www.tocpractice.

com

27th InternationalConferenceofthe
TOCPractitionersAlliance TOCPA
www.tocpractice.com

August1618,2016Johannesburg,SouthAfrica

IntegratingCCPM&DBRinaproduct
developmentcompany

Galia du Toit, OpsLogik, South Africa

17th 18th August, 2016

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

www.tocpractice.com

Galia du Toit & Paul Grobbelaar

Galia du Toit is a partner in OpsLogik,

advising businesses on implementing
the TOC methodologies and specializes
in Critical Chain Project Management
using the Sciforma software to
implement and execute Critical Chain
based projects.
Paul Grobbelaar is a qualified Industrial
Engineer and employee at Skeg Product
Development. He is the CCPM &
Sciforma manager at Skeg. With the
help of Sciforma he manages CCPM
projects using methodologies developed
for DBR and CCPM. The software is
integrated with Pastel, enabling real
time
Throughput
Accounting
measurements to be used in the
management of projects.

OpsLogik Solutions
Annandale Road, Stellenbosch,
Cape Town
+27 (0) 83 258 4843

Skeg Product Development,

Marconi Road, Montague
Gardens,
Cape Town
+27 (0) 84 205 6130

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

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Projects vs Manufacturing
LetscomparebetweenProjectsandManufacturingenvironments.
Thesimilaritiesaremuchgreaterthanthedifferences.
ManufacturingOperations

ProjectOperations

MethodsthatdriveManufacturing
EnterpriseResourcePlanning
(ERP,Symphony)

MethodsthatdriveProjects
CriticalChainMethod
(CCM,Sciforma)

FromaTOCperspective,thetwomethodcomparisons,
assumesthatsafetyislocalizedthroughouttherespectiveoperations,
andthatvalueismeasureablethroughouttherespectiveoperations
Safety
islocalizedinqueuingofproducts
(WIP)

Safety
islocalizedineachtaskofproject

TouchTime&Variability
Touchtimeisaverysmallpartofthe
totaltimespentintheprocess,
thereisalsolittlevariability
initsduration

TouchTime&Variability
Allthevariabilityinaprojectappears
tobeinthetouchtimeofthetask

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

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Projects vs Manufacturing
ManufacturingOperations

ProjectOperations

LeadTime
ProjectTask1
Start

Task2
Task3

Start

Finish

Inprojectenvironmentsthetouchtimes
isrelativelylong.

TouchTime
Wecanaggregatethetouchtimeandwecanaggregate
thequeuingtime.
Safety

Start

TouchTime

ProjectBuffer
Finish

Thetasksarelarge,thevariabilityistherefore
magnified.Ifwecanremovesafetythatis
embeddedandaddittotheendoftheprojectasa
buffer,weshortenthedurationoftheproject
withoutendangeringtheontimereliabilityofthe
completiondate.

Finish

DBRassumesthatthetouchtimeisverysmall(<10%)
comparedtothecurrentleadtime.Byaggregatingthe
queuingtimewemakethetotalqueuingtimeavailableto
thewholeprocess.

Thingsinsystem=LeadTimexFlowrate
Things/timeunit=Flowrate

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

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Skegs Effectiveness Model

Projects

Objective
Projects
View

NewProduct QuotationFunnel
Projects
Report

PrioritizationBoard
Project
Funnel

CCPMenvironment
SupportedwithSciformaSoftware
Throughput
Realization
Graph
RotoRoute BlackProjects
Report
Report

FeverChart
Report

ProjectBuffer

PR1

PR2

PR3

PR4

PR5

Manufacturing
Orders

PR6

Maunfacturing
PrioritizationBoard
MnfJob
Funnel

Customers

DBREnvironment
SupportedwithPastelBICMIS
Completed
Projects&
MNFjobs

DBRStatus
Report

Robot
Mill

CNCMill

3DPrint

DecisiveCompetitiveEdge

FB

Working
Projects
View

ChainIndex
Report

Reasons
forRed&
Black:

Etc
POOGIProjects

Pareto
Analysis

Reasonsfor
TaskDelay
Report

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

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Previous Skeg Business System

ExcelInterface
QuotetoCustomer(Calculations&
Form):
CreateTasks(Scope&Time)
Materials

Project,Job&task
informationstoredto
Evolutiondatabase

WorkaroundCCPMProjectplan

PastelEvolution
Project:
Tasks(Scope&Time)
Materials(Buying)

Smartsheet
Tasks(Scope&Time)
Materials
Informationusedtoplantasksand
runschedulingboard

