23rd International Conference of the

TOC Practitioners Alliance - TOCPA

www.tocpractice.com

21-22 March, 2016, Tennessee, USA

Fast TOC
How to Implement CCPM & DBR
In One-Third of the Time
With Team Buy-In

Gerry Kendall & John Zahora, TOC International, USA

March, 2016

Gerry Kendall / John Zahora

22 years successfully implementing TOC
worldwide after 25 year business career
Author of 5 TOC books;
Married to Jackie;
5 Children & 7 Grandchildren, so far!
gerryikendall@cs.com

TOC, Lean, Six Sigma Expert;

Extensive experience implementing all
TOC applications
25+ years success with focused system
improvement;
Lead singer in a Rock Band!
jczahora@aol.com
www.tocpractice.com

23rd International Conference of the TOC Practitioners Alliance - TOCPA

The Premise
Assumption: We have enough application knowledge to last
the next 20 years.
The constraint of any TOC implementation is the speed:
To fully implement
To get top management and implementation team buyin
For the organization to absorb knowledge
All of the above impacts the time needed to get bottom line
results

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

CCPM Pre-work
1. Data Gathering: Prove the benefits, get ammunition for
top management.
2. Top Management Buy-In: 4 hours, I use a combination of
Vision (based on past results), Statistics (Exepron
Simulators) and Multitasking Exercise.
3. CCPM Training: Maximum 1 Day. Dont kill them with
everything you know, just enough to get started.
4. Homework for top executive:

Set the Goal Statement in terms of T, I, OE, Project metrics

Define the implementation team and free up 33% capacity for 8
weeks

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

CCPM Rapid S&T

Overlapped Teams Working in Parallel
Technical Team
Project Networks & templates

Synchronization

Resource Pools

Schedule analysis / compression

Software

What if Analysis

Buffering

Software updates

Software reporting

Organization Team
Fast Track Issue Resolution

Daily Updating

Full Kit

Project Recovery

Freeze

Task time estimating

Synchronization control

Training & Audits

Task assignment

Resourcing of projects

Single Priority System

Long term resourcing

Full Rapid S&T Available Request from Gerryikendall@cs.com

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

CCPM Day 1
1. 4-8 Hours Network Building First Project: They are
already implementing their first project on Day 1!
2. Activate the project in Exepron.
3. If the Project Manager is not on the implementation team,
train them to do the daily updates and provide feedback
(30 minutes).
4. Both the Technical and Organization Teams participate,
since the first step of Network Building requires Full Kit,
stakeholder goals, scope and tangible success criteria,
impact on T, I, OE.
See Advanced Multi-Project Management Kendall & Austin
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23rd International Conference of the TOC Practitioners Alliance - TOCPA

CCPM Day 2 Go Live

1. Set Go Live Date.
2. Technical Team does Technical Work split and
allocated to team members. If there are many projects,
train more team members in Network Building
3. Organization Team does Organization Work split
policies between team members.
4. Reconvene joint meetings every few days to share and
get feedback.
5. Full Go Live, with all projects and policies activated Maximum 2 months after kick-off.
Implementation Team is engaged from the beginning.
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23rd International Conference of the TOC Practitioners Alliance - TOCPA

CCPM Results
1. 1998 My First CCPM Implementation 8 months, half
the time struggling with software.
2. 2009 - Many implementations later 4 months, painful
S&T, still struggling with software, batch updates, all
technical work done by consultants for first 3 months.
3. 2016 Live on Day 2 with one project, big learning curve
starts on Day 2 and builds, Client does all the software
work from Day 1 with no formal software training, Full
Live within 2 months.

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

CCPM Results
Thanks for the great recap and what I believe has been a great
growth and learning experience for the Project Team at Helion.
Your commitment to our successful implementation is inspiring.
Knowing the team, I am sure that they have all thanked you for
bringing this new way of operating to us. However, let me thank
you as well on behalf of all of us you have most certainly
exceeded our expectations.
Erik Nachbar, President, Helion Technologies
February 2016

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

DBR Fast and Good

Whole
Pain/Purpose $/
Base / Plan /
Buy-In

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Parts
Plan Plan/
Process/Metrics/
R&Rs

Whole
Approval/ Scary
Date/ Audit/
Improve

23rd International Conference of the TOC Practitioners Alliance - TOCPA

Whole
Pain/Purpose $ Base - Go/ Team
Buy-In / Plan
Understand the
Pain
HELP !!

