Leak zone
Throughput: where it leaks and how to measure it
Quick answer
Throughput loss is the saleable output a plant forfeits when material does not move cleanly through every step at the rated rate. It hides in micro-stops, slow running, starve-and-block events, and changeovers that run long.
What it looks like on site
Lines starve then surge, and product waits between steps.
What we measure
Capacity lost to sequencing, changeovers, and flow interruptions.
Key metrics
- Overall Equipment Effectiveness (OEE).
- rate loss.
- changeover time.
- starve and block time.
- schedule attainment.
What drives it
- Unbalanced lines where one constraint sets the pace for everything upstream and downstream.
- Changeovers and grade changes that run longer than standard.
- Quality holds and rework loops that pull product out of the flow.
- Poor short-interval control, so a slow hour is only noticed at shift end.
How to fix it
- Find and protect the true constraint, then schedule to it.
- Standardise and time changeovers, then attack the longest steps.
- Put a rate target and an hourly count in front of the crew running the line.
Frequently asked questions
How do you measure the throughput leak zone?
By measuring capacity lost to sequencing, changeovers, and flow interruptions. The Diagnostic quantifies it against your own CMMS and downtime data and translates it into annual dollars.
What does throughput leak look like on a plant floor?
Lines starve then surge, and product waits between steps.
See where your plant is leaking profit.
Score your operation across five leak zones in 3 minutes, or book a free 30-minute Fit Call to confirm whether a Diagnostic is the right next step.
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