Evolution
Database

ExcelInterface
Reporting:
Tasks(Scope&Time)
Materials

Reports(Timeperproject,
Projectrevenue,etc)reported
inbespokereports
27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

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Current Skeg Business System

Sciforma CCPM
ObjectiveProject(Workspace):
Quote,PT0,PT1,PT2,Manufacturing
CreateTasks(Scope&Time/timesheets)
Materials
Sciforma
Database

Interfacedbetween
Evolutionand
Sciforma

Sciforma CCPM

PastelEvolution
Project:
Tasks(Scope&Time)
Materials
Evolution
Database

DesignOffice:
ExecutionManagement
TasksandPriorities

ManufacturingDBR
WorkPackagecanbe
usedtomanageDBR
jobs

ManufacturingShop:
ExecutionManagement
JobCardsandPriorities

Reports(Timeper
project,Project
revenue,etc)reported
inbespokereports

ReportingStructure
Sciforma Reports
ExcelReports
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Measurements Implemented

ReleaseControlMechanism

CompetitiveAdvantage=99%Reliability
CapacityControl=T/day
Projectsflowsmoothlythroughshopfloor

LocalEfficienciesAbolished

Thingsinsystem=LeadTimexFlowrate
Things/timeunit=Flowrate

PrimaryObjective Improveflow(NOTEfficiencies)

ExecutionWIP(Historical)

SalesWIP(FuturePlanned)

POOGI

SumofT/dayof
openProjects

Convertor
Release?

DoNOTchangetheFundamentalOffering ChangetheModeofOperation
FocusonFlow(RatherthanEfficiency e.g.measuring)
MakeuseofaSinglePrioritizationMechanism drivenbybeingsubordinatedtothemarket
PrimaryMeasurementisThroughput=(SalesRevenue TrulyVariableCost)
EffectivelySegmenttheMarket
HighThroughputsegment ReliableResponse
EffectiveFlexMarket Sellexcesscapacity
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Projects & Task Drivers

intheProjectenvironment,
Sciformaisthedriver.

Projects
Everydayfeedback
toSciforma
howmanydays
remaining

ProjectsconsistsofDesign&ManufacturingTasks
Chain Index Prioritisation
Project ID
TAK-PT1Lock2892

Name

4 Sourcing and Procurement

Chain Index DBR Status

914.11

TAK-PT1Lock2892

15 Graphics User Interface Design

DEB-AUVMnf2836

127 3D Scan - 4.5.1 Front Section Covers

38.00

DEB-AUVMnf2836

60 4.1.6 3D Scan, Verify All Dimensions

672.00
35.54

ENV-PHeadDv2844

9 Cleaning Hardware Procurement

30.63

ENV-PHeadDv2844

5 Procurement

24.93

ENV-PHeadDv2844

15 Beerline Testing

BRU-RelMech2867

46 Import Competitor Analysis into Report

9.66

SKE-Lean5S2798

19 Training & Implementation

7.08

6 Area 1: Phase 1 Planning

6.12

SKE-Lean5S2798

17.71

WMS-TactCat2345

58 Design heaters and control

5.27

WMS-TactCat2345

47 Robot Machining - Stern Block

5.27

WMS-TactCat2345

42 Bag and Mould Seal - Starboard Hull

5.27

WMS-TactCat2345

31 Procurement - Port Hull Mould Materials

5.27

WMS-TactCat2345

30 Finish and Seal - Port Hull Block

5.27

WMS-TactCat2345

18 Tunnel Lay-up

5.27

RDM-01Slide2906
DEB-AUVMnf2836

1 3D Print
161 Bouyancy Foam - Samples

5.00
4.63

NEL-WaterMt2721

15 Application

4.22

ROY-ModCamP2890

25 Outsourced - Lens Manufacture

4.08

ARC-2.1Prot2806

68 Cast 6 Triggers And assemble handles

2.98

WMS-TactCat2345

64 Procurement - Hull Lay-up

2.93

ARC-EoHExpD2834

10 Test Pelton Wheel

RDM-3DPrint2905

2 3D Print

2.90
2.80

TMT-iCam90L2884

54 Machine Tooling inserts

2.67

TMT-iCam90L2884

16 Mould Inserts

2.67

TMT-iCam90L2884

3 Procurement - PX226 Local

2.67

TMT-iCam90L2884

2 Procurement - Tooling Materials

2.67

ARC-EoHExpD2834

13 Customer Review

2.67

PAT-FneAstr2886

31 CE Test Setup

2.64

ROY-ModCamP2890
NEL-WaterMt2721
VWS-Filters2876

9 Design for Demonstration Prototype

18 Java Server
9 Filter Assembly - 5 off

FUL-SntrGun2207

5 Awaiting Customer Confirmation

TAK-PT1Lock2892

5 Concept Design

ProjectTaskCardsareplacedon
thelandingzoneofthe
FloCutionBoardaccordingto
thetaskChainIndex

