How do you identify bottlenecks in a manufacturing system?

1 Method 1: Throughput Analysis

Throughput analysis is a method of measuring the output rate of a manufacturing system as a function of the input rate. By plotting the throughput curve, you can identify the bottleneck as the point where the output rate stops increasing with the input rate, or where the slope of the curve becomes zero. The throughput curve can also show you the maximum capacity of the system, and the optimal input rate that maximizes the output rate.

2 Method 2: Cycle Time Analysis

Cycle time analysis is a method of measuring the time it takes for a unit of product to complete a process or a stage in a manufacturing system. By comparing the cycle times of different processes or stages, you can identify the bottleneck as the process or stage with the longest cycle time, or the highest ratio of cycle time to capacity. The cycle time analysis can also help you calculate the utilization and efficiency of each process or stage, and the lead time and inventory of the system.

3 Method 3: Work-in-Progress Analysis

Work-in-progress analysis is a method of measuring the amount of unfinished product that is waiting or being processed in a manufacturing system. By observing the work-in-progress levels of different processes or stages, you can identify the bottleneck as the process or stage with the highest work-in-progress level, or the highest ratio of work-in-progress to capacity. The work-in-progress analysis can also help you determine the buffer size and the inventory turnover of the system.

4 Method 4: Simulation Modeling

Simulation modeling is a method of creating a digital representation of a manufacturing system that mimics its behavior and performance under different scenarios and conditions. By running simulations of the system, you can identify the bottleneck as the process or stage that has the highest impact on the system performance, such as the output rate, the lead time, the quality, or the cost. The simulation modeling can also help you test and compare different solutions and alternatives to eliminate or reduce the bottleneck.

5 Method 5: Value Stream Mapping

Value stream mapping is a method of visualizing the flow of materials and information in a manufacturing system from the supplier to the customer. By drawing a value stream map, you can identify the bottleneck as the process or stage that has the lowest value-added time, or the highest ratio of non-value-added time to value-added time. The value stream mapping can also help you identify the sources of waste and inefficiency in the system, and the opportunities for improvement and optimization.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?