26th International Conference of the

TOC Practitioners Alliance - TOCPA

www.tocpractice.com

19-20 May 2016, Fukuoka, Japan

TOC
- (MTO)(MTA)
Using TOC Replenishment to transform production from MTO to MTA

/
19 th May, 2016


Junichi Sato

1991
2008

2012

Junichi Sato is the project leader of Logistics reforming project of YAMAHA

KUMAMOTO PRODUCTS Co., Ltd.
He joined YAMAHA in 1991, and was engaged in Production Planning and IT.
He was involved in SAP implementation at that time.

Junichi_Sato@y-k-p.co.jp

In 2008, he became a manager and integrated Production Planning and IT

departments for the sake of improving production performance through making
full use of IT.
In 2012, he was in charge of Management Planning for achieving the
companys vision and strategy of creating a unique production system that any
competitors cant do. For that, he conducted MTA Implementation in 2013.
He is currently preparing for the next challenge DTA implementation.
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26th International Conference of the TOC Practitioners Alliance - TOCPA

180

MTO

20132MTIA - Make to Internal Availability

2
MTIAIT

MTOMTA
Win-Win
&
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26th International Conference of the TOC Practitioners Alliance - TOCPA

MTOMTA

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26th International Conference of the TOC Practitioners Alliance - TOCPA

www.tocpractice.com

26th International Conference of the TOC Practitioners Alliance - TOCPA

1998(10)11
49,000

556

218

YKP

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26th International Conference of the TOC Practitioners Alliance - TOCPA

99

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180

26th International Conference of the TOC Practitioners Alliance - TOCPA

5,500

*
(312H)

122

CCR
390

100

425

445

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th

26 International Conference of the TOC Practitioners

Alliance - TOCPA

MTOMTA

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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TPM
2006

10

2000

2010

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TOC

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11

UDE

/ave.

1
15
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26th International Conference of the TOC Practitioners Alliance - TOCPA

12


MTIA Make to Internal Availability

Availability

PTA

MTIA

PTA

X4

SFWH

X180

MTIA
SFWH Semi-Finished Goods Warehouse
PTA Purchase to Availability

CKD
Complete Knock-Down

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26th International Conference of the TOC Practitioners Alliance - TOCPA

13

Gate3

Gate1

Gate2

Gate4

TrT
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MTOMTA

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MTIA
2012
1

2013
8

10

11

&

by Juntos

12

MT*

MT

WS

WS

MT MT1

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26th International Conference of the TOC Practitioners Alliance - TOCPA

16

Juntos

PSNC

Juntos

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MTIA

MTIA

MTIA

MTIAIT

MTAMTO
IT

IT
IT
1

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26th International Conference of the TOC Practitioners Alliance - TOCPA

19


1.

100

20
93
10

MTIA
MTIA
MTIA
MTIA DIOH

2. RRT
Reliable Replenishment Time

3.
4. 2Excel
SKU

WO

SKU ID

JB8

JB9

SC1

30
6.0
80.0%
3.0

63
20.0
68.3%
2.5

9
0.0
100.0%
6.6

Name

Line

Type

68S-11

JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8
JB8

MTIA

68S4594200YY80

68U4594200YY80

68U-9

68V4594200YY80

68V-17

68V4594400YY80

68V-19

69G4594200YY80

69G-5-3/4

69G4594400YY80

69G-7

69W4594400YY80

69W-15

69W4594600YY80

69W-13

69W4594800YY80

69W-11

10

69W4595300YY80

69W-12

11

69W4595900YY80

69W-14

12

6E54594200YY80

6E5-19

13

6E54594400YY80

6E5-21

14

6E54594601YY80

6E5-17

15

6E54594800YY80

6E5-15

16

6E54595100YY80

6E5-13

17

6E54595300YY80

6E5-23

18

6E54595500YY80

6E5-11

19

6E54595700YY80

6E5-25

20

6E54595900YY80

6E5-14

21

6G54594200YY80

6G5-15

22

6G54594401YY80

6G5-21

23

6G54594601YY80

6G5-19

24

6G54594801YY80

6G5-17

25

6G54595100YY80

6G5-23

26

6G54595300YY80

6G5-16

27

6G84594800YY80

6G8-9-1/4

28

6J84594210YY80

6J8-8-1/4

29

6K14594600YY80

6K1-19

30

6K14594800YY80

6K1-17

MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA
MTIA

SKU

(TL)

414
244
49
36
414
3,618
515
2,274
1,343
1,872
278
966
323
1,801
3,709
1,156
40
618
3
423
481
65
472
552
19
99
251
76
87
97

(OH)

10
8
5
2
11
50
37
613
592
48
62
86
352
181
67
28
3
21
4
19
15
6
15
13
6
11
20
7
13
14

98%
97%
90%
94%
97%
99%
93%
73%
56%
97%
78%
91%
-9%
90%
98%
98%
93%
97%
-33%
96%
97%
91%
97%
98%
68%
89%
92%
91%
85%
86%

WO
(WIP)

(on request)
(in)
(out)

428
254
111
168
434
3,618
527
1,584
848
1,831
507
647
446
1,620
3,445
1,154
66
612
35
579
487
109
541
680
60
95
264
127
96
102

5.

