LEDS-Level track. The real failure modes, distributed across five machines. Now the bottleneck is a machine with a name and a reason.
At a glance
| Experiment | Single Run |
| Duration | 90 days |
| System efficiency | 54.0% |
| Production | 7.00M bottles · ~70,000 pallets |
| Output unit | bottles |
What this model is
The five-machine split of Five Constraints in Series, but carrying the LEDS-level interrupt sets rather than one rolled-up Weibull per machine.
The line
| Node | Name |
|---|---|
c0 |
Filler |
c1 |
Capper |
c2 |
Labeler |
c3 |
Case Packer |
c4 |
Palletizer |
The interrupts
36 named failure modes, distributed across the line:
| Machine | Failure modes |
|---|---|
| Filler | 7 — Filler, Silo to Weigh Hopper, Mix to Bulk Bin, Bulk to Filler Bin, and 3 more |
| Capper | 12 — Micro Stop, Upper Plow Area, Capper, Compression, and 8 more |
| Labeler | 3 — Labeler, Label Placement, Misalignment |
| Case Packer | 2 — Photo Eye, Case Packer |
| Palletizer | 12 — Hoist Area, Palletizer, Slat Sorter, Film_Break, and 8 more |
Each carries its own time-to-failure and time-to-repair distribution, fitted per mode. Click a node in the sandbox to see them.
A bottleneck you can act on
The Constraint-Level version of this model named the Case Packer, roughly 0.8 points below four identical siblings — noise. Here the Capper is the binding stage by a wide margin, and one of its own failure modes accounts for more than half of its downtime.
That is a work order. The previous model could not produce one, not because it was built wrong but because averaging a machine's failure modes into a single Weibull destroys the distinction between them.
What the run produced
- Bottleneck operating availability: 75.7%
- System OEE: 54.0%
- Bottleneck total downtime: 373.7 hours across 15,456 failure events
- Mean time between failures: 4.5 min · Mean time to recover: 1.5 min
- Throughput: 7,001,465 bottles
- Blocked or starved: 619.4 hours (28.7%)
Top contributors (Capper only)
| Rank | Interrupt | Downtime | Share |
|---|---|---|---|
| 1 | Capper_Upper Plow Area | 199.2 hrs | 53.3% |
| 2 | Capper_Picker Tree Assembly | 56.3 hrs | 15.1% |
| 3 | Capper_Lower Plow Area | 21.2 hrs | 5.7% |
| 4 | Capper_Glue Station | 21.1 hrs | 5.7% |
| 5 | Capper_Carton Magazine | 19.9 hrs | 5.3% |
The Upper Plow Area alone is 53% of Capper downtime. That's where the engineering investment goes. Downtime on other Constraints doesn't even place.
Where to go next
Add unit conversion: Two Constraints, Three Converters — LEDS.
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.