Current throughput
130units / hour
20% below targetProduction Bottleneck Agent
Generated operating condition · Seed 47291
Find the constraint.
Test the fix.
Generate a fresh set of synthetic line readings that mimics incoming event data. Review the line condition, then run a diagnosis to compare practical fixes before changing the real line.
Problems represented
MAPAcross the full production flow
IN Supply · schedule · qualityLINE Staffing · equipment · reworkOUT Staging · packing · pickupTarget throughput
162units / hour
Current shift goalWork in progress
43units on line
Low — stations may run out of workCurrent line readings
Line state
OKWatchCheck nowCircled = comparison clue
Main flow
01OK
Load
- Time / unit
- 10s / goal 15s
- Busy
- 57%
- Stopped
- 4%
- Waiting material
- 0%
- Can't unload
- 0%
Split
02OK
Preprocess
- Time / unit
- 14s / goal 15s
- Busy
- 60%
- Stopped
- 2%
- Waiting material
- 0%
- Can't unload
- 0%
Branch A
03OK
Process A
- Time / unit
- 14s / goal 16s
- Busy
- 77%
- Stopped
- 4%
- Waiting material
- 0%
- Can't unload
- 0%
Branch B
04WATCH
Process B
- Time / unit
- 15s / goal 16s
- Busy
- 64%
- Stopped
- 6%
- Waiting material
- 0%
- Can't unload
- 0%
Requires A + B
05OK
Merge
- Time / unit
- 9s / goal 12s
- Busy
- 58%
- Stopped
- 2%
- Waiting material
- 0%
- Can't unload
- 0%
Quality gate
06WATCH
Inspect
- Time / unit
- 13s / goal 14s
- Busy
- 61%
- Stopped
- 5%
- Waiting material
- 0%
- Can't unload
- 0%
Pass
07OK
Pack
- Time / unit
- 13s / goal 15s
- Busy
- 58%
- Stopped
- 1%
- Waiting material
- 0%
- Can't unload
- 0%
Rework loop ↺
split to parallel brancheswait for both branchesfailed units return to Inspect08OK
Rework
- Time / unit
- 16s / goal 18s
- Busy
- 36%
- Stopped
- 2%
- Waiting material
- 0%
- Can't unload
- 0%
What the event pattern showsSimulated observations; scenario assumptions are labeled
Material arrival patternHighly uneven
Both branches wait for material24%
Branch B short stops18 / hr
Staffing waits happening together39%
Scenario playbookSee every problem pattern, what it means, and the first action to testView playbook + terms
Clue: Work in progress is low and both processing branches wait at the same time.
Meaning: Units enter the line in uneven batches, so stations run out of work.
First action: Feed smaller batches at regular intervals without raising the planned total.
Clue: Work in progress is high and Pack has nowhere to place completed units.
Meaning: Pallet collection is too irregular, so congestion backs up through the line.
First action: Request pickup when the finished-goods area reaches a set fill level.
Clue: Rejects rise even though known-good parts still pass independent checks.
Meaning: Inspect is incorrectly rejecting good units.
First action: Recheck Inspect using known-good sample parts.
Clue: Output falls after frequent product-family changes.
Meaning: Too much time is spent changing the line between products.
First action: Run compatible product families together.
Clue: One processing branch pauses repeatedly and Merge waits for it.
Meaning: Process A or B has frequent brief equipment stops.
First action: Repair the recurring stop at the affected branch.
Clue: The completed-unit area stays full even with ordinary pickups.
Meaning: There is not enough staging space after Pack, so congestion backs up through the line.
First action: Add controlled temporary overflow space.
Clue: Inspect and Pack wait for help during the same periods.
Meaning: One operator is stretched across both stations.
First action: Provide separate coverage during peak periods.
Clue: Pack pauses frequently even when output space is available.
Meaning: A recurring equipment fault interrupts Pack.
First action: Repair the repeated Pack stoppage.
Clue: Too many units fail inspection and return through Rework.
Meaning: The upstream process is creating excess defects.
First action: Correct the upstream defect source before adding Rework capacity.
How to read these cluesUse combinations of clues—not one number alone.
Both branches wait togetherIncoming material may be arriving unevenly.
One station stops with work availableCheck that station for an equipment fault.
Pack cannot unloadPack is blocked—not starved—by pickup or staging space.
Rejects and Rework riseCheck Inspect and upstream quality before adding capacity.
Inspect and Pack wait togetherThey may be competing for the same operator.
Output falls after product changesSetup time may be consuming the shift.
OK / Watch / CheckWatch: over goal, ≥90% busy, ≥5% stopped, or ≥10% waiting/blocked. Check: over 20% above goal, ≥15% stopped, or ≥20% waiting/blocked.
Circled valueA comparison clue used by the diagnosis. It is not automatically a bad result.
Scenario assumptionA condition supplied to the synthetic case, not a conclusion inferred from another displayed clue.
Work in progress (WIP)Every unit on the line or waiting between stations. Too little can starve stations; too much can signal congestion.
Brief equipment stopA short unplanned pause caused by a jam, sensor, reset, or similar equipment issue.
Waiting for materialThe station is available, but no unit has reached it.
Cannot unloadThe station finished its work, but the next space is full.
ReworkA failed unit is corrected and sent through inspection again.
Next step
Ready to diagnose this line condition
Use the current line readings and event pattern to identify the likely cause and compare three possible first actions.