Bottleneck Analysis
Theory of Constraints — Bottleneck Identification
TOC 5 Steps
- Identify the constraint (bottleneck)
- Exploit the constraint
- Subordinate everything else
- Elevate the constraint
- Return to step 1, avoid inertia
System Throughput = 3600 / Bottleneck CT (pcs/hr)
A production supervisor wants to identify the bottleneck on a 5-station assembly line. The bottleneck analysis tool visualizes each station's load ratio (cycle time / Takt Time) — any station above 100% is a bottleneck — and calculates the capacity loss it causes.
Takt Time = 45 s; 5 station cycle times (s): 42, 51, 38, 49, 35. Station 2 (51 s): load = 51/45 = 113%, 13% over Takt Time — primary bottleneck. Station 4 (49 s): load = 109% — secondary bottleneck. Actual line takt = 51 s, theoretical output per shift = 480 × 60 / 51 = 565 pcs (max capacity 640 pcs, losing 75 pcs/shift). Improve Station 2 first: move 6 s of work to Station 1.
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