1st Edition

The Ultimate Improvement Cycle
Maximizing Profits through the Integration of Lean, Six Sigma, and the Theory of Constraints

ISBN 9781420090345
Published March 11, 2009 by Productivity Press
288 Pages 54 B/W Illustrations

USD $84.95

Prices & shipping based on shipping country


Book Description

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).

Table of Contents

The Ultimate Improvement Cycle
Lean, Six Sigma and TOC Principles, Tools and Methods
Identifying the Value Stream, Current and Next
Define, Measure & Analyze NVA Waste, Variation
Planning How to Exploit the Current Constraint
Reducing Waste and Variation in the Current Constraint
Plan How to Subordinate Non-Constraints to the Current Constraint
Line Balancing and Flow Optimization
Optimize the Constraint Buffer and Establish Pull System in the Non-Constraints
Elevate the Constraint and Implement Protective Controls
Breaking the Current Constraint
Implement Protective Controls to Sustain the Gains
System Constraints and Problems
Establishing the Environment for Change

View More



Kennesaw, Georgia, USA