so if there are bottlenecks in your operation then identifying these bottlenecks becomes essential
because it leads to the loss in revenue increased waiting time between different operations
loss in the customers and finally the poor quality of product will be produced so identifying them
and fixing them becomes utmost important in this video with the help of animated examples we have
again explained this concept of bottleneck and what is this bottleneck analysis and how
to remove this bottleneck from your operations so without wasting any further time let's start our
today video on bottleneck analysis so in this video we will be covering what is bottleneck
we'll first understand this concept and then we will understand what is bottleneck analysis
how to deal with this bottleneck what are different types of bottleneck whether the
short term or a long term bottleneck and some typical benefits of bottleneck analysis
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what is this bottleneck analysis so before we jump to this let us first understand this concept of
bottleneck so bottleneck is that that particular area in a production line
which restricts the smooth flow of production bottleneck in a production work the same way
as a physical bottle so in this example we can see as as the ball reaches the neck of the bottle
they slow down and can go only one at a time because all have to get through the
bottle at a slower rate and the rate of flow is hampered at the bottleneck
which is the point where the narrow neck reduces the rate at which the output is reduced
it occurs when the number of assigned tasks which must be completed exceeds the maximum production
capacity resulting in delaying the subsequent steps in the workflow so bottleneck basically
leads to loss in the revenue your increase waiting time between different operations
the poor quality of product will be produced and finally there will be loss in the customers let
us take one manufacturing example here so in this example machine a has a capacity of 20 pieces per
r and machine b has a capacity of 5 pieces per hour and for machine c it has 20 pieces per r
now in this case the machine a can process more parts but machine b
is not efficient enough to produce that much part that is why machine b is a bottleneck here
so there are two types of bottleneck short-term bottleneck and long-term bottleneck the short-term
bottleneck are basically caused by temporary problems it will only remain for shorter
period of time it could be the operator is missing for certain period of time
resulting in the lot of pileup of work or delay in receiving materials from another vendor or it
could be the obstruction in your supply chain or limited staff due to some festival holidays
long term bottleneck are which are reoccurring it remains for a long time it affects your production
line your capacity by huge margin and they may also result in the loss in the revenue
thus that is why they are considered as a major bottleneck it could be because of
the lack of appropriate technologies limited funds and resources are organized workforce
less trained workers lean manufacturing techniques which are not applied so now that you have
understood this concept of bottleneck let us understand what is this bottleneck analysis so
bottleneck analysis is a process of identifying a bottleneck where the actual problem is
occurring and the work that we need to complete a particular task is taking longer than the
expected time so instead of finding the symptoms let us try to find the root cause and understand
where the actual bottleneck is occurring after completing all this process you have identified
the bottleneck now we can look for some potential solutions some common bottleneck analysis tools
that we can use include are 5y root cause analysis where you ask the question five times to come to
the root cause another tool can be the fish bone diagram which is nothing but a visual
method to show the root cause analysis where you identify your major causes and the minor causes
another tool could be the theory of constraint which is a methodology for identifying the most
important factors or a constraint which stand in the way of achieving a particular goal and
then you can remove those constrained from the system but these are the some tools but
what are the main two causes of this potassium bottle neck so one is your poor line balancing
that means some jobs are taking longer time than expected or are running slower as a
result there is a huge pile of material and then we have the inadequate process controls
that means the equipment does not run and it was designed to run now how do you deal
with these potential bottlenecks one is your increased addition capacity so if bottleneck
is because of there's a huge pileup of work then you can increase your workforce here
and again additional workforce will eliminate the bottleneck problem then we have to eliminate the
non-value added steps here so there are some steps which will not add any value but will only add
waste to the end product so we have to find those steps eliminate waste because because of this
they may be causing some bottlenecks at additional workforce so additional workforce or additional
capacity means the same thing but here we're talking about increasing the workforce and first
step was about addition adding additional capacity machines to solve this bottleneck
and finally we have the balance production line it is often possible that your production line is
not balanced it means some workstations are more overloaded and some are less oriented
so you need to balance your production line accordingly so before we look at the benefits
uh if you like this video please share this video with all your friends and colleagues
and if you have any specific question or comment you can leave your questions in
the comment section below so the first benefit that we have it helps in eliminating the waste
so bottleneck are often caused by unnecessary or inefficient processes which result in a wide
variety of face so if you identify what is your bottleneck and you remove it through your analysis
you help in eliminating your waste it streamlines your processes so once you know that your process
you have removed all your waste you can streamline your process it helps in reducing your inventory
minimize the poor quality of products it reduces your downtime and increases the
overall production capacity which ultimately leads into the shorter late time so if you are
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