Bottleneck
What is a bottleneck?
A Bottleneck is the resource or process step that limits throughput in production because its capacity is less than the demand placed on it.
In other words, it’s the slowest or most overloaded workstation that creates a queue and delays for subsequent steps.
For example, if your shop has one ironworker station and all jobs require punched angles, that station can become a bottleneck if it can’t keep up with upstream cutting.
Identifying bottlenecks is crucial: according to the Theory of Constraints, improving the bottleneck’s capacity or scheduling (for example, adding an extra shift on the drill line) will directly increase overall output.
Bottlenecks in small steel fabrication shops are often caused by specialized equipment (a single CNC cutter, one painting booth) or limited skilled labor (only one certified weld inspector).
Actively managing bottlenecks, by balancing loads or adding capacity, helps prevent excessive WIP buildup and late orders.
