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