Interactive tool · T-01
Process Bottleneck Analyser
Calculates the capacity of each step in a process and identifies the constraint that limits output.
- For
- Operations managers, business owners and anyone running a multi-step process.
- Service area
- Process & Business Optimisation
- Privacy
- Runs in your browser. Nothing you enter is sent anywhere.
Process steps
| Step | Minutes per unit | Resources | Remove |
|---|---|---|---|
Example values are pre-filled. Replace them with your own. Resources are people or machines doing the same step in parallel.
Results
- Process output
- 8.6units/h
- Per shift
- 69units
- Constraint
- Assembly
- Effective cycle time
- 7min/unit
Capacity by step · utilisation at full output
Output is limited by Assembly, at 8.6 units per hour. Adding capacity elsewhere will not increase output until this step improves. One more resource here would raise its capacity to 17.1/h and process output to 12/h, making Preparation and Dispatch the new constraint.
Why it matters
A process can only move as fast as its slowest step. Improving any other step adds cost without adding output.
How it works
Each step can process resources × 60 ÷ minutes per unit units per hour. The step with the lowest capacity is the constraint, and its capacity is the output of the whole process.
Utilisation compares the rate each step must work at with its capacity. If you enter a demand rate, steps that would need more than 100% of their capacity to meet it are flagged.
Assumptions and limits
- Assumes a steady flow of work and average times per unit.
- Does not model variability, queues, set-up times, rework or downtime, which reduce real capacity.
- Treats resources at a step as identical and fully available for the whole shift.