Constraint-Level track. The same line as the 1-Constraint model, split into five per-machine Constraints. The throughput answer barely moves — and a new quantity appears that the rollup could not show.
At a glance
| Experiment | Single Run |
| Duration | 90 days |
| System efficiency | 54.7% |
| Production | 7.09M bottles · ~70,900 pallets |
| Output unit | bottles |
What this model is
The same bottling line as One Constraint, now modelled as five Constraints in series — Filler, Capper, Labeler, Case Packer, Palletizer — each running at 100/min and each carrying one interrupt.
The throughput prediction lands almost on top of the 1-Constraint rollup. That is the point: close-coupled machines roll up cleanly into a line-level view, so if all you want is how much the line makes, the simpler model was already enough.
The line
| Node | Name |
|---|---|
c0 |
Filler |
c1 |
Capper |
c2 |
Labeler |
c3 |
Case Packer |
c4 |
Palletizer |
The interrupts
| Interrupt | Machine | Time to failure | Time to repair |
|---|---|---|---|
| Filler | Filler | Weibull(30, 1.00) | Weibull(5, 1.00) |
| Capper | Capper | Weibull(30, 1.00) | Weibull(5, 1.00) |
| Labeler | Labeler | Weibull(30, 1.00) | Weibull(5, 1.00) |
| Case Packer | Case Packer | Weibull(30, 1.00) | Weibull(5, 1.00) |
| Palletizer | Palletizer | Weibull(30, 1.00) | Weibull(5, 1.00) |
Parameters are read from the model file as it ships. Open it in the sandbox and you will see these values.
The new thing: waiting
What the rollup could not show is how much of the time machines spend waiting on each other, because a single node has nobody to wait for. Split into five, and more than a third of the run is blocked-or-starved time.
That is not downtime. Those machines are available, staffed and ready; they have nothing to work on, or nowhere to put what they have made. It is the cost of coupling, and it is invisible at the line level.
What the run produced
- Bottleneck operating availability: 85.3%
- System OEE: 54.7%
- Bottleneck total downtime: 203.7 hours across 2,326 failure events
- Mean time between failures: 30.5 min · Mean time to recover: 5.3 min
- Throughput: 7,091,067 bottles
- Blocked or starved: 774.5 hours (35.9% of total time) — upstream/downstream constraints spent more than a third of the run waiting on each other
Top contributors
| Rank | Interrupt | Downtime | Share |
|---|---|---|---|
| 1 | Case Packer | 203.7 hrs | 100.0% |
With one interrupt per constraint, the "share of downtime" on the bottleneck stage is trivially 100% — but the real story is the 36% blocked-or-starved time, which only appears once you have serial Constraints.
Where to go next
Where the machine-level view still hides the cause: Five Constraints — LEDS, the same split with the real failure modes kept.
Open it
This model ships with ReliaSim® and runs in the browser sandbox — no install required. Open 5 Constraints in the sandbox.
Every recorded figure on this page is the published result for the model as it ships.