Eliminate Production Bottlenecks
Identify and eliminate production bottlenecks with real-time shop floor monitoring and constraint-based scheduling.
Eliminate Production Bottlenecks for 35% More Throughput
Identify constraints, balance workloads, and maximize flow with real-time visibility into your shop floor operations.
35%
More Throughput
50%
Less Queue Time
85%
Machine Utilization
30%
Faster Flow
5 Steps to Eliminate Bottlenecks
1. Identify Your Constraint
Your bottleneck is the machine or process with the longest queue. Real-time visibility shows which resources have work piling up. That's your constraint limiting total throughput.
Impact: Find bottlenecks in minutes, not weeks
Live queue monitoring pinpoints constraints immediately
2. Exploit the Constraint
Make sure your bottleneck never stops. Pre-stage materials, minimize changeovers, eliminate quality issues at the constraint. Every minute of downtime here costs you throughout.
Impact: 15-20% throughput increase
Keep the constraint running at maximum efficiency
3. Subordinate Everything Else
Non-bottleneck machines should work at the pace of the constraint. Don't overproduce upstream. Release work based on constraint capacity to prevent WIP buildup.
Impact: 40% reduction in WIP inventory
Match production flow to constraint capacity
4. Elevate the Constraint
Add capacity at the bottleneck. Buy another machine, add a shift, outsource overflow, or find faster methods. Investment here has the highest ROI because it increases total throughput.
Impact: 25-35% capacity expansion
Strategic investment at the right constraint
5. Repeat the Process
Once you elevate the constraint, a new one emerges. Continuous improvement means constantly identifying and managing the moving bottleneck through real-time monitoring.
Impact: Ongoing throughput gains
Theory of Constraints as a management system
Real Bottleneck Elimination Results
Metal Fabrication Shop
Custom fabricator, 60 employees, 25 machines
"We discovered our laser cutter was the bottleneck with 3 days of queue. We added a second shift there and subordinated upstream processes. Throughput increased 35% without buying new equipment."
35%
More Throughput
60%
Less Queue Time
$480K
Revenue Increase
Ready to Eliminate Your Production Bottlenecks?
See how MonitorZ identifies constraints and helps you maximize throughput with real-time shop floor visibility.