What Is BOTTLENECK In Garments Production Line? How To Find Out & Reducing BOTTLENECK?

What Is BOTTLENECK In Garments Production Line? How To Find Out & Reducing BOTTLENECK?

Writing By,

Nurul Amin Jibon

IE Executive (Mohammadi Group)

B.Sc In Textile Engineer

Primeasia University. Batch: 091

Phone No : 01687-201045

Bottleneck

The upper narrow portion of a bottle is called neck (opening side) that is an obstruction to go to the way from large portion of bottle through narrow portion of neck. It is a metaphorical scene of obstruction of production sector. It is an extreme point in a production sector where production is hampered from normal flow of production. In a production sector bottleneck means lost production and lost profit e.g. the lowest capacity of production.

Bottleneck in production line

The lowest output point in production line is called bottleneck. The bottleneck area is where supply gathered and production goes under capacity. In the chain working systems the supply of an operator is the feeding of next operator. So, the minimum supply from bottleneck point will be the feeding of 
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next operator as well as the production will not be more than the output of bottleneck point.

How the bottleneck may arise in the production line/sector

1. Bottleneck before input in line/group

• Unavailable issue from MCD/ store
• Delay issue from source
• Inconsistency /mistake of sequence of issue
• Inconsistency /mistake of bundling
• Wrong issue supply
• Pattern problem
• Material problem
• Unavailable machine. Etc.

2. Bottleneck in line/group

• Operators selection wrong
• Task selection wrong
• Task allocation wrong
• Wrong works flow/sequence of works
• Wrong measurement of task
• Works negligence by operator
• Operators absenteeism
• Machine disturbs / problem
• Lack of supply
• Non-serial supply from operators
• Color shading
• Quality problem
• Sickness of related operator

How To Find Out Bottleneck?

Bottleneck is the extreme point of line where the output / capacity of production is minimum however it is difficult to find out very quickly where a lot of operators are working together. In this situation we may consider the below factors to find out the bottleneck easily-

*By performing cycle check

It is very easy and accurate measuring system as well as the best of scientific way to find out the bottleneck at a glance from graph that is made from the data of cycle check. The extreme point of observation time that takes an operator to perform his/her task is the bottleneck point which is placed above the HPT line even though BPT line.

*By checking counter machine

It is easy to find out the bottleneck point by checking counting machine where the production has counted poor /lowest. This system may be done time to time like hourly or within an expected time.

*By observing the gathering of supply

Those point or area is the bottleneck point or area where a pile of supply is observed. Some of operators have a pile of feed but next or side of operator may get relax and it will be treated as bottleneck point or area.

*By observing serial number of supplied issue

Generally all operators perform their task as per sequence /serial number of process and if it is found in anywhere that, someone or some of operators are working the lowest serial number of running issue which is not reasonable deference with other operator, then it will be defined bottleneck point. 

Reducing bottleneck

• Arranging pre-production meeting in time
• Production costing
• Layout making before input in line
• Submitting the layout sheet to maintenance department in time
• Checking the fabrics & accessories before issue in the line
• Checking the pattern before issue in line
• Select right operator for right task
• Allocation the task as per standard produced value equally
• Reducing excess task from overloaded operator / find capacity where else
• Reducing ineffective time / task by production study
• Setting up good method instead of bad method by method analyzing
• Maintain sequence of task accordingly
• Keeping the supply available in time
• Should not forward the reject products
• Supply should be forwarded after checking
• Should not be forwarded inconsistency process
• Should not be forwarded quality fault product