, while most production management books stop with theory, this one starts with your reality: Missed shipments, chaotic schedules, and siloed teams. Above all, it gives you a way out.
Crafted from a business management perspective, this operational excellence framework shows you how to transform your operations for consistent on-time delivery without fail.
- Real-world TOC applications
- A step-by-step transition roadmap
- Proven, practical guidance – step by step
- An inventory management system that makes sense
- Guidance for managing change on the floor
- Strategies to reduce chaos and increase profit
- Tools for aligning people, processes, and performance management
“The way this book connects throughput to KPIs and profitability is spot on. It’s actionable, not academic.”
“This book doesn’t just solve manufacturing problems…it rewires how you think about them.”
Start with a Free Sample Chapter
Join 100s of plant managers who’ve already transformed their operations, making all their hard work finally pay off. Discover how the operational excellence framework can work for you by downloading your free sample today.
Book Outline
Part One - The Theory of Constraints
2. Understanding Your System: A Theory of Constraints Primer
3. Proven Solutions for Production: An Overview of ToC Applications for Manufacturers
4. Where to Start: Identifying the Constraint
5. Conserving Human Capital: Strategic Flexibility
6. Data-Driven Management: Decision-Making and Performance Management
7. Performance Management: Linking Behavior to Data-Driven Results
Part Two – The Theory of Constraints (ToC) Production System
8. Designing for Reliability and Resilience: Choosing the System’s Constraint
9. Demand-Pull Replenishment: Beyond Kanban Systems for Resilience
10. Designing a Resilient Production System: Qualities of a reliable, resilient system
11. Planning for Resilience: Demand and Capacity
12. Production Planning: Using the Drum-Buffer-Rope Scheduling Method
13. Executing a Resilient Production System: Bringing the Plans to Life
Part Three - ToCPS Implementation Template
14. The Approach: Preparing Your Mind and Team for Transformation
15. Aligning for Success: Reforming the Team as a Cohesive Unit
16. Delivering Reliably: Building Execution Processes
17. Thriving Through Resilience: Building Resilience
18. Sustaining the Shift: Habits and Structures to Fight Entropy
19. I Haven’t Told You Everything, But This Should Be Enough: Closing Summary
Appendix
A. Implementation Work Breakdown Structure: Implementation Tasks and Deliverables
B. Brown Fintube DBR Cast Study: Real-World Application and Results
C. Spirit AeroSystems ToCPS Cast Study: Real-World Application and Results
D. Leveraging Lean and Six Sigma for More Success: Combining ToC, Lean, & Six Sigma for Continuous Improvement