ABSTRACT
The objectives of this research work are to understand the groundbreaking philosophy of the Theory of Constraints (TOC) and to apply it to a complex manufacturing environment of the case company Futur Décor in order to find bottlenecks in their production processes and develop ways to eliminate them and improve organizational performance. Two significant constraints were identified, namely, the Assembly & Amp Testing (primary constraint) process and the Truss Box Assembly (secondary constraint) process, based on the cycle time of all processes. After exploiting these constraints and successfully breaking the bottlenecks, the cycle time of the primary and secondary constraint processes were reduced by 31.33% and 21.33%, respectively, and thereby, improving factory processes. Companies facing similar challenges in similar industries, to improve their performance as well, could apply the methods used in this research work.
