1. Company ABC
Ideas for improvement
Idea #1: Built some buffer in front of bottleneck machine:
Here according to theory of constraint we should have collect some time buffer in
before the bottleneck machine. Which will eliminate the waiting time for bottleneck.
Similar we should place some buffer where this component goes for next step. Since
constraint item must not wait for non-constraint item.
Idea #2:Rearranging man power i.e. balancing manpower:
Since welding, rolling and stamping operation requires 12, 8 and 3sec respectively, we
need to shift one man power from rolling and should use in combined welding and
stamping. These machines and product are flexible enough to change in there
processing order.
Idea #3: Roll Marking machine capacity enhancement:
Roll marking machine is one which runs on very low capacity due to various constraint,
In this case I would suggest to order new Roll marking machine which will increase the
capacity of whole plant. It can also be used for manufacturing of other items also

2. Empirical Support
Idea #1: Built some buffer in front of bottleneck machine:
It will eliminate the unused time of bottleneck machine by 100%. By this mean
assembly line can be run of full capacity of its weakest link. Reduce inventory for
further processing machines by around 25 %
Idea #2:Rearranging man power i.e. balancing manpower:
It reduces the time taken by welding machine by 1 sec and 1.5 sec by stamping and
rolling machine. It increases the man power utilisation by 15 % and less exhaustive work
for operators.
Idea #3: Roll Marking machine capacity enhancement:
This idea will improve the capacity of assembly line by 50%, it will reduce the total
processing time by 35% or 9 sec.

3. Comparison Table
Cost
Ease of
implementation
Magnitude of impact
Buffer Before
bottleneck
Low
Only inventory of raw
material and
assembly parts need
to put
Easy
Putting the inventory
near to station is not
big deal
Moderate
Maintain the flow of
assembly line, reduce
waiting time for
other machines
Rearranging man
power
Nil
It require only
repositioning of
operators
Easy
Only planning is
required
Good
It saves time, balance
the work and reduce
fatigue
Purchasing Roll
Marking machine
High
Since require
machine,
management
decisions, placing
order, transportation
cost etc.
Hard
Sufficient planning
and careful attention
is needed
High
It increases the
capacity of line.