Customer is asking for a Bottlenecks and Contingency Plan for our Mfg Processes



Our customer is asking for a Bottlenecks and ContingencyPlan for our manufacturing process which involves metal stamping and welding. I’venever made one before. Wanted to see if anyone had an example of a Bottlenecksand Contingency Plan they could share.


THIS PAGE from Mind tools has enough information for you to think and make such a plan.

Remember that a plan is about deciding in advance. So get that required clarity in such of your plan.


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I would look at bottlenecks and contingency as two separate things. Contingency planning is for when "disaster" hits. The previous post covered this pretty good.

Bottlenecks are really subject to your own facility. So you need to look where your constraints are and figure out how to deal with them. Could be a specific press which gets overloaded or a department. We generally deal with these instances with additional hours or outsourcing. We typically get a similar request when the customer is projecting significant increases in volume for a period of time. They want to ensure that we can support the volume. Good luck.

Richard Regalado

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Bottlenecks could be looked at from a perspective that these are the threats to the continuity of your company's operations. Typically, these "bottlenecks" have the potential to lead to the following scenarios:

loss of manpower
loss of infrastructure
loss of technology
disruption to the supply chain (upstream and downstream)
reputational loss

When threats manifest, containment is the first step to take, according to the Business Continuity Institute Good Practice Guidelines of 2013. If incidents are not contained and managed, business disruptions may happen.

When there are business disruptions, your contingency plans (i.e., business continuity plans or BCPs), needs to be activated in order for you to continue your operations within pre-determined time frames.


If the process is outsourced, can have one additional 3rd party supplier approved even if the low quantities of orders placed.

Provide reference to the Business Continuity Planning - can define a very simple to very complex processes depending on the size and the nature of ten business. There are of the shelf BCP available too.


We kept it simple and used our Risk Register. Our Manufacturing Manager had a list of equipment that had long lead times for parts for repairs. We got those on order and in our maintenance shop. So in our Manufacturing Process "Risks" this was listed in our Mitigation/Contingency Action column. We did the same thing in all processes for shortage of competent personnel, by indicating that we were cross-training.
Hope this helps.
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