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Question
Define bottlenecks with reference from the novel, The Goal. How did they optimize the
bottlenecks?
What is Bottleneck?
A point ofcongestionin a system that
occurs when workloads arrive at a given
point more quickly than that point can
handle them. The inefficiencies brought
about by the bottleneck often create a
queue and a longer overall cycle time.
The term is used to describe points of
congestion in everything from computer
networks to a factoryassembly line.
should distinguish
between bottleneck and
non-bottleneck resources
Problem No.1
Does Bottleneck has a slack capacity?
Jonah: Bottleneck has no slack capacity
Solution:
Alex organized the bottlenecks to work only on overdue
orders from the most overdue to the least
In order to keep the bottlenecks constantly busy, the team
formed a new system to inform the workers what materials
have priority at non bottlenecks.
Answer: Red and Green Tags
Twelve Orders got shipped
Materials
TAG
Bottleneck Parts
TAG
Non-Bottleneck
Parts
Problem No. 2
Increasing the Production Capacity and Efficiency of the plant
Solution:
The production Manager fixed some of the old machines to
complement what one of the bottlenecks did, thus increasing
the capacity
More Workers: One foreman for each location all the time.
Increasing the Efficiency: Mixing and Matching orders by
priority to process more parts, increasing efficiency by 10%.
Problem No. 3
Lower
Inventory
More
Bottlenecks
Revealed
Observation
What actually had happened was a result of some old thinking.
Working non-bottlenecks to maximum capacity on bottleneck
parts had caused the problem. All parts were stacked up in front
of the bottlenecks and others were awaiting non-bottleneck parts
for final assembly.
There needs to be balance
The red and green tags need to be modified.
Solution
Schedule for the bottleneck parts can be
made in order to decide when they should be
released, leading to alleviation of any excess
inventory
For non-bottlenecks: Out of the data for the
bottleneck parts to the final assembly, nonbottleneck parts can be predicted.
Conclusion
Keep bottleneck running, subject the rest to the bottleneck
Batch sizes: Long on bottleneck, short elsewhere
Five steps of bottleneck management
Thank You