Constraint Identifier

Overview

The Constraint Identifier skill provides comprehensive capabilities for identifying and exploiting system constraints using Theory of Constraints (TOC) principles. It supports bottleneck identification, throughput analysis, and implementation of the five focusing steps.

Capabilities

• Bottleneck identification algorithms
• Throughput rate analysis
• Constraint exploitation strategies
• Subordination planning
• Buffer sizing calculation
• Constraint elevation options
• Drum identification

Used By Processes

• TOC-001: Constraint Identification and Exploitation
• TOC-002: Drum-Buffer-Rope Scheduling
• CAP-001: Capacity Requirements Planning

Tools and Libraries

• Simulation software
• Throughput analysis tools
• Process mapping tools
• Data analytics platforms

Usage

skill: constraint-identifier
inputs:
  process_steps:
    - name: "Cutting"
      capacity: 120
      demand: 100
    - name: "Assembly"
      capacity: 80
      demand: 100
    - name: "Testing"
      capacity: 110
      demand: 100
    - name: "Packing"
      capacity: 150
      demand: 100
  current_throughput: 78
  target_throughput: 100
outputs:
  - constraint_identification
  - exploitation_strategies
  - subordination_plan
  - elevation_options
  - buffer_recommendations

Five Focusing Steps

Step 1: Identify the Constraint

• Analyze capacity vs. demand at each step
• Look for WIP accumulation points
• Identify resource with lowest throughput

Step 2: Exploit the Constraint

• Ensure constraint never starves or blocks
• Eliminate waste at constraint
• Maximize constraint utilization

Step 3: Subordinate Everything Else

• Pace non-constraints to constraint
• Implement pull system from constraint
• Don't overproduce at non-constraints

Step 4: Elevate the Constraint

• Add capacity at constraint
• Reduce setup time
• Improve quality at constraint

Step 5: Prevent Inertia

• Return to Step 1
• Find new constraint
• Continue improvement cycle

Constraint Types

Type	Description	Examples
Physical	Resource limitation	Machine capacity, labor
Policy	Rule-based limitation	Batch sizes, schedules
Market	Demand limitation	Customer orders
Supplier	Input limitation	Raw material availability

Integration Points

• Manufacturing Execution Systems
• ERP systems
• Simulation software
• Production planning systems