Application of the Theory of Constraints for Capacity Requirements Analysis: A Case Study

The project client, for this case study, would like to move toward the manufacturing strategy of Continuous Flow Manufacturing. This philosophy concentrates on maximizing throughput while simultaneously reducing inventory and operating expense. The initial phase of the project addressed the documentation of the production process at the company, and identification of process constraints. A constraint analysis was conducted using a set of linked Excel worksheets. In parallel, an analysis of quality defect causes was accomplished. Based on feedback from company management, a set of follow-on projects, regarding the Finishing Department, were determined. These included an analysis of labor cost drivers, and analyses of the hazing and sanding processes. Recommendations for improvement were established for these manufacturing processes.