Initial Situation
A mid-sized manufacturer reported recurring line blockages and unstable throughput during high-mix shifts.
Historic OEE values suggested mechanical downtime was the issue, but the pattern changed by product family.
What the Model Showed
Simulation runs revealed that short transport delays and buffer logic, not machine speed, were driving blockages.
After updating transfer rules and workstation sequencing, blocking time dropped significantly in most scenarios.
- 23% less blocking at the constraint station
- 11% throughput gain in peak-mix scenarios
- Fewer urgent line interventions per shift
Implementation Takeaway
The best results came from small control and flow changes, not a major capex project.
Simulation made trade-offs visible early and aligned engineering and operations around one decision model.