Understanding and Solving Bottleneck Operations in Garment Production

What is a Bottleneck Operation?

A bottleneck operation is a point in the production line where work slows down and expected output isn’t achieved. It becomes the slowest process in the line, causing work to pile up before it and delays for the next steps. This blockage can affect the overall flow of production.

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📌 Why Identifying Bottlenecks is Important

Bottlenecks usually happen when workers face difficulties completing tasks on time. If not addressed, it can:

• Slow down production

• Reduce employee efficiency

• Lower productivity

Finding and solving bottlenecks helps improve the production system and boosts overall output.

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✅ How to Improve Bottleneck Operations

Here are some practical steps to fix or reduce bottlenecks:

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1. Add Extra Manpower or Machines

One quick solution is to add more workers or machines to the slow operation. However, this also increases the cost, so it's not always the best option. A good manager will try to improve without adding extra cost.

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2. Work Overtime

Many factories use overtime to meet the production target. Workers stay longer to finish more pieces and prepare extra work for the next shift.

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3. Improve Work Methods

Industrial Engineers study the way tasks are done and look for faster and easier methods. Using work aids like folders, attachments, or semi-automation can help the operator do the same job in less time and with less effort.

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4. Improve Workstation Layout

If the operator’s work area is better arranged (following ergonomics), they spend less time handling materials. This saves time and improves output.

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5. Assign the Right Operator

Jobs should be given based on skill levels:

• A Grade = Highly skilled

• B Grade = Moderately skilled

• C Grade = Less skilled

Skilled workers should handle difficult tasks, while easier tasks can be assigned to less experienced workers. This ensures better performance.

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6. Use Time-Saving Techniques

Many small things can cause delays. Here are some smart ways to save time and reduce bottlenecks:

• Use well-maintained or modern machines

• Reduce rework, as it wastes time

• Cut down on idle or ineffective time

• Follow a proper layout to reduce extra movement

• Ensure materials are ready on time

• Stick to a clear and practical Standard Operating Procedure (SOP)

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Key Observations

• ✅ Collar edge stitch is performing well (90%)—this operator is close to meeting the target.

• ⚠️ Collar turning (60%) and collar joining (55%) are bottleneck operations. They are slowing down the production flow.

• 🚫 Since material flows downward, these bottlenecks delay the following operations.

• 📉 Because of these low outputs, the next operations receive fewer pieces, even if those operators are capable of more.

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Recommendations to Improve

1. Focus on Bottlenecks: Analyze the reasons behind low performance in collar turning and joining (skill issue, method, machine problems, etc.).

2. Provide Method Improvement: Offer training or work aids to reduce time.

3. Better Operator Allocation: If possible, assign skilled operators to these weak points.

4. Consider Work Sharing: Temporarily shift some work to other operators if feasible.

5. Layout Check: Ensure smooth material flow and minimal waiting time.