2.60
2.19
2.00
1.75
1.25
Printed on Friday, August 5, 2016

AnautomatedDBRTaskCard
iscreatedandtransferredto
theManufacturingBoard
TheSciformaBuffer
statuscalculatedtask
cardsaretransferredto
theManufacturingDBR
Board

Manufacturing

Everydayfeedback
toSciforma
howmanydays
remaining

IntheDBRenvironment,
theSchedulingboardisthe
reporterandSciformarelay
theprogressinformation.

Chain Index Prioritisation

Project ID
TAK-PT1Lock2892

Name

4 Sourcing and Procurement

Chain Index DBR Status

914.11

TAK-PT1Lock2892

15 Graphics User Interface Design

672.00

DEB-AUVMnf2836

127 3D Scan - 4.5.1 Front Section Covers

38.00

DEB-AUVMnf2836

60 4.1.6 3D Scan, Verify All Dimensions

35.54

ENV-PHeadDv2844
ENV-PHeadDv2844

9 Cleaning Hardware Procurement

5 Procurement

ENV-PHeadDv2844

15 Beerline Testing

BRU-RelMech2867

46 Import Competitor Analysis into Report

30.63
24.93
17.71
9.66

SKE-Lean5S2798

19 Training & Implementation

7.08

SKE-Lean5S2798

6 Area 1: Phase 1 Planning

6.12

WMS-TactCat2345

58 Design heaters and control

5.27

WMS-TactCat2345

47 Robot Machining - Stern Block

5.27

WMS-TactCat2345

42 Bag and Mould Seal - Starboard Hull

5.27

WMS-TactCat2345

31 Procurement - Port Hull Mould Materials

5.27

WMS-TactCat2345

30 Finish and Seal - Port Hull Block

5.27

WMS-TactCat2345

18 Tunnel Lay-up

5.27

RDM-01Slide2906

1 3D Print

5.00

DEB-AUVMnf2836

161 Bouyancy Foam - Samples

4.63

NEL-WaterMt2721

15 Application

4.22

ROY-ModCamP2890

25 Outsourced - Lens Manufacture

4.08

ARC-2.1Prot2806

68 Cast 6 Triggers And assemble handles

2.98

WMS-TactCat2345

64 Procurement - Hull Lay-up

2.93

ARC-EoHExpD2834

10 Test Pelton Wheel

2.90

RDM-3DPrint2905

2 3D Print

2.80

TMT-iCam90L2884

54 Machine Tooling inserts

2.67

TMT-iCam90L2884

16 Mould Inserts

2.67

TMT-iCam90L2884

3 Procurement - PX226 Local

2.67

TMT-iCam90L2884

2 Procurement - Tooling Materials

2.67

ARC-EoHExpD2834

13 Customer Review

2.67

PAT-FneAstr2886

31 CE Test Setup

2.64

ROY-ModCamP2890
NEL-WaterMt2721

9 Design for Demonstration Prototype

18 Java Server

VWS-Filters2876

9 Filter Assembly - 5 off

FUL-SntrGun2207

5 Awaiting Customer Confirmation

TAK-PT1Lock2892

5 Concept Design

2.60
2.19
2.00
1.75
1.25
Printed on Friday, August 5, 2016

Identifiedthroughasmallcoloredstickerthatis
placedonthetaskcardsonManufacturing
FloCutionBoard

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Calculating Buffer Status for Task Execution

ManufacturingBufferPenetrationCalculation:
BufferPenetration=

(Jobduration (Completiondate (Today())

JobDuration

i.e.BufferPenetration==
((Today() Startdate)
JobDuration

TaskDuration
BaselineDuration

Thetotaldurationofthe ManufacturingJobisconsideredtobethe
MANUFACTURINGTIMEBUFFER

StartDate

Today

PlannedCompletionDate

Manufacturing
bufferstatushasNO
relationtoamount
ofworkcompleted
Copyright2016

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

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Manufacturing Project Status Update

Actual
Start

ManufacturingProject:
DurationfortheDesignProject

Project
Duration

ManufacturingProject:TimeBufferDuration
InPlanning(StartingconditionforInTrackingmode):
TheDesignProjectManufacturingtaskdurationis2/3oftheManufacturingProject
TimeBufferDuration
InExecution:
Whentheduration(today+remainingduration)>2/3oftheManufacturingProject
TimeBufferDurationthen=actualduration
Predictedenddate=FinishinSciforma
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Buffer Status for Task Execution

Manufacturing

OP

Tasksareexecuted
accordingtotherule:Start
ASAPandexecuteAsFastas
possible RoadRunner
ethic.

