9. Source: Improve Phase 26jul07
Bottleneck Management
• Bottleneck
– The point which is currently reducing the
flow or slowing the entire process
– A managed buffer before a bottleneck is
necessary
– A bottleneck WILL exist in every process
– Bottlenecks move !
– High WIP can mask the bottleneck
– The people working at the bottleneck take
breaks, not the bottleneck
10. • Workers can do each others work, help out
when someone is sick, on holidays, quit
• Workers help improve bottleneck operations
by helping out each other
• Variety in work making it more full-filling
• Training new workers
Benefits of cross functionally
trained workers
11. QUESTION ON CYCLE TIME
40 min
20 min25 min
15 min
30 min
1
54
3
2
•What is the process cycle time?
•What is the process bottleneck?
12. HOW TO SET-UP 1-PC FLOW?
• GET ALL YOUR NEEDED MATERIAL BEFORE YOU
START!!
• Set-up equipment as close as possible together
so you can pass parts without using boxes
• Eliminate WIP BOXES
• Set-up a white board and record hourly PPMH
compared to target.
• List any issues you have during the run
• Run 1 order at a time in the cell until it’s
completed and then next order 12