Marris Consulting

Marris Consulting We apply Theory Of Constraints (TOC) + Lean. Marris Consulting is focused on improving sustainably the performance of manufacturing and process industries.

We have over 25 years of experience of combining the Theory Of Constraints (ToC) with Lean to go faster and further: 1 + 1 = 3

We help our clients reach and maintain ambitious levels of performance by combining actions on processes, organization, methodologies, tools … and people from the shop floor to the board room. We are recognized experts in Constraints Management. We promote an integrated a

pproach that combines Theory Of Constraints (ToC) to identify where to act and Lean and Six Sigma to improve performance. We also use ToC's Critical Chain Project Management (CCPM) approach to boost project performance especially for New Product Development portfolios. We sometimes combine this with Lean Engineering (a.k.a Toyota New Product and Process Development System). With our extensive experience of different industrial sectors and our expertise in change management we assist companies in all their departments especially: Manufacturing, Supply Chain, R&D and Industrialization, Marketing & Sales …

At a conference, Jeff Bezos, CEO of Amazon, spoke about how work is managed within an organization:“Put me in front of a...
03/06/2026

At a conference, Jeff Bezos, CEO of Amazon, spoke about how work is managed within an organization:

“Put me in front of a whiteboard and I can come up with a hundred ideas in half an hour.”

In the early days of Amazon, Jeff Wilke — who had only known me for about a year at the time — came to see me and said:

“Jeff, you have enough ideas to destroy Amazon.”

That remark deeply surprised me.

As a founder, I had the privilege of being able to recruit very experienced and brilliant leaders, such as Diego Piacentini and Jeff Wilke. I listened to them a lot; they taught me a great deal.

Jeff insisted: “You generate enough ideas per minute, per day, per week… to destroy the company.”

I asked him what he meant.

He explained: “You must release work at a rate the organization can absorb.”

For him, every new idea I launched created a queue — work in progress, a backlog.
As long as those ideas piled up without being processed, they created no value; on the contrary, they caused distraction.

His advice was simple: introduce new ideas only when the organization is ready to handle them.

Today this seems obvious, but at the time it was a revelation for me.

I then began to:
✔️ prioritize my ideas more effectively
✔️ write them down
✔️ keep them to myself until the right moment
✔️ think about how to make the organization capable of absorbing more of them

This involved:
✔️ a strong leadership team
✔️ appropriate leadership
✔️ executive bandwidth (available time and attention)

We gradually built a company capable of inventing while pursuing several initiatives in parallel.

But the idea of releasing work at the right pace’ was decisive. It made the organization far more operationally effective while remaining innovative.”

🫵 And you — how is work released within your organization?

How do you manage your flow?During my career, I have worked with over three hundred manufacturing firms, with a lot of d...
28/05/2026

How do you manage your flow?

During my career, I have worked with over three hundred manufacturing firms, with a lot of different products and very varied manufacturing processes.

I have seen that some managers do nothing at all to manage the flow (!), some use Kanban from the Toyota Production System , and a few are using the Drum Buffer Rope from the Theory Of Constraints.

After all these assignments with my clients, I found that the best method is to chase wastes or unnecessary Work In Progress (WIP) while making sure that you do not starve your bottlenecks.

Often, initially, there is much too much WIP (2 or 8 times too munch!). In that case we purge the system by implementing our "2 for 1" rule: 2 "things" must exit the system before we are allowed to launch a new "thing". That "thing" can be either a Work Order or a number of parts.

Often, simultaneously, we can quickly increase the output (Throughput) by improving the performance of the bottleneck.

I am convinced that it is the best way to manage a flow, whether it is for a manufacturing company or a service industry.

In this video, Ian Heptinstall and Philip Marris talk about the benefits of Critical Chain Project Management and the di...
22/05/2026

In this video, Ian Heptinstall and Philip Marris talk about the benefits of Critical Chain Project Management and the differences between project planning and ex*****on.

Ian Heptinstall is a Critical Chain expert. He has written a book on Critical Chain Project Management with Robert Bolton: "Breakthrough Project Management" (2016).

Since then, he has transitioned into academia, teaching on a master's program in project management at Birmingham University (UK).

Critical Chain is a method for scheduling and managing ex*****on of projects. The estimates are recognized to be rough, and excessive precision is avoided.

During ex*****on, the schedule is used to identify issues as early as possible for early intervention. While Critical Chain helps reduce the risk of certain ex*****on problems, it doesn't preempt them all. However, issues that do arise are noticed earlier, making intervention easier.

