May 2008
For any thermoforming company, timing is everything. After all, you want your part when you want it. At ThermoFab, we understand this. This is why we follow The Theory of Constraints (TOC) business management philosophy called Drum-Buffer-Rope (DBR), which was developed by Dr. Eli Goldratt, author of The Goal: A Process of Ongoing Improvement; It's Not Luck; Critical Chain; and Necessary But Not Sufficient.
Thermoforming Processes: Timing is Everything
Above Image: ThermoFab's thermoformed bezel for Titleist's golf swing analyzer
DBR controls the flow of materials through the plant so that products are produced according to market demand with a minimum of manufacturing lead-time, inventory and operating expenses.
Drum, Buffer, Rope Definitions
- Drum
- Constraints or bottlenecks in the process. This is what is being managed to ensure a smooth flow.
- Buffer
- A protection against Murphy. This is the time provided for parts to reach the protected area. The protected areas are the Drum, the due dates and the assemblies of constraint parts with non-constraint parts.
- Rope
- A schedule for releasing raw materials to the floor. The Rope is derived according to the Drum and Buffers; its mission is to ensure the proper subordination of the non-constraints.
The DBR technique enables companies to maximize a Capacity Constraint Resource and use time buffers to create schedules that help deliver products on time.
Drum-Buffer-Rope is based on the TOC logistics approach and its five steps of focusing:
- Identify the System's Constraint(s).
- Decide How to Exploit the System's Constraint(s).
- Subordinate Everything Else to the Above Decisions.
- Elevate the System's Constraint(s).
- If, in the Previous Steps, a Constraint Has Been Broken, Go Back to Step One, but Do Not Allow Inertia to Cause a System's Constraint.
Our lean manufacturing system provides you with the greatest flexibility of any manufacturer. ThermoFab will work with you to create a yearly blanket order with monthly releases based on a 45-day rolling forecast. This push-pull system with a 45-day window for planning deliveries offers you extensive flexibility - allowing for market changes and growth within your product lines.
To learn more about how ThermoFab's investment in lean processes helps us provide you with better service, request a copy of our white paper "Manufacturing At Warp Speed."
Case in Point
Above Image: SiCortex Blizzard
This "dense cluster" computer for SiCortex is currently in production. Because of the manufacturing processes that we subscribe to, such as the Theory of Constraints described above, this product is on schedule.
ThermoFab is committed to being the leader in custom plastic enclosures. Contact us today to learn how we can take you from files to finished product in just 4-6 weeks!
Sincerely,
Thomas A. King, Jr., President
ThermoFab
email: engineering@thermofab.com
phone: 888-494-9777
web: http://www.thermofab.com