Lean Manufacturing & Operations worked example

Bottleneck Cycle Time with base processing time per unit of 23 sec: a worked example

This worked example runs the bottleneck cycle time numbers for a tougher week than the baseline: base processing time per unit of 23 sec instead of the typical 45 sec. Identify your process bottleneck by calculating effective cycle time from processing time, setup frequency, and minor stop allowance.

The inputs for this scenario

  • Base processing time per unit: 23 sec (the input this scenario stresses; the baseline uses 45)
  • Amortized setup time per unit: 3 sec (held at the documented default)
  • Minor stop allowance per unit: 2 sec (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Effective Bottleneck Time = Processing Time + Amortized Setup + Minor Stops.
  • Effective bottleneck cycle time works out to 28 sec / unit at these inputs, and this is the headline figure for the scenario.
  • Element 1 works out to 23 sec / unit at these inputs.
  • Element 2 works out to 3 sec / unit at these inputs.
  • Element 3 + 4 works out to 2 sec / unit at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where base processing time per unit sits at 45 sec and the headline result is 50 sec / unit, this scenario comes in 44% below the baseline at 28 sec / unit.
  • Use it when you have identified the constraint operation and need its real per-unit pace to compute line throughput, schedule a batch, or quote a delivery date. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Effective bottleneck cycle time: 28 sec / unit (headline result)
  • Element 1: 23 sec / unit
  • Element 2: 3 sec / unit
  • Element 3 + 4: 2 sec / unit

Run it with your numbers

  • To rerun this with your own numbers, open the live Bottleneck Cycle Time calculator, set base processing time per unit to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.