BOTTLENECK IN PRODUCTION PROCESS-

Bottleneck in production process, is a process whose limited capacity reduces, delays or stops the flow of operation and affects the capacity of overall manufacturing processes.  

Almost every system has a bottleneck.

The machine with the longest queue of accumulated input for processing is usually a bottleneck in production process.

It is important to identify the bottleneck machine or process and to remove or reduce the waiting time for next operation so as to achieve the desired targets in manufacturing processes.

Here discussed the various types of  bottleneck in production process.

Types of Bottleneck in production process:

1.Short-term Bottleneck: 

These are caused by temporary problems. 

Short-term bottlenecks  do not need regular attention.

2.Long-term Bottleneck: 

Long-term bottlenecks occur all the time.

These have substantial impacts on the overall manufacturing processes. 

Long-term bottlenecks need solutions for their root causes.

An example of a long-term bottleneck is-when a machine is not efficient enough and as a result has a long queue of accumulation.

BOTTLENECK IDENTIFICATION: -

1.Accumulation-

Input in faster speed than the process is creating accumulation at some machines that are not have enough capacity,or not being fully utilized or operated by an unskilled operator. 

2.Throughput- 

In changing each machines throughput, it will be possible to assess which machine mostly affects the overall output for determining the bottleneck  in the chain of processes.

3.Full capacity -

It is possible to determine the machine which uses the highest percentage of its capacity which is bottlenecking the other machines by 'forcing' them to operate at a lower capacity.

4.Wait times -

Tracking the down time of machines to identify which machine is being bottlenecked  and under utilized due to prior machine with the highest waiting time or down time in the chain of processes.

5.Fishbone Diagram - 

A fishbone diagram is a graphical means for finding possible problems in a chain of processes. 

Most commonly used in a chain of processes to find the bottleneck machine or bottleneck process responsible for the delay in production.

Following are some steps for using fishbone diagram-

1.Collecting the relative data.

2.Inputting the data into the diagram.

3.Analyzing the data.

4.Determining the root cause. 

After the identification of bottleneck in production process or bottleneck machine, it is important to differentiate the degree of the bottleneck that which  bottleneck are minor and which are severe. 

Minor bottlneck in production process may not need to be immediate action, but the severe bottlneck must handled with immediate action.