No buffer
Points of efficiency the fix gives back
Runs
Efficiency–
Pallets in 90 days–
vs baseline––
–No buffers
–5 min each (500 / 500 / 50)
–Ceiling (buffers never fill)
Runs
Top 12 fixes by what they give back
ranked by Gain▲▼ places moved vs no buffer
Bin level
Bin full
Plant stuck: making blocked, packing waiting
The schedule: making run length
The plant: bin size
The packing schedule stays the same. It is timed to 24-hour making runs.
Compare with
Line efficiency after each fix
At or above 85%
85%
No buffers
Every other fix tried at that step
Average random planMiddle 80%
Same fixes, worst order
Buffer on the line
Buffer 3 sits before the Palletizer; Buffer 1 after the Capper.
Minutes the mill stood starved, a day
Your tower
Longest weld × 500 ft/min
Weld time
The average weld; 4 minutes is the line as built. Each weld runs a little longer or shorter.
On hand
On order
Plant 1 filled in full (0–100%)
Runs out
Demand spike
Demand spike
Cost (demand × distance)
–