3 Day Theory of Constraint Workshop with Process Simulation


The objective of the 3 Day – Theory of Constraint (TOC) Workshop is to develop participant skills and knowledge to a level where they can effectively plan and deliver products or services with the minimal amount of firefighting, and with a memorable amount of upturn in customer satisfaction.

The workshop has been developed to be delivered over a period of 3 Days, starting with an Efficiency Works process simulation program, moving into a Value Stream Mapping (VSM) Exercise, and concluding with a Theory of Constraint (TOC) program. It is intended that the program serve as a team building exercise for participants to broaden their knowledge, gain an improved understanding of the tools and identify the skills required to manage and implement continuous improvement through company values.

Efficiency Works Process Simulation

The Process Simulation workshop is a mechanism to explore and discuss Lean principles and how they can be most effectively applied to operational and administrative processes. It conveys many concepts in a memorable and effective manner and the hands-on nature of the workshop makes it an ideal learning tool. Concepts and techniques are vividly illustrated through practical application in an environment where people learn by doing.

The simulation workshop is designed to challenge conventional thinking about how processes are designed.

As a group, participants run two to three iterations of the same simulated business process, with a gradual and staged introduction of Lean tools and principles. At the end of each process run, we facilitate an assessment of the participants’ assigned roles as well as and the efficiency and effectiveness of the process as seen from organisational and customer perspectives.

Participants identify wasteful practices and aspects of the process that could be improved, and our facilitator provides training on the appropriate Lean tools that can be applied in the subsequent process run. Progress is monitored throughout the workshop by measuring different aspects of the group’s performance including:

  • Process lead-time
  • Value added ratio of the process
  • Service & financial outcomes
  • Workplace organisations
  • Maturity in a selection of practices

The workshop allows participants to experiment with the application of World Class continuous improvement techniques in a simulated environment before exploring how the simulation parallels issues found in their own workplaces.

Participant knowledge and skills are gradually increased, allowing them to see a direct correlation between the application of Lean and a resulting productivity improvement.

Participants learn the basic principles of the following Lean tools and techniques:

  • Value Stream Mapping provides participants with a basic understanding of process analysis and describes value-adding activity, identifies waste, and identifies business improvement opportunities
  • 7 Wastes helps identify Value Adding and Non-Value Adding process activities
  • Kaizen this concept covers a very action-oriented culture with many small process improvements and changes using high levels of input from frontline team members, resulting in good solutions and a high degree of ownership
  • DMAIC/Root Cause Analysis/Problem Solving (Define, Measure, Analyse, Improve, Control). Provides a structured and repeatable way to solve problems and sustain the outcomes
  • Visual Management shows participants a communication tool that helps to visualise workflow, monitor performance, and identify and solve problems
  • 5S demonstrates how to improve the workplace by simplifying, organising, and sustaining a productive work environment
  • Just In Time helps participants understand the benefits of providing products and services only as required by customer demand
  • Leadership & Teamwork demonstrates how leadership and working as a team has a direct impact on productivity, team morale and workplace culture
  • Theory of Constraints provides a basic understanding of a methodology for identifying the most important factor that stands in the way of achieving the group’s goals
  • Performance Measurement develops an understanding of how to collect, analyse and report information and the value of measuring performance
  • Lean Office / Lean Administration develops an understanding of how the Lean tools and techniques can be applied in an office or administrative environment

Value Stream Mapping

Value-stream mapping, also known as “material – and information-flow mapping”, is a lean-management method for analysing the current state and designing a future state for the series of events that take a product or service from the beginning of the specific process through to the customer. Rarely is the big picture seen or understood by staff using any other methodology.
To accommodate this program with-in the 3 Day Theory of Constraint workshop Efficiency Works would like to work with the client on a process that is impacting the business which will be used through to completion of the workshop.

