Exploring the World of Technopolis Through Blogging
RoadmapIT
June 10, 2025
7 Silent Bottle Necks Slowing Down Your Factory
Why busy factories still miss deadlines — and how to fix it
Every factory looks busy. Machines are running, people are moving, orders are coming in.
But delivery dates slip. Overtime piles up. Teams are always firefighting.
The problem isn’t effort — it’s invisible bottlenecks.
What Factory Heads Don’t Say
(But Always Feel)
“Why does everything feel so reactive?”
“Why do delays reach me only after customers complain?”
“Why is getting clear answers so hard?”
The 7 Silent Bottlenecks
1. Missing Job Priorities
Operators work on what’s available, not what’s urgent.
Fix: Daily priority board from planning
2. Material Shortages Mid-Process
Jobs stop halfway due to missing items.
Fix: Material check before job release
3. Informal Communication
Verbal or WhatsApp decisions — no traceability.
Fix: Written shift handovers
4. Invisible Downtime
Small daily stops become hours weekly.
Fix: Track all stoppages
5. Undocumented Rework
Rework becomes “normal” and ignored.
Fix: Log rework + weekly RCA
6. No WIP Visibility
Jobs disappear between stations.
Fix: Visual WIP tracking
One Change a Week = One Smooth Factory
- Monday – Observe
- Tuesday – Document
- Wednesday – Discuss
- Thursday – Decide
- Friday – Implement
Operations excellence doesn’t start in the boardroom.
It starts on the shopfloor — with clarity.
