In complex operations, the instinct to “work faster” often makes performance worse. Teams optimize local activity—more tasks, more movement, more overtime—while overall throughput stays flat. The reason is simple: throughput is governed by constraints.
If you improve everything except the constraint, the system doesn’t improve.
Local efficiency is not the same as flow
A department can be very busy and still not improve throughput. High utilization can actually increase queue time and delay. Flow improves when work moves smoothly through the constraint with minimal waiting, rework, and variation.
Find the constraint (not the loudest problem)
Constraints show up as:
- Persistent queues upstream
- Downstream starvation (waiting for input)
- Higher lead time and variability around one step
- Frequent expedites around the same area
But constraints can be hidden by firefighting. Use a simple approach:
- Trace a unit of work through the process (or a job through maintenance)
- Record waiting points and reasons
- Identify the step that consistently limits completion
The constraint is where work becomes “stuck,” not where people complain the most.
Measure what matters: queue time and variability
Most “bottleneck” discussions focus on cycle time. In reality, queue time dominates. Two levers matter:
- WIP (work-in-progress): too much work released creates congestion
- Variability: unstable inputs and frequent changes disrupt flow
Even small variability at the constraint can ripple through the system.
Five practical levers to improve constraint performance
You don’t need a full transformation. Start with these levers:
1) Protect the constraint
Ensure the constraint is not interrupted by avoidable issues: missing materials, unclear priorities, unplanned meetings, or low-value tasks. Protecting time is often the fastest win.
2) Subordinate upstream to the constraint
Stop releasing more work than the constraint can handle. This feels counterintuitive, but it reduces congestion and improves lead time.
3) Simplify changeovers and handoffs
If the constraint suffers frequent changeovers, clarify sequencing rules, reduce unnecessary switches, and standardize preparation.
4) Stabilize inputs
The constraint cannot perform with unstable inputs. Improve readiness checks upstream so the constraint receives “ready” work, not partial work.
5) Elevate only when necessary
Before adding people or equipment, remove waste and stabilize. Elevation is costly; control and simplification often deliver more.
Sustain improvements with a simple control routine
Constraint improvements will decay unless you manage them. Add:
- A daily constraint review (what blocked it yesterday?)
- A trigger list (top recurring blockers)
- Action tracking with owners
Where INJARO helps
INJARO helps teams diagnose constraints, redesign planning and release rules, and define control routines. We make the process automation-ready by defining priority logic and information requirements clearly—so digital workflow tools can be implemented later by internal IT or an implementation partner.
Improving flow is not about pushing harder everywhere. It’s about controlling the constraint and reducing the friction that keeps work from moving.
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