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Predict bottlenecks before they delay production.

Trooba Flow reveals where work will queue, how lead times will change, and where hidden capacity exists — before delivery performance is affected.

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Four-operation routing — Milling, Lathe, Assembly, Packing. Work queues before Assembly, the constrained operation at 91% projected utilisation.Milling62%0.5 dLathe74%1.1 dAssembly91%3.2 dPacking58%1.4 dQueue time before each operation · projected, illustrative modelAssembly · 91% projected utilisation · queue growing

Routing · projected utilisation and queue

  1. Milling62%queue 0.5 d
  2. Lathe74%queue 1.1 d
  3. Assembly91%queue 3.2 d
  4. Packing58%queue 1.4 d

Illustrative model of a four-operation plant.

Your factory may have capacity. Flow determines how much of it you can use.

Projected flow · illustrative model
Four-operation routing — Milling, Lathe, Assembly, Packing. Work queues before Assembly, the constrained operation at 91% projected utilisation.Milling62%0.5 dLathe74%1.1 dAssembly91%3.2 dPacking58%1.4 dQueue time before each operation · projected, illustrative modelAssembly · 91% projected utilisation · queue growingAssembly · 80% projected utilisation · queue clearedProjected manufacturing critical-path time, by operationMillingLatheAssemblyPacking8.4 daysMillingLatheAssemblyPacking5.1 dayscurrent 8.4 dDark: processing time. Light: waiting. Teal: waiting at Assembly.Segments follow the routing order above: Milling, Lathe, Assembly, Packing.

Routing · projected utilisation and queue

  1. Milling62%queue 0.5 d
  2. Lathe74%queue 1.1 d
  3. Assembly91%queue 3.2 d
  4. Packing58%queue 1.4 d

Lead time by operation

Milling
Lathe
Assembly
Packing
ProcessingWaitingWaiting at Assembly

8.4
days lead time
1,240
units of work in process
2.2
days of that spent processing — unchanged

Moving part of the Assembly load to a line the routing can already reach takes Assembly from 91% to 80%. Processing time does not change at all — every day saved is a day of waiting removed.

From factory data to a decision.

Every screen answers three questions in the same order: what is happening, why, and what to do about it.

Trooba FlowOverviewIllustrative model
  • Overview
  • Bottleneck Radar
  • What-if Studio
  • Flow & Queue
  • Capacity
  • Routings
  • Resources
  • Demand

What is happening

Assembly is predicted to become the next constraint.

91%
projected utilisation
3.2 d
projected queue
8.4 d
projected lead time

Why

Demand mix is shifting toward products that need more Assembly time.

64% of the increase

Work arrives from Lathe in large transfer lots, in bursts rather than steadily.

26% of the increase

Projected queue at Assembly. The dashed line is the current average.

Projected queue time at Assembly rises to 3.2 days over the next ten days, against a current average of about 1.1 days.3.2 d3 d1 dnow+10 daysProjected queue time at Assembly rises to 3.2 days over the next ten days, against a current average of about 1.1 days.3.2 d3 d1 dnow+10 days

What to do

Move part of the Assembly load to a second qualified line.

91% → 80%
projected utilisation at Assembly
−39%
projected lead time
±0
added capacity

Trooba Flow. Figures throughout are from an illustrative model, not a customer result.

Measured in a real factory.

28 → 7 days

>75% reduction in manufacturing lead time · same factory, same machines

The constraint was not machine speed. It was lot sizing and queue dynamics — the way work was moving through the system.

Tarinika · jewellery manufacturer · multi-SKU, make-to-order.
Tarinika is the founder’s manufacturing company.

Read the case study

Trooba Flow is also being validated with a high-mix packaging manufacturer as a design partner. Those results are modelled, and are labelled as modelled.

Model. Understand. Improve.

01

Model

Products, routings, resources, demand and variability.

A routing network: seven work centres connected by the paths products take through them.MillLatheSlitGlueAssyPackQC
02

Understand

See where queues, constraints and lead time emerge.

The same routing with work accumulating at the third operation, marked as the emerging constraint.MillingLatheAssemblyPackingConstraint emerging
03

Improve

Test changes before making them on the factory floor.

Current model at 8.4 days and 1,240 units against a scenario at 4.9 days and 760 units: 42 per cent less lead time, 39 per cent less work in process. Illustrative.Current8.4days lead time1,240units WIPScenario5.1days lead time750units WIPImpact−39%lead time−40%WIP

Sophisticated underneath. Simple where it matters.

Trooba models how demand, variability, routing and resource loading interact to create queues and lead time. AI explains the model. The mathematics grounds it.

See the methodology

See how work really flows through your factory.

Share a small set of factory data and see where queues, bottlenecks and hidden capacity are affecting performance.

Request a Flow Analysis