This method steers away from the conventional approach of fixating on getting the plan right, acknowledging that the plan needs to be good enough to react to the unpredictable reality.

With the Critical Chain approach, that comes from the Theory of Constraints (TOC), the emphasis is on having a plan that enables adaptability and responsiveness to an uncertain world.
https://youtu.be/aBzRjOMYA78

17/05/2026

The Theory Of Constraints is increasingly pertinent in a world that is increasingly volatile and uncertain.

12/05/2026

How to decide between 2 "red" projects in a Fever Chart ? In a Critical Chain Portfolio Fever Chart you can have several projects in the red zone. How do you decide which of these projects is the priority? Philip Marris answers this question in this short video.

09/05/2026

Critical Chain Project Management applied to portfolios of project is easy. The trick is that each individual project is properly planned and executed and has a high probability of finishing on time or early. So managing a collection of healthy projects is easy.

28/04/2026

Book review of "Goldratt's Rules of Flow" for project management by Efrat Goldratt-Ashlag. Recommended. The second best selling TOC book after the Goal by Eliyahu Goldratt.

During a company diagnostic in Spain, we encountered a misunderstanding that we see frequently. In a stand-up meeting, t...
20/04/2026

During a company diagnostic in Spain, we encountered a misunderstanding that we see frequently. In a stand-up meeting, the team declared, "The bottleneck is here in this part of the factory." However, upon closer examination, it became clear that this was not a bottleneck, it was a non-bottleneck with significant excess capacity, TEMPORARILY impacted by absenteeism and staffing challenges.

This scenario highlights a key principle: issues like absenteeism, waves of work, or quality problems or fairly long machine breakdowns can cause temporary backups, but they do not represent the system’s true constraint. Calling them bottlenecks can lead to misdirected efforts and inefficiencies.

In another instance, a ball-bearing manufacturer faced a similar challenge. They identified their capacity constraint as the rectification process for the balls. Yet, a quick analysis revealed ample excess capacity in that area. The real issue was a chronic quality problem in the final assembly. Ball bearing adjustments were made at the last moment, creating customer order delays and operational challenges. Again, this was not a constraint but an unaddressed process issue.

A true bottleneck or capacity constraint is a resource that CHRONICALLY has less capacity than other resources in the system. Less capacity over a one month period for example, not just a 3-day wave of work.

Non-bottlenecks typically have excess capacity, but they may experience temporary backups due to short-term disruptions.

It is critical to avoid confusing chronic or punctual problems with your capacity constraint. By staying focused on the real bottleneck, you can apply the Five Focusing Steps effectively, maximise throughput, and address challenges strategically.

If you use this definition of a bottleneck - then de facto -, wandering bottlenecks are extremely rare. Most so-called wandering bottlenecks are temporary disruptions. Indeed if you focus only one these wandering bottlenecks then they become distractions. Address issues where they occur, but always maintain focus on the true system constraint.

It is not the bottleneck that is wandering, it is the management attention that is wandering (the attention should remain essentially focused on the true structural bottleneck).

Please be careful how you apply the Theory Of Constraints to ensure it delivers its full potential of performance improvement.

Here is a 4-minute video on exactly this subject: https://youtu.be/JbEUMOu_sDU

Watch Out! Your Bottleneck Might Be MovingIf you're struggling to identify your bottlenecks because they seem to move ev...
09/04/2026

Watch Out! Your Bottleneck Might Be Moving
If you're struggling to identify your bottlenecks because they seem to move every day, you’re not alone.

In many cases, moving bottlenecks (or “wandering bottlenecks”) result from internal rules that companies impose on themselves. Whether it's large batch sizes, local optimizations, or working off forecasted demand, these practices can cloud where the real production bottleneck is.

Here’s an example:

One of our clients faced daily bottleneck shifts. Their managers were frustrated, as they couldn’t focus on solving the problem—it kept moving. After analyzing their system, we found high inventory levels and large batch sizes. Some products piled up in stock, while others were in short supply, causing daily resource overflows in different areas.

The Solution?

Switching to a pull-flow system brought clarity. It quickly revealed the true bottlenecks—the ones blocking products that customers actually demanded.

Remember, optimizing everything locally can make your bottleneck wander! (Goldratt).

Are you ready to stop chasing your bottlenecks?

👉 Our consulting programs (3, 6, or 12 months) can help you transform your processes and achieve your operational goals.

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