Free tool
Bottleneck Calculator
Find your production line’s bottleneck station and its cost in lost throughput.
Production line stations
| Station | Cycle time, sec/unit |
|---|
Additional inputs
Result: line bottleneck
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Request a production line analysisHow the calculation works
You enter the cycle times (seconds per unit) of five stations. Line throughput = 3600 ÷ longest cycle time, because the slowest station limits the whole line. Daily output = throughput × 8 h. Lost value is calculated from the difference between the fastest station’s theoretical throughput and the actual throughput, multiplied by the margin per unit.
Example: cycle times of 30, 45, 38, 52 and 33 seconds – the bottleneck is station 4 (52 s), throughput 69 units/h, daily output 554 units and lost value EUR 406 per hour (at a EUR 8 margin).
Frequently asked questions
What is a bottleneck?
The slowest station on the line, which determines the output of the whole line.
Does removing the bottleneck raise output?
Yes, up to the level of the next-slowest station. That station then becomes the bottleneck.
Does the tool account for stoppages?
No, only cycle times. To assess the effect of stoppages, use the MTBF/OEE calculator.
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Methodology and limitations
Methodology based on standard industry calculations and Maintest’s practical industrial experience. This tool provides a planning estimate and does not replace project-specific engineering assessment. This tool is a screening and planning aid developed by Maintest. Results are indicative and depend entirely on the figures and answers you enter. They are not an engineering calculation, a safety assessment or a substitute for the manufacturer’s instructions, applicable standards or professional judgement. Weights, benchmarks and default values are Maintest planning assumptions and can be adjusted to your situation. Do not use this tool as the only basis for safety-critical decisions such as lifting, electrical work or lockout procedures.
Tool version 1.0 · Updated October 2026
Related project: Production line relocation from Helsinki to Jüri
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