Increasing Throughput by Removing Flow Constraints in Chemical Plants
                     Increasing Throughput By 
Removing Flow Constraints In 
Chemical Plants
A structured approach to improve output without adding 
capacity
www.bmgindia.com
Introduction
In chemical plants, throughput is rarely limited by installed 
capacity alone. More often, it is constrained by how material, 
decisions, and information flow through the system.
Sustainable throughput improvement comes from removing 
flow constraints, not from pushing assets harder.
Why Throughput Plateaus 
Despite Adequate Capacity
Throughput often stalls due to:
• Local optimization across units instead of system-level flow
• Hidden constraints masked by buffers and workarounds
• Process instability forcing conservative operating rates
• Frequent interventions during transitions and disturbances
These issues are common even in well-equipped plants.
Identifying Flow Constraints 
Across the Plant
Flow constraints typically appear as:
• Units that frequently dictate plant rate
• Long recovery times after upsets or grade changes
• Accumulation of intermediate inventory
• Downstream units waiting on upstream stabilization
The apparent constraint often shifts, making end-to-end 
analysis essential.
Removing Constraints Through 
Process Excellence
Throughput improves when flow is designed intentionally.
Key actions include:
• Diagnosing value streams from feed intake to final product
• Reducing variation in critical process parameters
• Stabilizing operations before increasing rates
• Aligning operating windows across interconnected units
This improves output without increasing safety or reliability 
risk.
Execution Discipline and Problem-Solving
Constraint removal fails when issues are handled in isolation.
Effective execution requires:
• Treating recurring flow interruptions as system-level problems
• Applying structured problem-solving for root cause resolution
• Redesigning processes instead of adding manual controls
• Embedding flow-focused metrics into daily management
Discipline ensures improvements are sustained.
Role Of BMGI India
BMGI India supports chemical plants by:
• Identifying true flow constraints across the value stream
• Strengthening process stability and execution discipline
• Removing bottlenecks through structured problem-solving
• Aligning strategy deployment with throughput objectives
The focus remains on measurable and sustainable 
performance improvement.
Conclusion
Increasing throughput does not require more 
assets. It requires better flow.
Plants that identify and remove systemic 
constraints achieve higher, more stable output 
while protecting safety, quality, and reliability.
Breakthrough Management 
Group
India Private Limited
Location: 905/906 Raheja Chambers, 213 Nariman Point,
Mumbai, Pin-400021, India
Phone: +91 22 4002 0045/46 |  Email: [email protected]