Application of the theory of constraints to a bottleneck operation in a manufacturing plant
Journal of Manufacturing Technology Management
ISSN: 1741-038X
Article publication date: 1 April 2005
Abstract
Purpose
The purpose of this paper is to describe a study of the successful application of the theory of constraints (TOC) to a manufacturing plant operations problem. The TOC application required the identification of a bottleneck constraint in the manufacturing process which limited through‐put and thus negatively affected plant productivity and efficiency.
Design/methodology/approach
The methodology used was a detailed case study of the bottleneck in the manufacturing process. The bottleneck in this case was the mold‐changing operations, consisting of a plastic injection process for heavy‐duty truck‐lighting systems components.
Findings
It was found that to eliminate the bottleneck four separate solution approaches were applied to the problem, and these four solutions collectively eliminated the bottleneck constraint.
Research limitations/implications
The limitation of this approach is that the application of the TOC method is highly specific to the particular operation.
Originality/value
On completion of the study the mold‐changing process improvements resulted in increased through‐put and concomitant improvements in productivity and efficiency in the heavy‐duty truck‐lighting systems plant.
Keywords
Citation
Pegels, C.C. and Watrous, C. (2005), "Application of the theory of constraints to a bottleneck operation in a manufacturing plant", Journal of Manufacturing Technology Management, Vol. 16 No. 3, pp. 302-311. https://doi.org/10.1108/17410380510583617
Publisher
:Emerald Group Publishing Limited
Copyright © 2005, Emerald Group Publishing Limited