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There is Always a Bottleneck

8 September, 2012 by James Lawther 3 Comments

All processes have a bottle neck, a rate limiting step.  Something that holds them back.  There is always a bottleneck.

Maybe it’s the neck of the bottle:

Bottleneck

Maybe it’s the speed of the pump:

Fountain

Maybe it’s the width of the falls:

Niagra Falls

Maybe it’s even the lack of rain:

Dry River Bed

But there is always a bottleneck or constraint.  You can change it or move it, but you can never get rid of it.

There is always a bottleneck.

Why you need to know

If you are doing any operations analysis, working out how to make your operation faster or cheaper you must find the bottle neck.  It is the only place you will make any difference.  Fortunately finding the bottleneck is easy…

Look for the backlog

The backlog is always just before the bottleneck.  Find the biggest backlog, the queue of unhappy customers and there you will find your bottleneck, directly in-front of it.

Once you get your eye in you will find the bottleneck in all shapes and sizes.

What to do once you have found the bottleneck:

  1. Make sure the bottle neck is always working, as fast as it can.  Never let the bottleneck stop, if it stops everything stops.
  2. Open the bottle neck, hire some people and get them to work at the bottleneck, or improve the process, (a cheaper, wiser option) either which way cut the constraint.
  3. Find the next bottleneck, once you have reduced one constraint another will kick in.  Focus on that next.

But whatever else you do

Don’t let somebody stand by the bottleneck and ignore it.  That would just be plain foolish.

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Images by Tekke, x1kilma, Janine Curry and Grant Wickes

Filed Under: Blog, Operations Analysis, Tools & Techniques Tagged With: backlog, bottleneck, queue, waiting

About the Author

James Lawther
James Lawther

James Lawther is a middle-aged, middle manager.

To reach this highly elevated position he has worked in numerous industries, from supermarket retailing to tax collecting.  He has had several operational roles, including running the night shift in a frozen pea packing factory and carrying out operational research for a credit card company.

As you can see from his C.V. he has either a wealth of experience or is incapable of holding down a job.  If the latter is true this post isn’t worth a minute of your attention.

Unfortunately, the only way to find out is to read it and decide for yourself.

www.squawkpoint.com/

Comments

  1. Adrian Swinscoe says

    22 September, 2012 at 12:37 pm

    Hi James,
    What would systems thinking say about this?

    And, have you read The Goal by Eli Goldratt?

    Adrian

    Reply
  2. maz iqbal says

    23 September, 2012 at 11:49 am

    Hello James
    Excellent point that is highly pertinent to chain links systems. I suspect that you have come across Goldratt and the Theory of Constraints.

    Maz

    Reply
  3. James Lawther says

    3 October, 2012 at 5:47 am

    You are right Maz, I have read it and it is where the idea came from. This was my 3 minute version with pictures. Maybe the internet dumbs things down?

    James

    Reply

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