Whole

Parts
Plan Plan/ Process/
Metrics/ R&Rs

Purpose $Base- Go

Approval/ Scary
Date/
Audit/Improve
Team Buy-In training/ Implementation Plan- review

High Level DBR

overview
T ; I ; OE
The predicted impact
if we implement DBR

DBR training- simulator

relate to our system

Review implementation plan

block, adds for us
Duration thoughts

Rough outline high level current state flow/policies

how things flow , under what rules

Logic- Root Cause = DBR

Look at operation as a system
1st time, global view

Base understanding of DBR and

T Acct.
scratch their heads on some
Understand what is driving issues
decisions, now and future, might
stop hurtful symptom chasing
hold off or change some
decisions immediately
Understand the Pain

Phone calls
with ops
leader; day
visit (maybe)

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Gain understanding of DBR and T Acct. and how it applies to us.

Production Mgrs; production Control; Floor leaders start to
understand how the system will work and how certain policies are
killing flow. They start thinking about T;I;OE measures and look
very hard at: Batching rules; need for immediate lean mfg help
THINGS START TO CHANGE

Team Buy-In/ Plan

Purpose/ go

1 Day
with Staff

3 Days

23rd International Conference of the TOC Practitioners Alliance - TOCPA

Whole
Pain/Purpose $/
Plan/ Buy-In

Current
State/As-IS
Current System

Future/To-Be
Metrics/R&Rs
/ IT

Parts
Plan Plan/Process /
Metrics/R&R

Design Approval

Whole
Approval/ Scary
Date/ Audit /
Improve

Design "Turn on"

Sustain Audits/
Improve

Clear roadmap for implementation

Parts
Plan Plan/Process / Metrics/R&R

1 Week

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1 Week

1 Week

1 Week

2 days

23rd International Conference of the TOC Practitioners Alliance - TOCPA

Whole
Pain/Purpose $/
Plan/ Buy-In

Base Training

Current
State/As-IS
Current System

Whole

Parts
Plan Plan/Process /
Metrics/R&R

Future/To-Be
Metrics/R&Rs
/ IT

Design Approval

Approval/ Scary
Date/ Audit /
Improve

Design "Turn on"

Sustain Audits/
Improve

FAST alignment:
DBR Process Swim Lane

Very clear Roles and

Responsibilities to sustain tobe system, who does what,
when, in the DBR operating
system.
Many times the 1st time ever
the System has been
aligned.
( does it matter ?)

Catch holes in implementation (people, documentation, IT needs, ect.)

Thinking shifts even more
How do I fit ( thats all I really care about)
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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Whole
Pain/Purpose $ Base - Go/ Team
Buy-In / Plan

Base
Training

Current
State/As-IS
Current
System

Future/To-Be
Metrics/R&Rs
/ IT

Whole

Parts

Approval/ Scary
Date/
Audit/Improve

Plan Plan/ Process/

Metrics/ R&Rs

Design
Approval

Design
"Turn on"

Sustain Audits/
Improve

Step 1;2;3.
T + 30%; I- (25%); OE- (0)
Go LIVE 4/26

Design approved
Additional training
Metrics changed
Policies; R&Rs updated
IT / support working
Valium script filled

Future state documented

Impact estimated
Go Live date agreed upon

FocusedSustainable
Bottom Line impact
Audit--Improve

Approval/ Date

3-4 Days

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3-6 weeks

2 days

23rd International Conference of the TOC Practitioners Alliance - TOCPA

DBR Summary- so how long?

No piecemeal, NO false starts. Plan upfront, implement as planned---- go big or go home

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

DBR Typical Results

We all know,
Question is why more
companies arent taking
this path to great results
After a successful implementation, what next ?
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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Celebrate with a good band.

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23rd International Conference of the TOC Practitioners Alliance - TOCPA

Questions

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23rd International Conference of the TOC Practitioners Alliance - TOCPA