During the lunch break, Alex is continuing his thought process on how he can find balance in his plant. He makes a game up to experiment with statistical fluctuations. He has the boys play with dice and matches representing an inventory, fluctuations, and throughput. He also keeps a record during the game. With the goal of having a balanced plant with equal resources of capacity and demand, he uses this game to simulate the assembly line in his plant. As the hike continues, Alex proceeds to compare the experience of his …show more content…
The primary goal is to examine the bottlenecks, which Jonah mentioned every plant should have, of the plant so they can alleviate excess capacity. The team simply needed to correct their thinking; the answer was to make the machines run more efficiently, and they needed more capacity in the bottlenecks. A couple of things to ensure this is effective are not to have any downtime within the bottlenecks, and not to waste any time; the work must be focused only on quality products. Alex learns every moment of downtime in the bottleneck renders thousands of dollars of loss throughput. Without the elements from the bottleneck, selling the merchandise will not be possible. Alex and his team meet the next morning to discuss how to make the plant more productive. They have a debate regarding the actions that need to be implemented concerning the bottlenecks. For now, the strategy is to organize the bottlenecks to work on past due orders, where their biggest problem lies, from most to least. Alex discovers his wife; Julie is staying with her folks. After speaking to her, to his disappointment, she is very confused and still needs to stay away for the time