Value Stream Mapping offers several advantages over other process mapping tools, for example:

  • Tracks value added time and non-value-added time
  • Utilises process data such as cycle times, setup times and throughput rates
  • Considers available capacity at resources
  • Identifies the source and reasons for many types of waste
  • Provides a mechanism to plan improvements to the mapped process
  • Provides a mechanism for tracking the impact of changes to the process

The expected Benefits of using Value Stream Mapping are:

  • Improved lead times
  • Improved throughput
  • Increased capacity and service levels
  • Savings in time and resources
  • Improved financial performance
  • Reduced working capital (e.g., assets, inventory, materials, etc.)
  • Enhanced skills that can be applied to future Value Stream Mapping
  • Develops an action-oriented culture

Theory of Constraints

All too often, staff work on a problem that doesn’t realise tangible outcomes because the benefit is blocked by a constraint elsewhere in the process. The Theory of Constraints (TOC) is a management philosophy and set of tools that concentrates on improving the throughput of the whole system by identifying the constraint processes and subsequently removing or managing them so that organisational goals can be achieved.

TOC is an iterative process that focuses on removing the current constraint until it no longer limits the process, after which the focus moves to the next constraint, and so on. Application of TOC provides a number of organisational benefits which may include:

  • Removal of bottlenecks resulting in a smoother and more continuous process flow
  • Reduced process time
  • More productive and harmonious environment for process participants
  • Increased throughput capacity
  • A more focused business improvement investment that will convert into measurable outcomes
  • Higher service levels

The Lean Simulation workshop delivers the following outcomes for participants and the organisation:

  • A basic understanding of the principles, tools and techniques of Lean and a valuable first step towards further training
  • Business improvement knowledge and skills that can realise tangible benefits in the workplace
  • A heightened awareness of waste and how customer value is created
  • A positive impact on workplace behaviours and culture
  • A catalyst for a program of continuous improvement

Efficiency Works will identify with the customer / client through the briefing session and determine the length of the workshop based on the size and complexity of the customer’s needs. As this program is scheduled for three days due to the activities and outcomes Efficiency Works and the client are working towards. An additional consultation day may be required on the completion of the workshop to redefine actions / outcomes for the customer.

On the completion of the workshop each participant will be award with a certificate of achievement, in outlining the values of Theory of Constraint, Value Stream Mapping.

Additionally, each participant will walk away with.

  • Better skills to facilitate continuous improvement in the workplace
  • Improved understanding of continuous improvement techniques
  • Opportunity to realise their full potential

The learnings are relevant and applicable to all types of organisations’ and to all levels of management, administration, and delivery.

The program is designed to provide participants with knowledge and skills to a level that can be deployed in workplace business improvement projects which can produce measurable outcomes. The workshop also provides a cogent refresher for business improvement specialists and other staff who have had previous exposure to the Lean tools and techniques.

  • Team Leaders
  • Production Managers
  • Inventory Managers
  • Sales Managers
  • Operation Managers
  • Customer Advocate
  • Accounts Managers
  • IT Solutions Managers

Efficiency Works engage with professional facilitators that can deliver coaching, certified / non-certified training programs, team building, change management and leadership development services throughout all forms of business from the executive leadership team, senior managers, coordinators / team leaders and employees including contractors and volunteers where appropriate. Efficiency Works facilitators have a vast range of expertise from industry knowledge, practical application to formal qualifications with-in Training and Assessing.

Efficiency Works facilitators utilise a collaborative approach that quickly engages with participants, challenges thinking, transfers knowledge and builds skills. The facilitator utilises a combination of theory, learning exercises, visual aids, and group discussion to ensure that participants are fully engaged through-out the workshops and training programs.

Theory of Constraint workshop will deliver the following outcomes & benefits for the organisation:

  • Identification of opportunities to improve productivity and capacity
  • Improve ongoing processes with significant business impact
  • A high-level implementation plan, milestones, and schedule
  • Respond to a disappointing product roll out or missed company goal
  • Anticipate and solve potential problems for key projects
  • Where approved, implementation of ‘quick wins’
  • Transfer of business improvement knowledge and skills
  • Workshop participants who are attuned to business improvement
  • A high-level change plan and KPIs to monitor progress
  • A platform for further business improvement projects

What accreditation or recognition does this program have?

This is a non accredited program.

Does this program have any assessments requirements?

As a non-accredited program this course has no assessment requirements. The course contains a number of activities designed to reinforce the key skills and knowledge outcomes.

Who is my trainer for my program?

All of our trainers and assessors have extensive and current industry experience and qualifications that meet the national requirements for VET trainers.

Who do i contact in case of any query regarding my program?

For any program related queries, please email customer support at admin@efficiencyworks.com.au

Make an Enquiry