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26th International Conference of the TOC Practitioners Alliance - TOCPA

20

-24
-18
-67
-134
-31
-50
-49
77
-97
-7
-291
233
-475
0
197
-26
-29
-15
-36
-175
-21
-50
-84
-141
-47
-7
-33
-58
-22
-19

0
0
0
0
0
0
0
0
0
0
0
96
0
0
480
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
12
143
150
0
0
350
0
58
134
21
0
2
0
0
0
0
0
124
0
0
0
0
0
0

DIOH

17
5
3
3
3
32
5
144
114
106
18
45
3
58
114
54
0
14
0
13
6
2
9
8
0
1
4
0
2
1

0.6
1.8
1.7
0.6
3.9
1.6
7.5
4.3
5.2
0.5
3.4
1.9
136.9
3.1
0.6
0.5
10.5
1.5
0.0
1.4
2.4
3.5
1.7
1.7
63.0
7.5
5.5
21.0
7.0
12.8

MTOMTA

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26th International Conference of the TOC Practitioners Alliance - TOCPA

21

IT

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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MTO

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PIVOT
?

WO

WO

WO

WO

WO Work Order

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26th International Conference of the TOC Practitioners Alliance - TOCPA

24

MTIA Rule 1:

WIP

WIP

WIP

WIP

On-Hand
WIP

OH

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26th International Conference of the TOC Practitioners Alliance - TOCPA

25

MTIA Rule 2:

WO

MTIA:

SFWH

WO

SFWH Semi-Finished Goods Warehouse

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MTIA Rule 3:

100~78%

78~34%

33~0%

BM
WO

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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MTOMTA

Win-Win

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MTIA

TPM

MTIA

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29



Before

After

DBM

DIOH

WO

/
2

APS

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26th

International Conference of the TOC Practitioners Alliance - TOCPA

30

MTOMTA

MT

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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PJ

Injection:

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MTOMTA

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26th International Conference of the TOC Practitioners Alliance - TOCPA

33

 DIOH

DIOH

DIOH

100.0%

10.0

100.0%

20.0

90.0%

9.0

90.0%

18.0

80.0%

8.0

80.0%

16.0

70.0%

7.0

70.0%

60.0%

6.0

60.0%

14.0
12.0

50.0%

5.0

50.0%

10.0

40.0%

4.0

40.0%

8.0

30.0%

3.0

30.0%

6.0

2.0

20.0%

4.0

72% 82%

1.0

10.0%

DIOH

0.0

0.0%

2013/07/29

2013/07/25

2013/07/23

2013/07/18

2013/07/16

2013/07/11

2013/07/04

2013/07/02

2013/06/28

2013/06/26

2013/06/19

2013/06/17

2013/06/13

2013/06/11

2013/06/06

2013/06/04

2013/05/31

2013/05/29

2013/05/27

3.1d 4.3d
2013/05/23

2013/05/21

2013/05/17

2013/05/15

2013/05/13

2013/05/09

2013/05/07

2013/04/25

2013/04/23

2013/04/19

2013/04/17

2013/04/15

2013/04/05

2013/04/03

2013/04/01

2013/03/28

2013/03/26

2013/03/22

0.0%

2013/04/09

10.0%

2013/04/11

20.0%

92% 92%

2.0

DIOH

0.0

6.7d 8.1d

93 8
DIOH1/
DIOH Days Inventory On-hand
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26th International Conference of the TOC Practitioners Alliance - TOCPA

34

20

12
1 7 .6
18

1 0 .2
10
16
14

7 .5

1 2 .7
12
1 0 .6

6 .1
6

10
9 .2
8
6 .4

4
3 .8
6
4

0
0

. .

www.tocpractice.com

. .

26th International Conference of the TOC Practitioners Alliance - TOCPA

35

4000

80

4000

3500

70

3500

30

25
3000

60

Ave

3000

Ave
2500

20

50

2500
2000

40

Ave

1500

Ave

2000

15

30

1500
10

MTIA 2 0

1000

500

1000

500

MTIA5

10

2528 1827

www.tocpractice.com

/ /

2609 1668

20137

20136

20135

20134

20133

20132

20131

201212

201211

20129

201210

20128

20127

20126

20125

20124

20123

20122

20121

20137

20136

20135

20134

20133

20132

20131

201212

201211

20129

201210

20128

20127

20126

20125

20124

20123

20122

0
20121

/ /

26th International Conference of the TOC Practitioners Alliance - TOCPA

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After

Before

AB

Before

www.tocpractice.com

After

WO1 WO2 WO3

WO1 WO2 WO3

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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18 9

8.6

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26th International Conference of the TOC Practitioners Alliance - TOCPA

39


70% 90%

95

5keep

300

263
251

263 98

250

227
220
195

200

183
156

150
136
150

124
114

100

98
87

71

90

80
75

71

57
50
60
41

50

26
16
0
1

2013

www.tocpractice.com

2014

2013

26th International Conference of the TOC Practitioners Alliance - TOCPA

10

11

12

2014

40

MTOMTA

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26th International Conference of the TOC Practitioners Alliance - TOCPA

41


MTIAMTA/DTA

Replenishment Time

Phase 3

Phase 2

Phase 1
MTIA Make to Internal Availability

MTA Make to Availability

DTA Distribute to Availability

RWH

RWH

SFWH

CWH

RWH
RWH

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SFWH Semi-Finished Goods Warehouse

CWH Central Warehouse
RWH Regional
Warehouse
42
26th International Conference of the TOC Practitioners
Alliance
- TOCPA

MTOMTA

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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TOC

CCPMTOC
DTACCPMViable VisionS&TTOC

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26th International Conference of the TOC Practitioners Alliance - TOCPA

44

Special Thanks!!
Goldratt Oded Cohen

JUNTOS

PSNC

!?

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