The Ultimate Improvement Cycle

Recognizing the need to implement quality and eliminate waste, companies embrace Lean, Six Sigma, or a combination of the two, typically taking a broad approach that seeks to remediate every process, critical or not. When this happens, efforts become distracted, improvements indefinitely delayed, and results mediocre at best. The Ultimate Improvement Cycle (UIC) integrates Lean, Six Sigma, and the Theory of Constraints into a combined strategy that will help you immediately focus your efforts on those areas that will make the greatest difference. The book presents basic laws of factory physics that show why the UIC delivers significant bottom-line improvement while other initiatives so often fail. It explains to you why focusing your efforts on apparent problems rather than systemic concerns is wasted effort. Focus on key areas and take improvement to the next level The Ultimate Improvement Cycle: Maximizing Profits through the Integration of Lean, Six Sigma, and the Theory of Constraints show you how to draw the best from Lean and Six Sigma by employing principles drawn from the Theory of Constraints. This approach will ensure that your effort is focused in the right place, at the right time, using the right tools, and the right amount of resources. This multi-pronged approach addresses cost accounting, variation, waste, and performance measurements. But most importantly, it focuses your organization on the right areas to optimize. Applying years of hands-on work in many environments, Bob Sproull has developed a unique proven method that capitalizes on a time-release formula for evoking the key tools that improvement requires. He shows you how to take advantage of the cyclical nature of improvement to implement change that is perpetually effective, and his approach does not require more resources than you have on hand. Although originally developed in manufacturing, the UIC works equally well in any environment whether it be manufacturing or service-oriented, including Maintenance, Repair and Overhaul (MRO) and Critical Chain Project Management (CCPM).

Recognizing the need to implement quality and eliminate waste, companies embrace Lean, Six Sigma, or a combination of the two, typically taking a broad approach that seeks to remediate every process, critical or not. When this happens, efforts become distracted, improvements indefinitely delayed, and results mediocre at best. The Ultimate Improvement Cycle (UIC) integrates Lean, Six Sigma, and the Theory of Constraints into a combined strategy that will help you immediately focus your efforts on those areas that will make the greatest difference. The book presents basic laws of factory physics that show why the UIC delivers significant bottom-line improvement while other initiatives so often fail. It explains to you why focusing your efforts on apparent problems rather than systemic concerns is wasted effort.Focus on key areas and take improvement to the next levelThe Ultimate Improvement Cycle: Maximizing Profits through the Integration of Lean, Six Sigma, and the Theory of Constraintsshow you how to draw the best from Lean and Six Sigma by employing principles drawn from the Theory of Constraints. This approach will ensure that your effort is focused in the right place, at the right time, using the right tools, and the right amount of resources. This multi-pronged approach addresses cost accounting, variation, waste, and performance measurements. But most importantly, it focuses your organization on the right areas to optimize. Applying years of hands-on work in many environments, Bob Sproull has developed a unique proven method that capitalizes on a time-release formula for evoking the key tools that improvement requires. He shows you how to take advantage of the cyclical nature of improvement to implement change that is perpetually effective, and hisapproach does not require more resources than you have on hand. Although originally developed in manufacturing, the UIC works equally well in any environment whether it be manufacturing or service-oriented, including Maintenance, Repair and Overhaul (MRO) and Critical Chain Project Management (CCPM).

Many leaders and managers have led improvement initiatives in a variety of different industry sectors. Most believe that when they begin these efforts, they already have the tools they need in their improvement "backpack." Using these tools, they make substantial improvements to processes in a wide array of industry segments. As time passes, however, most realize that there is a missing link in their arsenal of tools for improvement. The author of this book faced this same predicament and he discovered what the missing link was in his improvement tool kit: Theory of Constraints (TOC). Once he learned the details of TOC, his ability to make major improvements jettisoned upward to levels he had not seen before. TOC is the common denominator in all the case studies presented in this book. This book opens with a chapter on what Theory of Constraints is and why it works so well in improvement efforts. The second and third chapters cover the important points related to Lean Manufacturing and Six Sigma as well as key points related to variability. Chapter 4 demonstrates how to effectively combine these three components to achieve maximum improvement and the corresponding enhancement to your company’s profitability. The remainder of this book is composed of true case studies from different industry segments, using this integrated improvement methodology. Essentially, this book lays the foundation for what most practitioners are just beginning to understand—this integrated improvement methodology is superior to the three components used in isolation from each other. This book presents a step-by-step method of how to combine the Theory of Constraints, Lean, and Six Sigma, and then demonstrates its effectiveness in a very diverse array of industries.

This book is a sequel to the business novel, The Secret to Maximizing Profitability – A Business Novel on How to Successfully Combine the Theory of Constraints, Lean, and Six Sigma to Drive Profit Margins to New Levels. In The New Beginning, Tom Mahanan, Tires for All’s former Director of Finance, who learned how to combine the Theory of Constraints with Lean and Six Sigma, and then applied it to Tires for All, strives to take his company to levels of profitability they had never experienced before. As a reward for his work, Tom was given a permanent seat on the Board of Directors, as long as he continued his improvement work at the remaining portfolio of companies owned by the Board of Directors. Tom performed extremely well, but one day he receives a life-changing phone call from his former mentor, Bob Nelson, the man who he had worked with at Tires for All to make amazing improvements. Bob asks him to play golf with him and two others, Jeff Johnson, from Toner International, and Pete Hallwell, the CFO at Maximo Health Center Complex. Pete and Tom share a golf cart during the round and begin chatting about the work Tom had done at Tires for All and the other portfolio of companies. Pete, who works for a healthcare complex of hospitals, is so impressed with the results Tom had achieved, that he invites him to lunch the following week. Tom accepts his offer of lunch and ultimately, Tom signs a consulting agreement with Pete. Tom had provided an example from a previous improvement effort where he worked with a hospital in Chicago to improve their Emergency Department time for STEMI-type heart attack patients. In his explanation, Tom presents a variety of improvement tools which includes the integration of the Theory of Constraints, Lean, and Six Sigma. Tom then meets with his current employer and specifically, the Chairman of the Board of Directors, Jonathan Briggs, to let him know that he will be resigning to form his own consulting firm. Jonathan then surprises Tom by offering him a consulting agreement to improve all of their portfolio companies. The remainder of the book is all about teaching companies how to combine the Theory of Constraints, Lean, and Six Sigma to obtain optimal results. In the final two chapters, a new problem surfaces, which is the Corona Virus. Essentially, this book teaches the reader how to successfully combine and implement the Theory of Constraints, Lean, and Six Sigma to produce results that many companies only dream of having. It covers a variety of different company types including manufacturing and healthcare.

