(S) DBR – Steering and optimization of production- and administrative processes

Specific Targets

Steering the operational chains for maximal yield and reliability with minimal resources.

Usual results

  • Shortening of throughput times without changes or investment in production (usually 30% to 40% shorter after 4 months of implementation
  • Strong improvement of delivery reliability (usually starting out at 70% and up to 95% after 4 months). Diminishing of work in progress (WIP) with 40%
  • Large reduction of ‘urgent’ orders
  • Calmer flow
  • Less management time
  • Safe delegation to the operational level

Specific techniques

  • Application of the 5 focussing steps
  • Steering on critical resources, synchronisation of non-critical resources using Buffer Management
  • Liberation of material. The start of production is synchronised on the critical resources (not on the forecast or on global MRP-signals) Buffermanagement
  • The synchronisation of the entire chain is being steered by very transparent signals, that show the correct and up-to-date priorities for every step
  • Focussed follow-up. The number of focus points diminishes drastically and is clear for everyone (= Management by exceptions!) Built in control. The incorrect execution or follow up of an activity rapidly becomes clear.
  • Immune to disruptions. The correct buffer technique allows for timely intervention
  • Planning of resource needs. MPR-run becomes obsolete
  • Synchronisation of purchase
  • Purchase planning is kept up-to-date by the same Buffer Management signals
  • POOGI: Reliability of resources/suppliers/subcontractors is being monitored and processed into actions of improvement


Our Offer

Diagnosis and implementation plan

2-day EDM (Executive Decision Making) – session as an introduction

Complete courses with possible transfer of know-how will be guided by TOC experts

Adaptable and integrable software available



DBR steering is applied in companies such as: