Recognizing Constraints & Bottlenecks

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All dynamic systems — online or offline — consists of discrete and dependent processes. Each step in the system has a finite capacity. When one step is feeding more than what the next step can handle, you’ll have yourself a constraint. Constraints or Bottlenecks aren’t bad, they’re expected and are found in any process. The key is recognizing and then managing the constraint.

Recognizing Your Constraints

Imagine the following generic process:

It doesn’t even matter what IPH stands for — just look at the raw outputs, because that is what will “feed” the next dependent process step. Do you see the constraint?

The Role of a Bottleneck

1. Bottlenecks determines the throughput of a system.
2. An increase in the bottleneck rates is the only way to increase throughput.
3. All other process steps should be slaves to the bottleneck.
4. It’s okay to take resources from a non-bottleneck if it will help the bottleneck.

Managing Constraints & Bottleneck Principles

1. Bottlenecks should never be idle; to lose time on a bottleneck, is to lose throughput.
2. Never let a bottleneck run out of work. It’s okay to build inventory in front of a bottleneck.
3. Increase productivity rates (offline and online processes) by reducing down-time, change-over time, and off-task time.
4. Reduce defects by having Quality Assurance and Quality Control in front of a bottleneck, not after.
5. Focus all improvements on the bottleneck.

In any offline or online process, there will be contraints. It’s important that you identify the contstraint, then manage it; once you manage it, it’s important to remember that bottlenecks move. When this happens, follow the above steps again to identify, then manage your bottlenecks.

Check out these articles on The Theory of Constraints and Queueing Theory.

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