Unlocking the Future of Manufacturing with the Flow Production System ??

The manufacturing world is at a crossroads. Traditional paradigms that once drove efficiency are now holding us back. With ever-increasing complexity, global competition, and shifting consumer demands, how do we adapt? The answer lies in a fresh perspective—one that combines proven methodologies with innovative thinking to create a system built for the challenges of today and tomorrow.

I’m thrilled to announce my upcoming book, The Flow Production System (FPS), which offers a comprehensive framework for designing, managing, and continuously improving production systems. Based on 38 years of hands-on experience and the principles of the Theory of Constraints (TOC), FPS integrates strategy, tactics, and tools to revolutionize the way we think about manufacturing.

What’s Inside the Book

Here’s a glimpse of what you’ll learn:

Manufacturing Design

We start at the very beginning—designing systems that can build products in demand. By examining the early stages of system design, we’ll uncover why so many systems fail to meet their production targets and how to fix these foundational issues.

FPS Production

At the heart of FPS are the decisions managers face daily: setting priorities, choosing metrics, and knowing when to apply the Throughput Improvement Process (TIP). This is where the majority of actionable improvements happen.

Continuous Improvement with TIP

TIP combines strategy, tactics, and tools to enhance profitability. But unlike static systems, FPS evolves over time, incorporating new methods that logically align with achieving the goal. For example, metrics like OEE are excluded when they detract from overall system performance.

Inventory Management and DDMRP

Inventory, purchasing, and distribution are critical elements of FPS, managed through Demand-Driven MRP (DDMRP). Combining principles from the Toyota Production System and TOC, DDMRP ensures materials are Available When Needed rather than strictly Just In Time.

Simulation-Based Learning

The book includes a unique simulation tool centered around a Lego Police Car assembly. This interactive tool allows readers to explore FPS concepts in a hands-on way, demonstrating how small improvements can lead to significant gains.

Data Collection and Metrics

Using the four-state model for data collection, we’ll delve into metrics like Mean Cycle Between Failure (MCBF) and Mean Time to Resume (MTTR) to design and evaluate systems effectively.

Lead Time Management for Engineer-to-Order (ETO)

By applying TOC’s Critical Chain methodology, we’ll explore how to reduce lead times and improve on-time delivery for ETO products.

Industrial Engineering Insights

We’ll challenge outdated paradigms like TAKT time and explore how modern industrial engineering can better align with throughput-focused goals.

Who Should Read This Book?

This book is for the forward-thinkers—young engineers, problem solvers, and anyone frustrated by the limitations of traditional methods. It’s also for those who are curious about integrating diverse methodologies like Lean, TOC, Demand-Driven MRP, and more into a cohesive, logical system.

However, this isn’t a book for those too entrenched in legacy frameworks to consider new approaches. Change requires an open mind, and FPS is for those ready to embrace it.

A Personal Note

I’ve spent decades refining these concepts, including developing the Throughput Improvement Process at GM, which generated $3 billion in profits in just six years. Recent health challenges have underscored the importance of leaving a legacy, and this book is my way of sharing what I’ve learned.

While the Flow Production System may not be widely adopted immediately, I believe its principles will stand the test of time. For those ready to learn and apply these ideas, this book could be a game-changer.

Coming Soon!

The book is in its final stages of development and will be available soon. If you’re interested in improving your production systems and achieving breakthrough results, stay tuned!

?? Want to learn more or reserve your copy? Comment below, connect with me, or follow this page for updates. Let’s transform the way we think about manufacturing—together.

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