Most readers are at least familiar with continuous improvement programs such as lean and six sigma. Perhaps your shop or company is well along in the implementation of one or the other—if not both. But what about theory of constraints (TOC), introduced in Dr. Eliyahu Goldratt’s 1984 book, The Goal? Despite its rather negative-sounding name, this continuous improvement process has much to offer manufacturers of all stripes. And when combined with lean and six sigma, the results can be dramatic. Dr. Lisa Lang, a TOC consultant and speaker, explains why and how in the following Q&A session with Gear Technology.

How lean manufacturing principles can help transform your gear manufacturing business.

For many in the gear and gear products business, these may seem like the best of times...

The gear companies enjoying the most success in today’s global market are those that firmly believe quality is much more than expert craftsmanship and foolproof inspection methodologies.

While universally known as a Japanese “invention” that was popularized by Toyota, lean in fact traces its roots to the work of post-World War II American occupation forces in Japan.

Google “lean manufacturing” and you will find a virtually endless font of information regarding formal lean implementation. You’ll see definitions for Japanese words such as kaizen, gemba, muda, mura, kanban, and so on. You will also find other variations or iterations of lean, e.g.: Six Sigma, Lean Sigma, TPS (Toyota Production System), TOC (Theory of Constraints), JIT (Just in Time), and others.

POLCA: An alternative to Kanban for high-variety or custom-engineered products.

A look at three gear industry companies at varying stages in the journey.