Hello TOC

Free courses

TOC in Operations

Seven lessons on running a plant for flow instead of local efficiency, with two games built into the lessons: Choke the Release and the Daily Buffer Meeting.

  1. 1 The busy plantMost plants are managed by keeping every work centre productive. Look at five simple plants and predict what goes wrong when everyone chases efficiency. 14 min
  2. 2 Flow problems and plant typesPart 1 names the four flow problems: over-activation, resource stealing, material stealing and de-synchronisation. Part 2 shows the four shapes of plant, V, A, T and I, and which problems each one breeds. 12 min
  3. 3 The core conflictPlant managers are torn between controlling cost and ensuring flow. See the conflict, the assumption that keeps it alive, and why removing efficiency measures alone doesn’t fix it. 13 min
  4. 4 The TOC way of productionFlow as the first objective of operations. Why local efficiencies have to go, how Drum-Buffer-Rope controls work in progress for the whole plant, and how it differs from controlling it everywhere. 14 min
  5. 5 Choke the releaseMost of an order’s lead time is spent waiting. Limit how far ahead work is released, and watch work in progress, lead time and lateness fall together. Then find the sweet spot yourself. 18 min
  6. 6 Buffer managementOne colour per order tells everyone what to work on next. Run a daily buffer meeting, then use the reasons for red orders to choose what to improve. 18 min
  7. 7 Reliable due datesWhy MRP and advanced planning systems struggle to keep their promises, and how TOC quotes dates it can keep: a good-enough plan, a buffer, and disciplined execution. 14 min
  8. ✓Your certificateUnlocks when all seven quizzes are passed.

Start lesson 1

This course is built from the TOC in Operations sessions I teach, and from what I learned implementing these ideas on real shop floors. Take Fundamentals of TOC first if the Five Focusing Steps are new to you.