How to solve Bottle Neck?

 

Already we know why creating bottleneck in a line.

How many types of problem are there to create it? How to find it?

 

Today we will learn what the impact for bottle neck is & how to solve?

Impact for bottle neck in line-

• Less production from other operator.
• Less production from the line
• Less efficiency of that  line
• Incentive getting less & it make them unhappy for group & individual team member.
• On time delivery impacted
• Extra overtime / Excess duty to cover up delivery
• Fail to maintain proper housekeeping & many more.

 

 

Eliminate bottleneck from the line by the following steps:

•       Workstation improvements: First need to check his workplace as per IE standard or not. Need proper light, fan availability, seat adjustment with the machine need to check & adjust if need anything. Then need to check his garments pick & dispose distance, it should very close to him/her.
•       Method improvement: Improve the way of handling the material and doing the operation. Like what is the standard method for that & how they are doing? Are they using excess motion? Improve all the areas. Read also MethodStudy for better understand.
•       Allocate right operator: Select right skilled operator in right operation on layout time. Check if any High skilled operator is allocated on a comparatively easy process whether a low performer are working on bottle neck operation then both the operators could be swapped to get more productivity out of bottleneck.
•       Machine speed: Use maximum speed of machine by ensuring expected quality level.
•       Work aids: To get more output ensure maximum use of guide, Folder, attachment etc. Using computerized UBTs and other specialized machines.
•       Work breakdown: If possible we can divide the process again to make it easy.
•       Work sharing: We can reduce some part of work from him/her like thread/yarn cut, marking, Finishing yarn remove etc. & share with the nearby operation which have more capacity than required for line output.
•       Quality Issue: Due to quality issue flow of production will hampered from one operation to another operation.
•       Extra Work: Can plan some extra hour to remove it & ensure proper WIP for next operation.
•       Use additional manpower/machine: Finally after apply all those things but still there are too less production than the target, we will use another machine & manpower as well.

 

Conclusion:

Process bottlenecks are among the reasons why delivery may delayed, the whole process becomes unpredictable.

So, in case of urgent delivery we can’t waste much time to decide use of extra machine to remove bottleneck. Decision need to take very first then apply all those steps. After removing bottleneck & ensure running capacity will meet expected target, we can remove extra machine from there.

Read also: Root cause of Bottle Neck?