FI-2026-000234SolvedBusiness

Shop floor productivity fell after we installed better equipment

Reference
FI-2026-000234
Category
Business
Published
Oct 11, 2026
Read by
1

The problem

We replaced ageing machines with faster ones and output per shift went down. Operators say they prefer the old setup.

What we told them

When output falls after a capability increase, the bottleneck moved and nobody re-planned around it. Faster machines upstream simply build inventory in front of whatever is now the slowest step, and that queue hides as "busy". Walk the line and find where work is waiting, not where people are working. Listen to the operators properly — they usually know exactly where it now jams and are rarely asked.

Got one of your own?

Tell us what is actually going wrong, in your own words.
No forms to decode, no jargon required.

Submit your problem