Cross Line Bottleneck Synchronization & Real Time Throughput Balancing
A high speed beverage bottling and packaging plant running 6 canning lines producing 1,500 cans per minute per line across depalletizing, filling, seaming, pasteurization, and case packing.
Run on Yantra · Plant Operations & Safety
The challenge
Micro stoppages lasting 10 to 30 seconds at downstream case packers caused massive conveyor accumulation jams back to the primary filler.
Line supervisors lacked visibility into instantaneous conveyor buffer levels, leading to line speed mismatches and frequent machine tripping.
Daily plant canning output fell 18% below nameplate capacity due to uncoordinated speed transitions and accumulation backlogs.
How Yantra solves it
High Speed Optical & Accumulation Sensor Tracking
Yantra monitors can flow rates, photo eye sensor states, and conveyor accumulation buffer percentages in real time.
Micro Stoppage Root Cause Detection
Identifies recurring 15 second packaging machine jams and calculates the upstream throughput impact on primary filling units.
Dynamic Conveyor Speed Modulating
Dynamically modulates variable frequency drives (VFDs) along conveyor sections to absorb minor downstream delays without stopping the filler.
Operator Station Line Flow Displays
Renders real time bottleneck indicators and buffer capacities on overhead LED screens for machine operators.
Shift Output Optimization Analytics
Provides line managers with automated shift end loss analysis detailing top downtime contributors and recommended mechanical adjustments.
The outcome
- plant Overall Equipment Effectiveness (OEE) increased
- 0%plant Overall Equipment Effectiveness (OEE) increased
- conveyor accumulation line stoppages reduced
- 0%conveyor accumulation line stoppages reduced
Plant Overall Equipment Effectiveness (OEE) increased from 68% to 84%.
Conveyor accumulation line stoppages reduced by 55%, unlocking 180,000 additional cans produced per line daily.
Micro stoppage diagnostic time reduced from hours of manual video review to instant automated classification.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
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