Roy Stratton

The strategic integration of agile and lean supply

Lean supply is closely associated with enabling flow and the elimination of wasteful variation within the supply chain. However, lean operations depend on level scheduling and the growing need to accommodate variety and demand uncertainty has resulted in the emergence of the concept of agility. This paper explores the role of inventory and capacity in accommodating such variation and identifies how TRIZ separation principles and TOC tools may be combined in the integrated development of responsive and efficient supply chains. A detailed apparel industry case study is used to illustrate the application of these concepts and tools.

Questioning the relentless shift to offshore manufacturing

A device for providing a voltage indicating the angular velocity of rotation of the armature in a limited rotation, polarized, moving iron galvanometer. The device includes a means for providing a first voltage dependent upon the angular velocity of the armature, the self-inductance of the galvanometer drive coil, and the drive current in the drive coil. A compensation coil is magnetically coupled to the drive coil and magnetically isolated from the effects of the rotating armature to provide a second voltage which is dependent upon mutual inductance between the drive and compensation coils and upon the drive current, but is not dependent upon the effects of the rotating armature due to the magnetic isolation of the compensation coil from the armature. A combining means proportionally combines the first and second voltages to provide a voltage indicating the angular velocity of rotation of the armature. The means for providing the first voltage includes either the drive coil, with the first voltage appearing across the drive coil, or a pickoff coil wound coaxially with and adjacent to the drive coil so that the first voltage appears across the pickoff coil and is proportional to the voltage appearing across the drive coil. The velocity signal thus derived is introduced to the drive circuit to provide effective damping.

The optimal quantity of quick response manufacturing for an onshore and offshore sourcing model

Consumer demand for innovative and fashion products is highly unpredictable, but could be fulfilled through quick response manufacturing (QRM). However, the extra cost is usually considered to be a barrier to such an approach. The newsvendor algorithm is applied to demonstrate that a strategic combination of onshore and offshore manufacturing can be more profitable than a 100% offshore approach, highlighting the growing importance of a cost versus response trade-off. The optimal split between onshore and offshore manufacturing is calculated. We discuss the successful application of the QRM model in two practical cases: quick response manufacturing for athletic wear; and onshore garment dyeing versus offshore yarn dyeing. In the right context, QRM is a viable and profitable option. Issues in the practical application of the model are discussed.

Managing patient flow using time buffers

Purpose – The purpose of this paper is to determine how and why theory of constraints based time buffer management has contributed to improved patient flow in health and social care applications.Design/methodology/approach – The focus of the research is on the application and implementation of time buffer management by QFI Consulting. Four UK hospital implementations of the QFI Jonah software and methodology were investigated to establish how buffer management was being applied and why the reported benefits were being achieved. This involved collecting service delivery data together with semi‐structured interviews. To support this evaluation, four control functions of time buffer management have been identified as a basis for evaluation of the application designs and their implementation.Findings – Case research evidence shows significant and rapid improvement in length of stay (LOS) following implementation of the approach, amounting to a reduction in LOS of over 20 per cent and significantly improved ac...

Variation and uncertainty buffering: a grocery supply case

Purpose – The key constructs and causal relationships underpinning supply chain dynamics have long been established but this understanding is not readily related to more recently developed supply chain models and theory. The purpose of this paper is to use a case to investigate how selected constructs (variation, uncertainty, performance trade‐offs and buffering mechanisms) may be used to show the dominant causal relationships and through that enhance the theoretical explanation of such models.Design/methodology/approach – The paper uses a single case study that was selected because the transition in supply chain management strategy clearly questioned the need for improved causal reasoning. The case research sources include interviews, temporal performance data and multiple site visits across three echelons of the supply chain.Findings – The cause and effect logic underpinning the case transition have been explained and mapped using these constructs which have then been used to propose enhancements to the...

Agile manufacturing and constraints management: a strategic perspective

The definition of the agile paradigm has proved elusive and is often viewed as a panacea, in contention with more traditional approaches to operations strategy development and Larkin its own methodology and tools. The Theory of Constraints (TOC) is also poorly understood, as it is commonly solely associated with production planning and control systems and bottleneck management. This paper will demonstrate the synergy between these two approaches together with the Theory of Inventive Problem Solving (TRIZ), and establish how the systematic elimination of trade-offs can support the agile paradigm. Whereas agility is often seen as a trade-off free destination, both TOC and TRIZ may be considered to be route finders, as they comprise methodologies that focus on the identification and elimination of the trade-offs that constrain the purposeful improvement of a system, be it organizational or mechanical. This paper will also show how the TOC thinking process may be combined with the TRIZ knowledge based approach and used in breaking contradictions within agile logistics.