V-capacity optimalisation – What is it?

 

Typically, there's one critical process responsible for the maximum capacity of a line. That process is the one with the lowest productivity and needs to be up and running as much as possible. It's generally surrounded by up and downstream parts that are faster to ensure this part is constantly fed and has the room to release it after its adding its value. If there is an issue with this part, it will negatively affect the entire efficiency of the line as there is no way of winning back the lost time as it's already running at maximum capacity.

The bottleneck needs to be protected on both sides. This is because its infeed and outfeed need to be able to run as long as possible without interruptions. In case of an upstream issue the bottleneck still needs to get enough products to keep going. And, in case of a downstream issue it still needs a way to keep its output going.

To solve this it’s possible you need to have an accumulator on both sides of this machine, depending which machine is the bottleneck. You need one in front to ensure a non-stop, steady stream of products. This can be achieved by having an accumulator stay filled for 50% (depending on the situation) and essentially act as a buffer. The front accumulator can then release products in case of an upstream stop and give service enough time to fix the issue.

Additionally, you need a second accumulator to catch any output of the bottleneck in case of a downstream issue. This way the machine can keep on producing while the issue is being fixed.

A setup like this will keep the most critical part (for efficiency) safe from any disturbances and efficiency at its maximum potential.