Theory of Constraints and the five focusing steps

Learning objectives

• Explain the purpose of theory of constraints and five focusing steps in garment operations.
• Describe when and how to apply theory of constraints and five focusing steps on the shop floor.
• Identify common mistakes and how to avoid them.

Core idea

Identify the system constraint, exploit it, subordinate other work, elevate it, then repeat when the constraint moves.

Method

Define throughput goal and boundary; use data; manage buffer; measure whole-system result. Avoid improving nonconstraints merely because they look inefficient.

Garment-factory example

Keep the true constraint supplied with defect-free work, protect breaks/changeovers, move support tasks, add capacity only after exploitation/subordination.

Method

1. Define throughput goal and boundary;
2. use data;
3. manage buffer;
4. measure whole-system result

Common mistakes

• Avoid improving nonconstraints merely because they look inefficient