Your plant's dashboards are green. Utilization is on target, downtime is inside tolerance, and the operation still cannot ship more. So a capital request goes to the board for equipment the plant may not need. After forty-seven years walking manufacturing operations, Trevor Cusworth has found the same pattern almost everywhere: the constraint limiting output is rarely the station everyone blames, and the measurement systems most plants run on were designed for a manufacturing world that no longer exists. Where's Your Herbie? translates Goldratt's Theory of Constraints for the plant you actually run — two hundred SKUs, constant changeovers, a constraint that moves with the mix. It gives you the seven places constraints hide, a diagnostic you can run in a single walk of your plant this week, and Zero Loss Analysis: a method for quantifying exactly what the gap is costing, in hours and in cash. Most plants are running at sixty to eighty percent of what they already own. This book is about finding the other twenty.
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