International Conference of the

TOC Practitioners Alliance - TOCPA

www.tocpractice.com

09 November 2016, UK

BA Systems UK- Case Study

Antony Hynd, Russell Briston,

BA Systems, United Kingdom
09 November, 2016

Brief bio

Antony Hynd
Managing Director

Russell Briston
Pre-Construction Manager

Company Intro
Who are we?

Manufacture & Installer of Stainless Steel, Glass

Aluminium Balustrade Products throughout the UK.

Projects up to 1 Million in Revenue

Key Facts

6 million
Projected revenue
for 2016-17

25 Staff
Full time
excluding
installers

90%
Business within
the Greater
London area

17 Years
Established in the
UK

What We Stand For

Balustrades for the Construction Industry

focused on Rapid

Hassle-Free Design and

Installation. Market-leading design and manufacture

Guaranteed Timeline Assurance

with
on large-scale projects. Design-led solutions in glass,
stainless steel and extruded aluminium.

Project Success.

We Deliver

Norwich Head Office

Cad Design Dept.

TIG Welding Tube Fabrication.

Automated Tube Drilling.

Project Care Home, Ascot.

Project Care Home, Ascot

Project Care Home, Ascot.

Project Greenwich Millennium Village

Project Greenwich Millennium Village

Project University of West London

Find out More Online

basystems.co.uk

FACT CHECK - Challenges In Construction

Rife with uncertainties & unknowns

Poor due date performance
Client requirements subject to last-minute-change
Rework and snagging
Traditionally an industry where conflict is par for the
course within and between companies..

Measurements force Companies to achieve

local optima

History with TOC Prior to 2015

Introduced to The
Goal Video

Audio book made

available to staff

Removed
Multi-Tasking in
Production

Engaged with
Goldratt UK

First 12 Months The Story

Initial Challenges Faced at Start of Implementation

Site survey
capacity
wasted
Clients unable
to agree dates
Pressure to
start work as
early as
possible

Internal time
estimates
inaccurate

Not enough
work to
promote
flow

Site surveys
taken too early,
pick up bad
info

Turnover
measured in
every dept.
Departmental
KPIs in
Conflict

We believed
early start =
early finish
Lack of
abundance
mindset

First 12 Months The Story

Paradigm Shift Over The 12 Months
Sales Focus on
Order Book Size

Local KPI Driven

Large Batch sizes

Lots of detailed
early planning

Focus on when sales

will deliver revenue
Throughput Driven

Batch sizes getting smaller

Cant plan more accurately

than the noise!

First 12 Months Tools - RopeWeaver

First 12 Months Tools Sales Pipe

First 12 Months Tools Sales Pipe

Trend
16,000,000
14,000,000
12,000,000
10,000,000
8,000,000
6,000,000

Early Communication
Interest
Desire

4,000,000
2,000,000
0

Action

First 12 Months The Story

Key Challenges in Last 6 Months

Belief in the big

Numbers!

Need to keep
Orders
Coming in at
Increased rate

Keeping TVC
under Control

Keeping systems
up to speed with
growth- (suppliers
etc)

First 12 Months The

Celebration

The Road Ahead Phase 2

4
Mafia Offer..

3
Focus on Installation Completion

2
New Flow Model

1
Vigorous Full Kit

Unusual Implementation.

Projects

Installation

Manufacture

Supply
Chain

Building Operational Excellence Next Steps

Start with a story..

Building Operational Excellence Next Steps

Step 5..If in a previous step,

the constraint has been
broken, go back to step 1 but..
BEWARE of inertia

Building Operational Excellence Next Steps

Our constraint had changed
Moved from design to installation
Manufacture

Design

Installation

Supply

Building Operational Excellence

Five key needs of main contractors from subbies.
Effective
synchronisation

No Hassle

Rapid
Installation

Flexibility

Reliability

Building Operational Excellence

Where are we so far?
Effective synchronisation

Flexibility

Reliability

Rapid Installation

4
5

No Hassle

Building Operational Excellence

Vigorous Full Kit
GOAL Make Money
FACT - Can 0nly charge for what we have fitted
FACT Installation Very difficult to manage
TACTIC Introduce full kit to ensure only work that has a very
high chance of completion should be allowed to flow!
TACTIC Reduce batch sizes to make work more
manageable and ensure installations are not left open.
RIGOROUS dont be afraid to sop a section from
flowing if FK not achieved.

New Flow Model

Operates on Drum-Buffer-Rope principal.
Uses a High-Touch-Time buffer to manage operations.
Hybrid approach between DBR and critical chain.

HIGH TOUCH TIME

Due Date
Today

WORK PACKET LEAD TIME

Touch time = ??

Summary

18 Months In.
Monthly revenue generation rate x 2
Net full time staff have increased by just 2 in the same
period.
Substantial increase in ROS as a result

Questions?