Epiphanized: A Novel on Unifying Theory of Constraints, Lean, and Six Sigma, Second Edition

  • 7h 7m
  • Bob Sproull, Bruce Nelson
  • CRC Press
  • 2015

Updating the tools, principles, and methods presented in the bestselling first edition, this updated edition explains how to implement the authors’ proven improvement methodology that unifies the Theory of Constraints with Lean and Six Sigma. The book uses a compelling novel format to demonstrate how to achieve superior on-time delivery along with unprecedented levels of profitability.

Besides explaining how to implement the authors’ unified improvement methodology, the book arms readers with a proven method for convincing management that using the improvement methodology outlined in the text will lead to significantly higher levels of profitability.

This edition has been updated with an expanded appendix that includes more in-depth discussions of the tools covered in the first edition. This edition also sheds more light on the reasoning behind why the very best improvement results can be achieved by the unification of the Theory of Constraints, Lean, and Six Sigma (TLS). The appendix also provides additional detail about how the concepts covered in the book can be applied to your organization.

The primary theme throughout this book is the focus on the unity and enhancement of improvement tools and methods. The book includes an appendix that allows readers to explore, in much more detail, the principles, tools, and techniques presented in the novel portion of the book.

The authors detail a pioneering pathway for significant gains in profitability and market share for any company choosing to implement the methodologies that are presented. Some of the concepts, tools, and principles presented may seem counterintuitive to many readers, but if the principles are understood and followed, the exceptional results are sure to follow

About the Authors

Bob Sproull is an independent consultant who, along with Bruce Nelson, owns and operates Focus and Leverage Consulting, a management consulting firm specializing in improving the profitability of organizations from all business sectors. Bob is a certified Lean Six Sigma Master Black Belt and a Theory of Constraints Jonah and an experienced manufacturing executive who has served as a vice president of quality, engineering, and continuous improvement for two different manufacturing companies, with extensive consulting background in manufacturing, healthcare, and MRO and focuses on teaching companies how to maximize their profitability through an integrated Theory of Constraints, Lean and Six Sigma (TLS) improvement methodology. Bob completed his undergraduate degree (BS) with a dual major in math and physics and is a nationally known speaker and the author of three different books: Epiphanized: Integrating Theory of Constraints, Lean and Six Sigma (co-authored with Bruce Nelson 2012, North River Press); The Ultimate Improvement Cycle – Maximizing Profits Through the Integration of Lean, Six Sigma and the Theory of Constraints (2009, Taylor and Francis); Process Problem Solving – A Guide for Maintenance and Operation’s Teams (2001, Productivity Press).

Bruce Nelson is an independent consultant who, along with Bob Sproull, owns and operates Focus and Leverage Consulting, a management consulting firm specializing in improving the profitability of organizations from all business sectors. Bruce is an internationally recognized expert in constraints management and systems analysis. He is a certified Jonah, Jonah’s Jonah, Academic Jonah, and is Board Certified by the International Certification Organizations (TOCICO) in the TOC Thinking Processes, TOC Operations Management, and TOC Project Management and has B.S. degrees, in chemistry, zoology, and allied health, Weber State University, Ogden, Utah (1982). Bruce has 32 years combined experience as an educator, executive, and consultant with many Fortune 500 companies and several international companies. Bruce has an extensive consulting background in manufacturing, production, seminars, and workshops focusing on teaching how to maximize profitability through an integrated Theory of Constraints, Lean and Six Sigma (TLS) improvement methodology. Bruce is the co-author of Epiphanized: Integrating Theory of Constraints, Lean and Six Sigma (co-authored with Bob Sproull, 2012, North River Press). Bruce also has articles published from previous process improvement engagements.

In this Book

  • Epiphanized──Theory of Constraints, Lean, and Six Sigma, Second Edition
  • Foreword
  • Preface
  • Joe’s First Day
  • Joe’s Second Day
  • Joe’s Meeting with Connor
  • Joe’s Meeting with the Vice President of Operations
  • Sam and Connor Meet
  • The Strategy Session at Jonah’s
  • The Second Meeting with Connor
  • The Interference Diagram
  • The Meeting with Jerry
  • Becky Meets Connor
  • Another Meeting at Jonah’s
  • The Parts Issue
  • Fabrics-R-Us
  • Training Fabrics and Greg
  • Performance Metrics
  • CCPM─Part 1
  • CCPM: Part 2
  • Joe and Sam’s Trip to Corporate
  • The Corporate Purchasing Team
  • Connor Goes to Simco
  • The Finale
  • TLS Overview
  • The Systems Thinking Tools
  • Performance Metrics Using Cost Accounting (CA) and Throughput Accounting (TA)
  • TOC Distribution and Replenish Model
  • Drum–Buffer–Rope (DBR)
  • Critical Path Method (CPM) versus Critical Chain Project Management (CCPM)
  • The Interference Diagram (ID)/Intermediate Objectives (IO) Map
  • Systems Analysis
  • Supplemental Thinking Tools
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