Find and remove a production bottleneck

Is the restriction in a machine, a transfer or the operating conditions?

For queues, repeated waiting, unstable output or packing that cannot keep up.

Confirm the problem

Locate where product accumulates and where machines wait. Compare observations from the same production period before identifying the equipment to replace.

Observe the flow before naming the bottleneck

Upstream output
Queue or waiting point
Suspected restriction
Downstream demand

Use timed observations and production records to establish the limiting point; the diagram does not identify a measured bottleneck.

Prepare the evidence

Collect these records before narrowing the equipment or service scope.

Output and stoppage records for the same product and operating period.
Queue locations, buffer levels, transfer interruptions and operator interventions.
Changeover time, rejects and actual packing configuration.

Compare approaches

Repair or adjust the current arrangement

Investigate recurrent stops, transfer problems and operating settings.

Check before choosing

Separate confirmed faults from assumptions about capacity.

Upgrade the limiting function

Review a feeder, buffer, transfer, drive or end-of-line module.

Check before choosing

Confirm the upgrade will not move the same problem to another stage.

Replace the limiting machine

Use measured requirements to compare candidate equipment.

Check before choosing

Test with the intended product and include the surrounding interfaces.

Check the limits

Compare stages under comparable product and operating conditions.
Published maximum speed does not include all stoppages, changes and rejects.
Check the full downstream chain before approving a faster machine.

Your decision file

A bottleneck evidence list and repair, upgrade or replacement options to compare.

Find equipment and support

Review relevant equipment

Open the individual equipment records and compare their condition and included scope.

Sorting & Packing Squaring & Finishing Glazing & Decoration

Define the work around the machine

Choose fit checks, inspection, export preparation, installation and acceptance planning for the project.

Choose your service scope

Worked examples for this decision

Does the packing line meet your actual output requirement?

Prepare your project requirements

Carry this buying task into a brief and add the measurements, equipment references and open questions you have.

Prepare a Project Brief