Increase revenue and profitability using continuous improvement process

Flow issue reporting-based CI process uses TOC, lean and six sigma to maximize business performance
Monday, Oct. 24 Location Code
8:00am-12:00pm Dallas D2, 1st floor MW/22

Discover the process to establish a new, flow issue reporting-based CI approach that results in significant revenue and profitability improvement. Utilize games and simulations to establish a common understanding of the current plant performance and apply five layers of buy-in process to journey from the agreement on the problem to the agreement that the new solution can be successfully implemented.


Many organizations decided to start lean or six sigma journeys with hopes of creating robust CI programs. Many didn't experience desired business profitability increases and most didn't even hope to impact their revenue. In fact, 74 percent of U.S. companies claim to be adopting lean and only 24 percent claim any positive results. Despite significant progress and development of the big three improvement  methodologies (lean, six sigma, theory of constraints) many manufacturers still suffer from ineffective CI programs with longer than desired lead times, late deliveries and high operational costs, negatively impacting their ability to maximize revenue and profitability. Learn how the flow issue reporting-based CI process uses the TOC methodology to identify reasons and plant locations that most often hinder the production flow. It also uses Pareto diagrams to prioritize plant-wide improvement opportunities. Then lean and six sigma principles and tools are used to deliver a better performance.


CMS Montera provides management solutions and software to accelerate projects and optimize operations for manufacturing, engineering, R&D and project management. These solutions provide greater visibility and synchronization to help clients dramatically improve productivity. Its management solutions are: Accelerate Project Execution, Optimize Production Execution and Synchronize Inventory Management. Its software, CMS RoadRunner, enables its implementations and speeds up productivity improvements. In 2015, the company received the Top 10 Manufacturing Execution System Providers award from Manufacturing Tech Insights.

Presenters: Jack Warchalowski / Duncan Patrick

Jack Warchalowski focuses on growth strategy development and implementation for a variety of manufacturing and engineering clients. Prior to CMS, he was the head of operations for the high tech manufacturer, Ernst & Young Management Consultant, and a project engineer with Babcock & Wilcox. Warchalowski is a certified management consultant and a professional engineer. He holds an MBA from the Wilfrid Laurier University, Canada, and a bachelor of applied science in mechanical engineering from the University of Waterloo, Canada. He is also certified by the Theory of Constraints International Certification Organization in all aspects of TOC.  

Duncan Patrick assists clients to design and implement lean and theory of constraints-based solutions, focused on optimizing production execution, synchronizing inventory replenishment and accelerating project execution. Prior to CMS Montera, he was a member of the senior leadership team of an industrial distributor, Ernst & Young Management Consultant, and landman for Husky Oil Operations Limited.