What is Bottleneck? Why Arises Bottleneck? How to Identify Bottleneck Operation? How to Reduce Bottleneck?

What is Bottleneck?

A bottleneck is an occurrence where the capacity of a system is limited by a single or more operation. We know that the neck of a bottle is narrow in comparison to another portion. This narrow part is an obstacle to go or out something from the bottle smoothly. It is used figuratively in the production and service sector to mean a low capacity or performing operation or service.

If we think about a sewing line of garments industry, the bottleneck is an operation of the lowest capacity of that line. Say, for example, that line has a total 30 operations. The capacity of 29 operations is near about to 120 pieces per hour but the capacity of 1 operation is 95 pieces per hour. So, for that behind this lowest capacity operation jobs will be stuck 25 pieces per hour. This operation is called the bottleneck operation. After the bottleneck operation, the final output is equal to the capacity of the bottleneck operation. 



In the above example, if the bottleneck is remained or not balanced, the final output of that sewing line will be 95 pieces per hour.

Bottleneck reduce the line productivity, efficiency and profitability as well as waste the operator skills.

 

Figure: Bottleneck Operation

Why Arises Bottleneck?

In a sewing line, the bottleneck may occur due to the following reasons-

✔ Poor line balancing

✔ Critical operation

✔ Wrong worker selection for the particular operation

✔ Worker negligence

✔ Running operator absenteeism

✔ Sudden sickness of operator

✔ Machine problem

✔ High alteration in the process (Quality problem)

✔ Lack of supply chain

How to Identify Bottleneck Operation?

In a sewing line, the bottleneck may identify by following ways-

✔ By checking the hourly production of each operator

✔ By observing gathered supply in the line.

✔ By checking the cycle time of each operator

✔ By observing final line output against average line output of the previous time.

How to Reduce Bottleneck?

In a sewing line, the bottleneck may reduce by following ways-

✔ Doing proper line balancing by time study of each operator

✔ Selecting the right operator for the right operation

✔ Maintaining the skill matrix of all operator to select capably operator

✔ Study the garments before going to bulk production due to identify critical operation and train operator.

✔ Motivate operator not to neglect any operation

✔ Ensuring back of supply chain

✔ Reducing excess pressure from the operator

✔ Reducing defect from the line and not forwarding defected pieces