Elimination of constraints in the production process of power equipment components and the analysis of the resulting benefits


The article presents the results regarding the elimination of constraints in the production process of a power equipment subassembly, a boiler chamber, together with an analysis of the benefits resulting from this, both financial and non-financial. The significance of bottlenecks in the production process, ways of its identification and limitations - in general - are presented. The article is a case-study of an attempt to eliminate the bottleneck in the production process of the boiler chamber, which turned out to be the process of drilling and marking-off, and work stations representing these processes. In order to eliminate the limitation, it was decided to replace the existing tracing and drilling work with a numerically controlled device - a boring machine moved from the liquidated department.. As a result, labor-intensive, manual chambers marking-off and the process of drilling holes with a smaller diameter drill have been eliminated. A number of benefits has been demonstrated resulting from the elimination of the bottleneck in the process, first of all, it was possible to reduce the duration of the marking-off and drilling operations and reduce the costs of the boiler chamber production process.

If the inline PDF is not rendering correctly, you can download the PDF file here.

  • Goldratt, E., 1990. What is this thing called Theory of Constrains and how should it be implemented?, North River Press, New York.

  • Hamrol, A., 2017. Management and quality engineering, PWN, Warsaw. (in: Polish).

  • Hamrol, A., 2018. Strategies and practices of efficient operation. Lean Six Sigma and others, PWN, Warsaw. (in: Polish).

  • Tomkowiak, A., Koliński A., 2010. Elimination of bottlenecks as a tool to optimize production costs, Gospodarka Materiałowa i Logistyka, 10, 20–26. (in: Polish).

  • Mabin, V.J., Balderstone, S.J., 2000. The World of the Theory of Constraints: A Review of the International Literature, St. Lucie Press, Boca Raton.

  • Moor, R., Scheinkopr, L., 1998. Theory of Constraints and Lean Manufacturing: Fiends or Foes?, Chesapeake Consulting, http://www.international-paper.com.

  • Nowakowska-grunt, J., Mróz, E., 2013. Theory of Constraints as an Effective Tool for Supply Chain Management, Advanced Logistic Systems. Theory and Practice, 7(1), 71–78.

  • Panizzolo, R., 2016. Theory of Constraints (TOC) Production and Manufacturing Performance, International Journal of Industrial Engineering and Management (IJIEM), 7(1), 15–23. ISSN 2217-2661.

  • Panizzolo, R., Garengo, P., 2013. Using Theory of Constraints to Control Manufacturing Systems: A Conceptual Model, Industrial Engineering & Management, 2(111), 2169–0316. DOI:10.4172/2169-0316.1000111.

  • Pegels, C., Watrous, C., 2005. Application of the theory of constraints to a bottleneck operation in a manufacturing plant, Journal of Manufacturing Technology Management, 16(3), 302–311. DOI:10.1108/17410380510583617.

  • Rahan, S., 1998. Theory of constraints: A review of the philosophy and its applications. International Journal of Operations and Production Management, 18(4), 336–355. DOI: 10.1108/01443579810199720.

  • Shrimali, A., Soni, V., 2018. A study on the Utilization of Lean techniques/tools in Indian SMEs, Production Engineering Archives, 20(20), 32–37. DOI: 30657/pea.2018.20.07.

  • Qassim, R.Y., 2000. The Theory of Constraints in Manufacturing, Journal of the Brazilian Society of Mechanical Sciences, 22(4), DOI: 10.1590/S0100-73862000000400001.

  • Trojanowska, J., Dostatni, E., 2017. Application of the Theory of Constraints for Project Management, MPER, 8(3), 87–95. DOI: 10.1515/mper-2017-0031.

  • Ulewicz, R., 2013. Effectiveness Assessment of Functioning of Quality Assurance System, Production Engineering Archives, 1, 38–40. DOI: 10.30657/pea.2013.01.12

  • Zarzycka, E., 2010. Theory of Constraints and Lean Accounting - similarities and differences, possibilities of coexist in times of crisis. Chapter 5. In: I. Sobańka, P. Kabalski (Eds.), Accounting system during the economic crisis, 219–233. (in: Polish).


Journal + Issues