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1、7CONSTRAINTVARLEY/SIPA/NewscomMANAGEMENTOilcontainmenthardboomcollectingfoamingseawateratQueenBessIslandnearGrandIsle,LouisianaBritishPetroleumOilSpillinGulfofMexicoritishPetroleum(BP)isoneoftheworld’sleadinginternationaloil,gas,andBpetrochemicalproductscompany,withoperationsin29countr
2、ies,79,000employees,and2010salesofnearly$30billion.Itoperatesover22,000retailsites.OnApril20,2010,therewasanexplosionandfireonTransoceanLtd’sDeepwaterHorizondrillingrigthathadbeenlicensedtoBP.Itsanktwodayslaterin5,000feetofwater,andreleasedasmanyas4.9billionbarrelsofoilintotheGulfofMex
3、icobeforethedamagedwellwasfinallycappedinmid-July2010.Theresultingoilspillcloseddownfisheriesandthreatenedthedelicatecoastlineanditsfragileecosystems.PinnacleStrategieswasoneofthefirmshiredbyBPtohelpinboostingtheoutputofspill-fightingequipmentlikeboats,ships,andrigs,aswellassuppliesofc
4、riticalresourceslikecontainmentbooms,skimmers,anddecontaminationsuits.Aboomisaninflatablefloatingdevicethatcanbeusedtotrapoildownwindonabodyofwater.Thisoilcanthenbepumpedintocontainersbyskimmingequipment.Limitedproductioncapacitiesofbooms,however,representedadauntingchallenge.PrestigeP
5、roductsinWalker,Michigan,couldonlymake500feetofboomaday,whereasasingleorderofthesizerequestedbyBPwouldexceedthecombinedcapacityofeveryboommanufacturerintheUnitedStates.Despiteincreasingthestafffrom5to75andraisingproductionto12,800feetdaily,thePrestigeplantfeltthatithadreacheditslimit.T
6、hatiswhereEdKincerfromPinnacleStrategiessteppedin.Henoticedthattheboomwasassembledinaflurry,with243244PART2MANAGINGPROCESSESlittletodoin-betweenforseveralminutes.Cuttersslicedboombycuttingoneside,thenwalking100feettocuttheotherside.Workersalsosatidlewhilewaitingforaweldingmachine.Waste
7、occurredintheformofexcessivewalks,waitingformachines,andchangingproductionrhythms.Kinceridentifiedtheconstraintsintheprocess,foundwaystomanagethem,andmorethantripledcapacity.PrestigeeventuallyendedupmakingmorethanamillionfeetofboomforBP.Theoryofconstraintsisthescientificapproachthatw