OP

OP

OP

OP

TaskDBR
BufferStatus
OP

CompletedJobs

2
11
Copyright2014

12

10

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Buffer Status for Task Execution

Manufacturing

Start
Date

OP

TasksBufferstatusrelateto
theirindividualDBRbuffer
status.

OP

Example
Today

OP

OP

OP
3

CompletedJobs

OP

11

12

OP

10

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Buffer Status for Task Execution

Manufacturing
Taskcompletedearly

Task
Completion
Status

OP

OP

OP

OP

OP

OP

OP
OP

CompletedJobs
3
11

OP

12

OP 9

10

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Chain Index for Task Execution

Projects
InProjects,weprioritizedthetaskstobeexecutedaccordingtotheirChainIndex
Chain Index Prioritisation
Project ID
TAK-PT1Lock2892

CriticalChainTasks;(CriticalChain)
ChainIndex=

%CriticalBufferIncursion
%CriticalChainCompletion

NonCriticalChainTasks;(FeedingChain)
ChainIndex=

PortfolioFeverChart
%FeedingBufferIncursion
%FeedingChainCompletion

Name

4 Sourcing and Procurement

Chain Index DBR Status

914.11

TAK-PT1Lock2892

15 Graphics User Interface Design

672.00

DEB-AUVMnf2836

127 3D Scan - 4.5.1 Front Section Covers

38.00

DEB-AUVMnf2836

60 4.1.6 3D Scan, Verify All Dimensions

35.54

ENV-PHeadDv2844

9 Cleaning Hardware Procurement

30.63

ENV-PHeadDv2844

5 Procurement

24.93

ENV-PHeadDv2844

15 Beerline Testing

BRU-RelMech2867

46 Import Competitor Analysis into Report

9.66

SKE-Lean5S2798

19 Training & Implementation

7.08

SKE-Lean5S2798

6 Area 1: Phase 1 Planning

6.12

WMS-TactCat2345

58 Design heaters and control

5.27

WMS-TactCat2345

47 Robot Machining - Stern Block

5.27

WMS-TactCat2345

42 Bag and Mould Seal - Starboard Hull

5.27

WMS-TactCat2345

31 Procurement - Port Hull Mould Materials

5.27

WMS-TactCat2345

30 Finish and Seal - Port Hull Block

5.27

WMS-TactCat2345

18 Tunnel Lay-up

5.27

RDM-01Slide2906

1 3D Print

17.71

5.00

DEB-AUVMnf2836

161 Bouyancy Foam - Samples

4.63

NEL-WaterMt2721

15 Application

4.22

ROY-ModCamP2890

25 Outsourced - Lens Manufacture

4.08

ARC-2.1Prot2806

68 Cast 6 Triggers And assemble handles

2.98

WMS-TactCat2345

64 Procurement - Hull Lay-up

2.93

ARC-EoHExpD2834

10 Test Pelton Wheel

2.90

RDM-3DPrint2905

2 3D Print

2.80

TMT-iCam90L2884

54 Machine Tooling inserts

2.67

TMT-iCam90L2884

16 Mould Inserts

2.67

TMT-iCam90L2884

3 Procurement - PX226 Local

2.67

TMT-iCam90L2884

2 Procurement - Tooling Materials

2.67

ARC-EoHExpD2834

13 Customer Review

2.67

PAT-FneAstr2886

31 CE Test Setup

2.64

ROY-ModCamP2890
NEL-WaterMt2721

9 Design for Demonstration Prototype

18 Java Server

2.60
2.19

VWS-Filters2876

9 Filter Assembly - 5 off

2.00

FUL-SntrGun2207

5 Awaiting Customer Confirmation

1.75

TAK-PT1Lock2892

5 Concept Design

1.25
Printed on Friday, August 5, 2016

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

www.tocpractice.com

Daily Management Reports

RotoRouteReport

ChainIndex
Prioritization

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

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Daily Management Reports

Current&UpcomingTasks

PortfolioFeverChart

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA

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Daily Management Reports

ThroughputRealizationGraph
POOGIAnalysis

27th InternationalConferenceoftheTOCPractitionersAlliance TOCPA