In this episode of Supply Chain Now, Scott Luton and special guest host Kim Humphrey, President & CEO of AME (Association for Manufacturing Excellence), welcome retired Air Force Lieutenant General Andy Busch, Strategic Advisor at Goldratt Consulting, for a high-impact conversation on the Theory of Constraints (TOC) and its ability to transform complex operations. Drawing from a 38-year military career, Andy shares how TOC’s five focusing steps helped him cut C-5 aircraft maintenance timelines from 340 days to 110, save hundreds of millions through inventory discipline, and reduce a 15-month procurement backlog to just three months. He also highlights the leadership skills required to drive these changes, including clear communication, organizational alignment, and active workforce engagement.
They also discuss the universal applicability of TOC across industries and geographies, with Andy recounting implementations at the Defense Logistics Agency, large-scale MRO depots, and in international settings such as Japan and India. From managing high-variability environments to avoiding the trap of local optimization, the conversation delivers actionable insights for supply chain and manufacturing leaders seeking breakthrough results, stronger team alignment, and sustained performance improvement in today’s volatile business climate.
Jump into the conversation:
(00:00) Intro
(02:47) Meet Andy Busch
(05:29) From Utah trails to global supply chain insights
(13:32) The impact of the Theory of Constraints
(25:28) Implementing consumption pull systems
(29:29) Five focusing steps vs. five whys
(30:42) Work in process discipline
(32:44) Overcoming supply chain hurdles
(37:05) International experiences with TOC
(43:07) How to navigate industry volatility
(45:45) Why focus is key to organization's success
Resources:
This episode was hosted by Scott Luton and Kim Humphrey and produced by Trisha Cordes, Joshua Miranda, and Amanda Luton. For additional information, please visit our dedicated show page at: https://supplychainnow.com/how-theory-constraints-drive-enterprise-impact-1472
