Throughput Calculator
Calculate production throughput rate and identify bottleneck constraints.
Calculator
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Throughput: 216 units/shift
Formula
Throughput = Available time × Efficiency / Cycle time. Bottleneck throughput = min(throughput across all workstations). System throughput is limited by the slowest workstation.
Example calculation
Three workstations with cycle times 2.0, 3.5, 2.8 min/unit, all with 90% efficiency over 480 min shift. Throughputs: 480×0.9/2.0=216, 480×0.9/3.5=123, 480×0.9/2.8=154 units/shift. Bottleneck = WS2 at 123 units/shift.
Engineering notes
Theory of Constraints (TOC) states: the system output equals the bottleneck output. Improving any non-bottleneck workstation does not increase system throughput — only improving the bottleneck matters. Identify the bottleneck, exploit it, subordinate everything else to it, then elevate it.
When to use this calculator
- Bottleneck identification — find the constraint limiting overall plant output
- Production scheduling — set realistic daily output targets from actual measured throughput
- Capacity expansion — determine whether adding a second shift or machine at the bottleneck is needed
- Process improvement prioritisation — focus improvement projects on the bottleneck for maximum impact
- Sales forecasting — provide accurate maximum monthly output for sales and order commitment purposes
Frequently asked questions
- What is the Theory of Constraints and how does it relate to throughput?
- The Theory of Constraints (TOC), developed by Eli Goldratt, states that every system has at least one constraint that limits its output. To increase throughput: (1) Identify the constraint. (2) Exploit it — maximise use of the constraint, eliminate its idle time. (3) Subordinate everything else — schedule all other resources to feed the constraint optimally. (4) Elevate the constraint — add capacity if needed. (5) Find the new constraint and repeat.
- How do I calculate throughput in a multi-product production line?
- For multiple products sharing the same line, calculate throughput in standard minutes or equivalent units. Convert each product to "standard units" using relative cycle time ratios. Alternatively, calculate required capacity in minutes/shift for the planned product mix and compare with available minutes. The product requiring the most time per planned unit defines the effective throughput constraint.
- What is throughput accounting?
- Throughput accounting is a TOC-based management accounting method: Throughput (T) = Sales − Totally Variable Costs (material only). Investment (I) = all money tied up in the system. Operating Expense (OE) = all other costs. Profit = T − OE. Decisions are evaluated by their impact on T, I, and OE in that priority order — rather than traditional cost allocation which can lead to decisions that reduce throughput.