BOTTLENECKS

Describe how you would identify bottlenecks in your value stream?  How would you ensure sustained flow through those bottlenecks?

Answer:

The term ‘bottleneck’ (capacity constraint) comes from the area at the top of the bottle that limits the flow coming out. It doesn’t matter how big the rest of the bottle is—liquid will only flow out as fast as the size of the neck will allow.

There are two main types of bottlenecks:

· Short-term bottlenecks – These are caused by temporary problems.

· Long-term bottlenecks – These occur all the time. 

Bottleneck identification in value stream:

The simplest and most logical way to identify process bottlenecks is to look for the biggest causes of stress.  Consider these questions:

· Is there a routine or system that has a high level of employee stress involved in it?  If there is, then it is not a well-laid out system.

· Is work continually delayed because employees are waiting for reports, products, more information or other resources?

· Is there too much work piled up at one end of the production (or service) cycle and not enough at the other end?

· Are certain departments always late in delivering needed items to both internal and external customers?

· Perform simulation of system according to flow chart of value chain

Way to eliminate bottleneck for sustained flow:

Once you identify the root cause of your bottleneck, try one or more of these ideas to improve workflow:

· Increase quality of input.-zero defect feed at bottlenecks

· Reorganize workflow

· Assign your best teams & technology at bottlenecks

· Add capacity. 

· Accept partial delivery

References

http://www.qmpls.org/KnowledgeCentre/Newsletter/CurrentIssue/tabid/88/entryid/153/Default.aspx

http://www.slideshare.net/dutconsult/eliminating-the-production-bottlenecks

Describe the importance of process mapping in a supply chain flow?  How would you use process maps?  How do you know what to focus on when creating a process map?

Answer

Supply chain mapping allows a company to identify bottlenecks by:

· providing visibility into how processes are carried out;

· identifying where the processes are executed;

· identifying who is doing what within the processes;

· revealing how processes affect other processes;

· determining why a process is being executed

· identify activities within a process that are not adding value; 

Process maps are also known as flowcharts, flow diagrams, relationship maps or blueprints. Process maps can be used to create virtual model of system and performing simulations. Which will be used for analyzing bottlenecks in system , Rework pattern, Time consumption for at rework, cycle time, Inventory at various stages of system. They Can also be used to train new employees or to brief consultant about business process. Process maps can be created by Microsoft visio and eVSM add in for manufacturing unit.

When creating process maps:

· Identify All Value adding process/ activities

· Identifies value add points

· Identifies value add points

· Identifies value add points that are still necessary

· Timings at all process

· Use specific process mapping tools and standards

References:

http://www.qmpls.org/KnowledgeCentre/Newsletter/CurrentIssue/tabid/88/entryid/153/Default.aspx

http://www.slideshare.net/dutconsult/eliminating-the-production-bottlenecks

http://www.netmba.com/operations/process/analysis/