BOTTLENECK REDUCTION CAPACITY ANALYSIS

PROJECT INCLUDES:

• Capacity Planning

A leading industrial spring manufacturer was struggling to keep up with growing demand and maintain on-time delivery. To improve efficiency, they hired IMEG to perform a capacity utilization analysis to identify bottlenecks, optimize production flow, and increase throughput.

THE PROBLEM

  • Production Bottlenecks: Certain processes had lower capacity, limiting overall throughput.
  • Imbalanced Workload Distribution: Some operations were overloaded while others had idle time.
  • Underutilized Capacity: Inefficiencies in process flow prevented optimal use of available resources.
  • Inconsistent On-Time Delivery: Delays in production affected customer commitments.
capacity planning

THE PLAN

  • Time Studies & Standardization:
  • Conducted detailed time studies to establish standard times for each process.
  • Developed a clear understanding of current cycle times and process inefficiencies.
  • Capacity Utilization Analysis:
  • Measured current machine and labor utilization to determine constraints.
  • Identified bottlenecks and areas of underutilization across production lines.
  • Proposed Future State:
  • Designed an optimized future state to balance workloads across processes.
  • Focused on improving production throughput while using existing resources.
  • Implementation Strategy:
  • Recommended process adjustments to reduce bottlenecks and idle time.
  • Ensured better synchronization between operations for a smoother production flow.

THE RESULTS

  • The capacity utilization analysis led to:
  • Increased Production Throughput: More units produced within the same time frame.
  • Elimination of Bottlenecks: Better balance across processes ensured smooth workflow.
  • Higher On-Time Delivery Rate: Improved scheduling accuracy and reduced delays.
  • Optimal Resource Utilization: Achieved higher efficiency without adding extra resources.
  • Through capacity utilization analysis, time studies, and process balancing, IMEG successfully helped increase throughput and meet customer demand while maintaining cost efficiency.

CAPACITY PLANNING CASE STUDIES

Future Facility Capacity Utilization
Future Facility Capacity Utilization
Updating Machine Capacity
Updating Machine Capacity
Material Cut Standardization
Material Cut Standardization
Pump Resource Planning
Pump Resource Planning
Bottleneck Reduction Capacity Analysis
Bottleneck Reduction Capacity Analysis
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