Bottleneck Analysis
Bottleneck Analysis & Capacity Optimization
Core Theory
Theory of Constraints (TOC).
Analysis Method
Cycle Time Measurement, Capacity Utilization, Takt Time Alignment.
Target Outcome
Maximum Throughput and Minimum Work-in-Process (WIP).
Bottleneck Management Strategies
Identifying the slowest link (constraint) in the process through data-driven time studies,
Maximizing efficiency by minimizing downtime of the constraint resource (Exploit),
Synchronizing all non-constraint resources to the pace of the bottleneck (Subordinate),
Increasing the capacity of the bottleneck through new investments or process re-engineering (Elevate).
Technical Lexicon
Theory of Constraints, Drum-Buffer-Rope (DBR), Cycle Time vs Takt Time, Work-in-Process (WIP), Throughput Accounting, Resource Leveling, Line Balancing, Capacity Requirements Planning (CRP), Heijunka, Value Stream Mapping, Overall Equipment Effectiveness (OEE).