Simulation Profiles

Choose a profile to simulate different factory conditions. Each profile affects machine availability, performance, quality, and energy consumption.

World Class 85%+ OEE

Best-in-class manufacturing with minimal downtime, high efficiency, and excellent quality. Represents a well-optimized, lean production environment.

Availability
MTBF20 min
MTTR1 min
Fault Rate0.01%
Performance
Efficiency98%
Speed Loss2%
Quality
Defect Rate0.5%
Scrap Ratio30%
Energy
Efficiency95%
Waste5%
Typical 65-75% OEE

Average manufacturing plant with normal operational challenges. Represents most real-world factories with room for improvement.

Availability
MTBF10 min
MTTR3 min
Fault Rate0.05%
Performance
Efficiency90%
Speed Loss8%
Quality
Defect Rate2%
Scrap Ratio50%
Energy
Efficiency85%
Waste15%
Struggling 45-55% OEE

Problem plant with frequent breakdowns, slow cycles, and quality issues. Good for testing monitoring and alerting systems.

Availability
MTBF5 min
MTTR2 min
Fault Rate0.8%
Performance
Efficiency75%
Speed Loss20%
Quality
Defect Rate5%
Scrap Ratio70%
Energy
Efficiency70%
Waste30%
Demo Fast Mode

Ultra fast-paced demonstration mode with 5x faster cycles and frequent faults. Ideal for showcasing the system with rapid events.

Availability
MTBF1 min
MTTR6 sec
Fault Rate2%
Performance
Speed5x faster
Speed Loss1%
Quality
Defect Rate1%
Scrap Ratio40%
Energy
Efficiency92%
Waste8%
Availability Problem Variable OEE

Frequent machine breakdowns and long repairs, but good quality and performance when running. Focus area: maintenance improvement.

Availability
MTBF3 min
MTTR5 min
Fault Rate0.3%
Performance
Efficiency95%
Speed Loss5%
Quality
Defect Rate1%
Scrap Ratio40%
Energy
Efficiency88%
Waste20%
Quality Problem Variable OEE

High machine uptime but significant quality defects. Good for testing quality monitoring and SPC systems.

Availability
MTBF15 min
MTTR2 min
Fault Rate0.02%
Performance
Efficiency92%
Speed Loss6%
Quality
Defect Rate12%
Scrap Ratio60%
Energy
Efficiency80%
Waste18%
Performance Problem Variable OEE

Machines run reliably but at reduced speed with frequent minor stops. Focus area: cycle time optimization.

Availability
MTBF12 min
MTTR2 min
Fault Rate0.03%
Performance
Efficiency65%
Speed Loss30%
Quality
Defect Rate2%
Scrap Ratio50%
Energy
Efficiency75%
Waste25%

Parameter Explanations

Availability

MTBF (Mean Time Between Failures)
Average time a machine runs before experiencing a fault
MTTR (Mean Time To Repair)
Average time to fix a machine after a fault occurs
Fault Rate
Probability of a fault occurring each simulation tick

Performance

Cycle Efficiency
How close actual cycle time is to ideal (100% = no slowdown)
Speed Loss Factor
Percentage of speed reduction due to various factors
Minor Stop Probability
Chance of brief micro-stops during production

Quality

Defect Rate
Percentage of parts that fail quality inspection
Scrap Ratio
Of defects, percentage that are scrapped vs reworked
Process Drift Rate
How quickly process parameters drift from optimal

Energy

Efficiency Factor
How efficiently power is converted to useful work
Idle Power Factor
Power consumption multiplier when machine is idle
Waste Factor
Percentage of energy wasted during non-production

Fault Events (Downtime)

When a machine experiences a fault, it enters a FAULTED state and stops production. Faults are generated based on MTBF and cleared after the MTTR period.

Mechanical Faults

E001 - Spindle Overload
Spindle motor drew excessive current
E002 - Tool Breakage
Cutting tool fractured during machining
E004 - Chip Conveyor Jam
Metal chips jammed the conveyor system
E005 - Part Clamp Error
Workholding fixture failed to clamp properly

System Faults

E003 - Coolant Pressure Low
Cutting fluid pressure dropped below threshold
E006 - Servo Error
Axis drive servo reported position error
E007 - Hydraulic Pressure Low
Hydraulic system pressure insufficient
E008 - Safety Door Open
Safety interlock triggered by access door

Fault Behavior

Fault Generation
Faults occur randomly based on exponential distribution using MTBF
Fault Duration
Each fault lasts approximately MTTR minutes with random variation
Auto Recovery
Faults automatically clear after repair time
Downtime Tracking
All fault events logged for OEE calculation