KEVOS® WORKOS · Operations
Bottleneck and Line Balance
Which step is constraining the process?
Identifies the constraint step in a three-step flow, compares it with takt time and shows line balance efficiency.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Available production time | min/day | Net available production minutes per day |
| Daily demand | units | Units required per day |
| Step A cycle time | min | Observed cycle time of step A (0 if not used) |
| Step B cycle time | min | Observed cycle time of step B (0 if not used) |
| Step C cycle time | min | Observed cycle time of step C (0 if not used) |
Method and formulas
- Takt = available minutes ÷ demand
- Constraint = step with the longest cycle time
- Line capacity = available minutes ÷ constraint cycle
- Balance efficiency = sum of cycles ÷ (steps × constraint cycle)
Limitations
- Three steps, one product, no buffers or downtime
- Uses average cycle times
Typical uses
- Finding where to improve first
- Balancing work between stations
Who it is for
- Production engineers
- Lean practitioners
- Supervisors
What you get
- The constraint step and whether it meets takt
- Line capacity and balance efficiency
- Step loading table
Interpreting the result
- Improving a non-constraint step does not raise output
- Low balance efficiency means idle time at faster steps
References
- Goldratt E. M. and Cox J., The Goal (North River Press)
- Rother M. and Shook J., Learning to See (Lean Enterprise Institute)
WORKOS tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.
