LEDS-Level track. Real failure modes plus bottle-to-pallet conversion. This is the closest model to a real plant's actual question.
At a glance
| Experiment | Single Run |
| Duration | 90 days |
| System efficiency | 54.3% |
| Production | 70,361 pallets |
| Output unit | pallets |
What this model is
The Converter topology — bottles to cases to pallets — carrying the LEDS-level failure modes. Output is measured in pallets, and the failure modes are the ones on the line's own fault list.
The line
| Node | Name |
|---|---|
c0 |
Capper |
c1 |
Labeler |
n0 |
Filler |
n1 |
Case Packer |
n2 |
Palletizer |
The interrupts
36 named failure modes, distributed across the line:
| Machine | Failure modes |
|---|---|
| Capper | 12 — Micro Stop, Upper Plow Area, Capper, Compression, and 8 more |
| Case Packer | 2 — Photo Eye, Case Packer |
| Labeler | 3 — Labeler, Label Placement, Misalignment |
| Filler | 7 — Filler, Silo to Weigh Hopper, Mix to Bulk Bin, Bulk to Filler Bin, and 3 more |
| 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.
Gain is not loss
This model carries a gain/loss analysis, and it is where the demo earns its keep. Two failure modes recorded almost identical direct losses. Removing each and re-running returns very different amounts — one returns more than it cost, the other less.
A loss report ranks where time was charged. Only re-running the model ranks where it would come back.
What the run produced
- Bottleneck operating availability: 75.4%
- System OEE: 54.3%
- Bottleneck total downtime: 382.7 hours across 15,705 failure events
- Mean time between failures: 4.5 min · Mean time to recover: 1.5 min
- Throughput: 7,036,099 units (~70,361 pallets downstream of the converters)
- Blocked or starved: 604.6 hours (28.0%)
Top contributors (Capper)
| Rank | Interrupt | Downtime | Share |
|---|---|---|---|
| 1 | Capper_Upper Plow Area | 206.4 hrs | 53.9% |
| 2 | Capper_Picker Tree Assembly | 57.9 hrs | 15.1% |
| 3 | Capper_Lower Plow Area | 22.8 hrs | 5.9% |
| 4 | Capper_Glue Station | 20.6 hrs | 5.4% |
| 5 | Capper_Carton Magazine | 18.5 hrs | 4.8% |
Where to go next
Does buffering help this line? Buffer Options — LEDS.
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.