Constraint-Level track. Bottles become cases, cases become pallets. The unit of the answer changes, and so does where the constraint sits.
At a glance
| Experiment | Single Run |
| Duration | 90 days |
| System efficiency | 54.1% |
| Production | ~70,113 pallets |
| Output unit | pallets |
What this model is
Three of the five stages are now Converters rather than Constraints: the Filler, the Case Packer and the Palletizer transform the unit of flow rather than simply rate-limiting it. Ten bottles make a case, ten cases make a pallet.
This matters because a real line's output is not measured in the unit it starts in. A plant commits to pallets shipped, not bottles filled, and a model that cannot convert cannot answer the question that gets asked.
The line
| Node | Name |
|---|---|
c0 |
Capper |
c1 |
Labeler |
n0 |
Filler |
n1 |
Case Packer |
n2 |
Palletizer |
The interrupts
| Interrupt | Machine | Time to failure | Time to repair |
|---|---|---|---|
| Palletizer | Palletizer | Weibull(30, 1.00) | Weibull(5, 1.00) |
| Capper | Capper | Weibull(30, 1.00) | Weibull(5, 1.00) |
| Case Packer | Case Packer | Weibull(30, 1.00) | Weibull(5, 1.00) |
| Labeler | Labeler | Weibull(30, 1.00) | Weibull(5, 1.00) |
| Interrupt 2 | Filler | 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.
Why the bottleneck moved
With conversion in the model the binding stage is the Filler, not the Case Packer the previous model named. Neither answer is wrong; they are answers about different models. The previous one asked which of five identical-rate machines lost most time, and got noise. This one asks which stage limits pallets out, which is a question with a real answer.
What the run produced
- Bottleneck operating availability: 85.1%
- System OEE: 54.1%
- Bottleneck total downtime: 204.5 hours across 2,415 events
- Mean time between failures: 29.0 min · Mean time to recover: 5.1 min
- Throughput: 7,011,327 units (report is at the Filler-output level — 10× convert-down gets you ~70k pallets downstream)
- Blocked or starved: 787.0 hours (36.4%)
Where to go next
Does adding storage between the stages help? Adding Inline Buffers runs exactly that experiment.
Open it
This model ships with ReliaSim® and runs in the browser sandbox — no install required. Open 2 Constraints + 3 Converters in the sandbox.
Every recorded figure on this page is the published result for the model as it ships.