DeadendBetrieb

DeadendBetrieb is a term used in industrial engineering and production planning to describe a production line, department, or facility that has reached a dead end in the workflow. In this state, downstream processes cannot proceed, value-adding activity halts, and overall throughput declines, unless external intervention restores flow.

Origin and scope: The compound name blends the English "dead end" with the German word "Betrieb" meaning operation or plant. It is used as a descriptive label in lean manufacturing and operations management to highlight a localized blockage rather than a systemic failure. The term is not a formal measurement but a diagnostic concept.

Causes: Common causes include bottlenecks at subsequent processes, quality problems requiring rework, equipment failures, material shortages, incorrect line balancing, or irregular demand causing work-in-progress to pile up at the end of a line. Market changes or supply chain disruptions can convert a temporarily problematic line into a persistent deadend.

Consequences: DeadendBetrieb leads to idle capacity, increased inventory, longer cycle times, elevated work-in-progress, higher unit costs, and potential customer service issues. It can also mask underlying design or planning flaws that affect multiple lines.

Management and mitigation: Detection relies on metrics such as cycle time, throughput, overall equipment effectiveness (OEE), and WIP levels. Remedies include root-cause analysis, line balancing, preventive maintenance, supplier reliability improvements, demand smoothing, and alternative routing or subcontracting to divert bottlenecks. In some cases, redesign of the process or product may be necessary to reestablish flow.

See also: Lean manufacturing, bottleneck, throughput, value stream mapping, production planning.