Find and fix the bottleneck

Who this is for

Founder led lower-middle market companies with 5 to 50 million in annual revenue that want stable delivery while they scale.

The quick answer

Map the path from order to cash and measure flow at each step. Look for growing queues, long cycle time, and high rework. Confirm the one constraint and protect it with the right skills, tools, and buffers. Move work that does not add value away from the constraint. Track throughput, work in progress, and lead time each week until the constraint shifts.

The method in seven steps

Draw the flow
Start with order entry and end at cash in. List each step, the average time, queue size, and rework rate. Keep it on one page.
Measure three signals
Throughput per day or per week, work in progress at each step, and total lead time. Rising queues or rework usually point to the constraint.
Confirm the constraint
Run a short test by adding capacity or priority to the suspected step. If total output rises, you found the constraint.
Protect the constraint
Place your best people there, keep the tools maintained, and pre stage materials. Add small buffers to keep it fed.
Move non value work away
Shift inspections, admin, or prep steps before or after the constraint. Anything that does not add value should not sit on the constraint.
Elevate only when needed
If protection is not enough, add hours, cross train, bring in a partner, or invest in tooling. Start with the lightest option.
Track weekly and repeat
Watch throughput, work in progress, and lead time. When the constraint moves, repeat the process.

Example

A light manufacturer mapped the flow and found a build cell that starved because picking was slow. They moved labelling and paperwork out of the cell and pre staged parts. Throughput rose by twenty two percent and lead time fell.

Pitfalls and fixes

Fixing everywhere at once. Focus on the single constraint.
Large batch sizes. Use smaller batches so flow improves.
No data. Count units and queues by step once a week.

Checklist

One page flow map
Three core signals tracked
Constraint named and protected
Non value work moved away
Weekly review on the calendar