In lean production, what is the purpose of buffer spaces at bottlenecks?

In lean production, what is the purpose of buffer spaces at bottlenecks?

• A. To relieve bottlenecks and ensure smooth flow
• B. To increase machine downtime
• C. To confuse workers
• D. To enlarge inventory

Answer: (B)

Buffers around bottlenecks act as a cushion of work-in-process that protects the bottleneck from variability in earlier steps. By having a small stock of unfinished work queued before the bottleneck, the machine or operation designated as the bottleneck seldom sits idle. If upstream processes slow down or encounter minor delays, the buffer keeps the bottleneck busy, helping the overall line keep moving and maintain steady throughput. This approach is about smoothing flow and reducing the risk of line stoppages, which is a key aim in lean systems. It does require storing some inventory, but the benefit is more reliable production and less downtime at the constraint. The goal isn’t to increase downtime or to confuse workers or to simply enlarge inventory; it’s to protect the flow by absorbing variability so the bottleneck can operate consistently.

Buffers around bottlenecks act as a cushion of work-in-process that protects the bottleneck from variability in earlier steps. By having a small stock of unfinished work queued before the bottleneck, the machine or operation designated as the bottleneck seldom sits idle. If upstream processes slow down or encounter minor delays, the buffer keeps the bottleneck busy, helping the overall line keep moving and maintain steady throughput.

This approach is about smoothing flow and reducing the risk of line stoppages, which is a key aim in lean systems. It does require storing some inventory, but the benefit is more reliable production and less downtime at the constraint. The goal isn’t to increase downtime or to confuse workers or to simply enlarge inventory; it’s to protect the flow by absorbing variability so the bottleneck can operate consistently.