This book fully details, as the title suggests, the real secret to maximizing an organization's profitability. While many companies have implemented improvement initiatives such as Six Sigma and Lean Manufacturing, there is a missing link which, when discovered and implemented, will take these same companies to profit levels not seen before. This missing link is the Theory of Constraints, and when it’s combined with Lean and Six Sigma, true transformational improvements are sure to follow. In this book, the author walks you through the step-by-step method on how to combine these three methodologies with the result being significant improvements to flow, major improvements in variation, substantial reductions in waste, superior on-time delivery, and ultimately, maximized profitability. He has been using this integrated methodology for many years and each time, the results realized were well beyond what the leadership teams had experienced previously. The genesis behind this combined improvement cycle is based upon many years of analysis of both failures and successes using Lean, Six Sigma, and the Theory of Constraints as stand-alone improvement initiatives. By integrating Lean, Six Sigma and the Theory of Constraints into a single improvement cycle, the author has developed a recipe that will maximize your return on investment, cash flow, and net profit. The Secret to Maximizing Profitability is both stimulating and thought provoking, but more importantly it will provide your organization with a roadmap for maximizing the use of your resources to achieve more bottom-line improvement than you ever imagined possible.

Companies all over the world try their best to improve their business by implementing efforts such as Six Sigma, Lean Manufacturing, or a combination of the two methodologies. Logic would tell you that these two methods would be the right approach because you would have an improvement method that, through Lean, reduces waste and make value flow, while Six Sigma reduces and controls variation. If this were true, then why is it that many of these initiatives simply aren’t delivering quantifiable bottom-line results? After having studied many of these on-going improvement efforts, the author believes that these efforts are missing an important focusing mechanism. That is, most of these improvement efforts attempt to improve "everything" rather than finding that key part of the system that should be assessed and improved, the constraining factor, and then focusing the improvement efforts there and only there. The hallmark of this book is how to first locate this constraining factor and then determine the best way to exploit it to generate extreme profits, radically improve on-time delivery of products or services and increase market share by outperforming your competition at rates you never expected possible. How do we do this? By combining Lean and Six Sigma with the Theory of Constraints. This book demonstrates both the basics of improvement (i.e. results) with the "how to" (i.e. the methodology) in a very simple format that everyone within your organization will understand.

Most books about continuous and process improvement are written in a textbook format with straightforward information and plenty of graphs and charts to convey the points being made. Sometimes, even the best step-by-step instructions can escape even the most adamant of followers for an improvement method in determining exactly how to apply what they’ve learned. Taking a different approach, Focus and Leverage is presented in an engaging business-novel format and is a sequel to the authors’ bestselling book, Epiphanized, Second Edition. The primary characters remain the same, but this time the storyline features two different industries: Maintenance, Repair, and Overhaul (MRO) and Healthcare (hospital) environments. This book expands and highlights the two improvement methods first introduced in the appendix section of Epiphanized: the Interference Diagram (ID)/Intermediate Objectives (IO) map (ID/IO Simplified Strategy) and Multiple-Drum-Buffer-Rope (M-DBR). Both of these innovative methods are the result of some much-focused thinking that allows for multiple improvement methods, and steps, to be combined into a single thinking process tool. This groundbreaking new method is designed to save time and money and allows faster and better results to be achieved. The two storylines move the reader through the necessary system analysis, problem identification, and solution implementation. The novel format aids in presenting several realistic situational discussions as well as a multitude of graphs and figures to explain the step-by-step process for success. The storyline of this book weaves some well-known and some not-so-well-known thinking tools into the problem-solving sphere to provide you with an understanding of how to first discover and then overcome issues not readily known or expected at the start of any project.

"This book fully details, as the title suggests, the real secret to maximizing an organization's profitability. While many companies have implemented improvement initiatives such as Six Sigma and Lean Manufacturing, there is a missing link which, when discovered and implemented, will take these same companies to profit levels not seen before. This missing link is the Theory of Constraints, and when it's combined with Lean and Six Sigma, true transformational improvements are sure to follow. In this book, the author walks you through the step-by-step method on how to combine these three methodologies with the result being significant improvements to flow, major improvements in variation, substantial reductions in waste, superior on-time delivery, and ultimately, maximized profitability. He has been using this integrated methodology for many years and each time, the results realized were well beyond what the leadership teams had experienced previously. The genesis behind this combined improvement cycle is based upon many years of analysis of both failures and successes using Lean, Six Sigma, and the Theory of Constraints as stand-alone improvement initiatives. By integrating Lean, Six Sigma and the Theory of Constraints into a single improvement cycle, the author has developed a recipe that will maximize your return on investment, cash flow, and net profit. The Secret to Maximizing Profitability is both stimulating and thought provoking, but more importantly it will provide your organization with a roadmap for maximizing the use of your resources to achieve more bottom-line improvement than you ever imagined possible"--