Metrics & analysisBottleneck / Constraint

What is Bottleneck?

The bottleneck is the process in a chain with the lowest capacity, which thereby limits the throughput of the entire system. An hour lost at the bottleneck is an hour lost for the whole factory — capacity gained everywhere else is an illusion.

The Theory of Constraints (Goldratt) gives the recipe: (1) find the bottleneck, (2) exploit it fully — no stops, no waiting, no scrap, (3) subordinate the rest of the system to its rhythm, (4) elevate its capacity, (5) find the new bottleneck and repeat.

Bottlenecks reveal themselves by accumulation in front and idle time behind. But beware of wandering bottlenecks: unstable processes move the constraint around from day to day — stabilisation comes before optimisation.

Related concepts

From concept to practice

The methods only work when they are anchored in daily routines and leadership behaviour. The operations check shows in 4 minutes where your operations stand — and what the next step is.