Bottleneck Basics
This should never happen to a constraint while the plant is running.
What is idle
These tags tell non-bottlenecks which parts must go to the constraint first.
What are red tags?
The best way to exploit a bottleneck operator who wants a break with work waiting.
What is keep the bottleneck running (or do not let it idle)?
Non-bottlenecks should do this instead of staying busy making unnecessary inventory.
What is help feed the bottleneck?
Even a small process change that removes parts from the bottleneck does this to capacity.
What is elevates the constraint (or increases effective capacity)?
The constraint determines this for the whole plant
What is throughput?
These tags are for parts that do not need to go to the bottle neck first.
What are green tags
One foreman discovered this small trick that gave a 10% boost at the bottleneck.
What is mixing orders cleverly (or combining different orders to keep the machine fuller)?
When non-bottleneck workers finish their jobs, they should do this.
What is help support/feed the bottleneck?
High inventory but still missing deliveries usually means this is the problem
What is the constraint (is not being properly exploited)?
A minute lost at the bottleneck equals this for the entire plant
What is a minute lost for the entire plant?
This tag color was added later to show parts that had already been through the bottleneck.
What are yellow tags?
The team dedicated one of these to stay at each bottleneck at all times.
What is foreman (supervisor)?
You should pull people from other stations to do this if the bottleneck is starving.
What is keep the constraint fed?
The big celebration in Chapter 23 — they shipped this many overdue orders.
What is 57 (worth over $3 million)?
What is the bottleneck (constraint)
Red tags were numbered ( Red #1, Red #2 etc) for this reason.
What is to prioritize among bottleneck parts?
Bob reactivated these old machines to help relieve the NCX-10 bottleneck.
What are the Zmegma machines?
Local efficiency at non-bottlenecks is far less important than this.
What is keeping the bottleneck running?
Any improvement that does not increase throughput at the constraint is not considered this.
What is a real improvement for the plant?
You should track how much time the bottleneck is running versus this.
What is idle time
The main purpose of the red/green tagging system.
What is to communicate priorities so non-bottlenecks support the constraint?
Moving quality inspection to this location protected bottleneck capacity.
What is before the bottleneck?
Creating excess inventory at non-bottlenecks to keep workers busy does this to the plant.
What is increases inventory without increasing throughput?
The team’s ultimate goal when managing the bottlenecks.
What is maximize throughput while reducing inventory and operating expense?