Meaning
Capacity limitations highlight the specific resource or station that restricts the total output of an entire production line. A single point bottleneck determines the maximum possible throughput for the system regardless of how fast other machines operate. Identifying this point is the first step in any process improvement effort.
It is the place where work in progress typically accumulates.
Capacity Constraint
Efficiency of the line is capped by the cycle time of this one specific station. If the bottleneck can produce ten units an hour, the entire line is limited to ten units an hour. Adding capacity to other stations will increase their idle time but will not increase the total output of the factory.
Flow Obstruction
Material handling systems often show a buildup of parts right before the restricted process. This congestion increases the lead time for every product and ties up capital in unfinished goods. Managers must focus their resources on keeping this station running at all times to maximize the yield.
System Optimization
Improving the performance of the bottleneck is the only way to increase the total capacity of the line. This might involve upgrading the hardware, adding a second machine in parallel or reducing the setup time. Every minute of downtime at the single point bottleneck is a minute of lost production for the entire facility.