How does lean synchronization compare with other approaches?
■ There are other approaches that attempt to perform the same function as lean synchronization.
Two alternatives to lean synchronization as a planning and control method are the theory of
constraints (TOC), and material requirements planning (MRP).
■ Although both TOC and MRP may seem to be different approaches, they can be combined.
■ The way in which they can be combined depends on the complexity of product structures, the
complexity of product routeing, the volume–variety characteristics of the operation and the
level of control required.
‘There must be a better way of running this place!’, said
Dean Hammond, recently recruited General Manager of
B&B, as he finished a somewhat stressful conversation
with a complaining customer, a large and loyal local building
contractor. ‘We had six weeks to make their special
staircase, and we are still late. I’ll have to persuade one of
the joiners to work overtime this weekend to get everything
ready for Monday. We never seem to get complaints about
quality . . . our men always do an excellent job, but there is
usually a big backlog of work, so how can we set priorities?
We could do the most profitable work first, or the work for
our biggest customers, or the jobs which are most behind.
In practice, we try to satisfy everyone as best we can, but
inevitably someone’s order will be late. On paper, each job
should be quite profitable, since we build in a big allowance
for waste, and for timber defects. And we know the
work content