Bottleneck analysis looks for the constraints, barriers which actually slow down the production process and it develop methods to eliminate or to remove the particular slowdown in the manufacturing process. A bottleneck is any area along the production line where work can get backed up for one reason or another.
Performing a bottleneck analysis can help to identify the cause of a bottleneck, and lead to potential solutions to get work flowing at a more even rate. Performing a bottleneck analysis can offer a company a variety of important benefits. The obvious advantage is that it can help you to eliminate the bottleneck and get work flowing at a more steady pace. Unfortunately, a bottleneck is often acknowledged only after it has caused a blockage in the workflow. In Lean Management and Kanban, there are simple yet effective analysis tools that can help you both prevent work congestion and spot an existing bottleneck.


Performing bottle neck analysis

The following are the steps followed to perform bottle neck analysis

ü Visualize the process (Gather data)

In this process gather complete data of the manufacturing process or process which need a analysis. This will provide essential information about the processes leading up to the bottleneck, the bottleneck itself, and what takes place directly after the bottleneck. This is important for a variety of reasons, including the fact that if a bottleneck early in the production process is eliminated, it may result in a new one forming further down the line. A properly performed analysis will not only help to find solutions to the existing bottleneck, but will also help to prevent new ones from forming.
Example:
Let us take the example of machining process for drill holed bar. The following pictures shows sequence of machining process with type of machine used





ü Gathering cycle time data for each process:

 Measuring cycle time at every stage lets you build a cycle time heat map
diagram. In this we have measured the cycle time for each process that include (loading time of a component processing time + un loading time of a component) and map them accordingly.


ü Bottle neck analysis

Some bottlenecks can be identified and resolved quickly without any need for an extensive analysis. When performing a full investigation on how to find the cause of these issues, a bottleneck analysis tool should always be used. Tools can be used are written chart (as we seen in example) and computer programming method to find out the complex task.
In this example the bottleneck process is drilling machine process because the cycle time of other machine in and around 20 seconds averagely but in drilling process it consumes more cycle time of 35 seconds due to this uneven cycle time there is no level of production process is possible. Hence for drilling process we need to adapt two machine operation or we need to develop new multipurpose tool to reduce the cycle time .

Benefits of Bottle neck analysis

ü It reduce machine idle time
ü  It manage work in process (WIP)limits
ü It encourage single piece flow or continuous flow of process
ü It helps to achieve customer Takt time
ü  It improve productivity

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