Theory of Constraints applied to a EPS foam manufacturer

Abstract

This article aims to evaluate applicability of the Theory of Constraints (TOC) within the logistics subcategory, the Drum-Buffer-Rope (DBR). A case study of the production of expanded molded polystyrene (EPS), in a company located in the northeast region of Brazil, was performed with focus on five steps of the TOC. The data collected in the survey made it possible to evaluate and compare the demand with the constraint process and apply, in a diagram format, the operation of DBR. This diagram has resulted in the review of the production process: identify ideal spots for buffers and scaled it up the rope needed for system optimization to operate synchronized with minimal in-process inventory. In addition, the use of TPC system provided the critical ability for creating control points, improving the deployment process of the system. It is concluded that once the bottleneck is defined, we can propose improvements that it can imply that will be reflected in the global process.

Keywords

• EPS
• Theory of Constraints
• Drum-Buffer-Rope