In the corrugated cardboard industry, efficiency is key to staying competitive. However, many plants face a common issue that limits productivity: bottlenecks.
The restrictions created by bottlenecks within the workflow slow down production, increase operating costs, and negatively affect service quality. Therefore, identifying and eliminating them is essential for improving the plant.
What is a bottleneck?
A bottleneck is any point in a process (or production stage) where capacity is lower than demand. When part of the process cannot keep pace with the rest, the entire system is affected, leading to work accumulation, downtime, or a general slowdown.
In corrugated cardboard manufacturing, such situations can arise at various stages of the production process.
Example of a production bottleneck
In a corrugated cardboard manufacturing plant, the process consists of several stages: paper corrugation, die-cutting, printing, stacking, and palletizing. During a production analysis, it was identified that the die-cutter was operating at a lower capacity than the other machines. While the corrugator and printer could process up to 200 sheets per minute, the die-cutter could only reach 120 sheets per minute due to its age and poor maintenance.
As a result, the production flow had to adjust to the slower pace of the die-cutter, leading to sheet buildup at the machine’s entry point. This accumulation not only took up space on the production floor but also forced operators to temporarily stop the previous machines to avoid saturation, thereby decreasing overall system efficiency.
In this case, the die-cutter represents a bottleneck, as it limits the production capacity of the entire line and reduces overall output.
How to identify bottlenecks?
In real-world industries with large production chains, processes are rarely fully homogeneous, and bottlenecks are not always easily visible.
Detecting bottlenecks requires careful observation of the workflow. Common signs include:
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Accumulation of materials at a specific stage.
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Longer waiting times between processes.
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Machines with low utilization compared to others.
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Operators inactive for long periods.
Using key performance indicators (KPIs), such as OEE (Overall Equipment Effectiveness), and tools like time and motion analysis or value stream mapping can help identify bottlenecks.
Strategies to eliminate bottlenecks
Once identified, bottlenecks can be resolved through various strategies.
Sometimes, small adjustments in the operating sequence can free up capacity or improve synchronization between machines. Process optimization—reconfiguring production lines to balance workloads—can be a solution.
Automation is another option. Implementing technologies such as smart conveyors, automatic stackers, or planning software can help streamline repetitive tasks, minimize errors, and increase speed without compromising quality.
Avoiding unexpected failures through scheduled maintenance is crucial. Unplanned downtime can create temporary bottlenecks with high hidden costs.
Finally, a well-trained team can respond more quickly to unforeseen events and manage the workflow more efficiently, especially in manual operations.
