Bottleneck is not that neck of an bottle. It is the low efficiency process. There is an word: the bottleneck decide the maximum capacity. As we know, if an process is slow in 100 process production. That other 99 step can not make the whole production process faster.
How to effectively remove the bottleneck process?
The commonly used five-step for removing bottlenecks:
- Step 1. Find the bottleneck
- Step 2. How to made the best use of the bottleneck
- Step 3. More resource support the bottleneck
- Step 4. Untie the bottleneck (bypass, substitute, outsource)
- Step 5. If step 4 solve the bottleneck, then go back to step 1, continue to improve and find new bottlenecks again.
From step 3 we will know the bottleneck usually cost the most resource. From the step 5 we will know if an old bottleneck been solved and new bottleneck are created. Bottlenecks are continuously eliminated, and portfolio optimization is continuously promoted to achieve a great improvement in production efficiency.
Bottleneck of Water Bottling Plant
Step 1. Find the bottleneck of the water bottling plant. As we are manufacturer of the bottled water machine over 20 years. We can give the answer is that plastic bottle blowing machine. Because the bottle blowing machine price almost 40% of an whole water bottling plant.
Step 2. How to made the best use of the bottleneck ? There is an word: the bottleneck decide the maximum capacity. So that made other step capacity bigger than the plastic bottle blowing machine. Make other equipment capacity consistent with the plastic bottle blowing machine.
For example, for produce 500ml bottled water, if buy an 2000 bottles per hour bottle blowing machine. Then other machine capacity must bigger than 2000 bottles per hour. But do not need faster too much, because more faster machine price is more high. So that can save the cost.
Made the synchronize capacity of complete water bottling plant is 2000 bottles per hour. If any other machine capacity is smaller than 2000BPH. It will became the new bottleneck.
Step 3. More resource support the bottleneck. A lot bottled water company produce plastic bottle then collect by bag or box. Then manual moving and loading to the filling machine. That manual speed will became new bottleneck. To solve this question. NEPTUNE MACHINE bottle blowing machine optional air conveyor outlet way. It can directly connection with air inlet of the filling machine. It is catch the neck of the bottle to conveyor by air blowing.
Step 4: A lot bottled water company solve this bottleneck by Untie the bottleneck (bypass, substitute, outsource). They buy the plastic bottle from bottle supplier. But it lead another bottleneck. That is freight empty plastic bottle cost high and easy damage and pollution.