What is a Bottleneck?

A bottleneck is an inefficiency in a process that slows progress, often by increasing the workload.

A bottleneck is a constraint in the process that creates a backlog of work to be done. These are typically not good for any process.

The following questions may help the team understand the nature of the bottlenecks:

What is being constrained: information, product, service?
Why does it exist, what are the factors contributing, and are these factors people, systems, or organisational?
Is the bottleneck the result of handoffs or lack of information?
Is the bottleneck the result of a resource constraint and what type of resource: human, system, or machinery?
Are there unnecessary checkpoints that can be eliminated?
If multiple streams are processing information in parallel, do the streams come together at the same time or is one waiting for the other?
Does the process create a backlog upstream or downstream from the process?

How to tackle bottlenecks?

Multiple solutions are available to tackle identified issues. It must go through a deep analysis to find the most suitable resolution. Here are some suggestions of how to deal with bottlenecks:

Increasing the workforce and/or operators – with a larger workforce it’s possible to create a smoother transition between processes, increasing efficiency.
Minimising downtime – With proper preparation it’s possible to reduce setup and changeover times giving more time to focus on the actual work.
Eliminating unnecessary activities – Remove waste operations to give more time for your efficient processes, increasing productivity.
Provide a constant buffer stock upstream – The most effective processes are in perpetual motion. They require stocks and materials to be ready for use immediately.