Your historian shows what happened. ReliaSim shows what will happen—revealing the leverage points traditional analysis systematically misses.
Validated within 1% OEE accuracy — Tom Lange, 36 years P&G
Each step builds on the last. Skip one, and your predictions lose their foundation.
Capture the physical reality of your line—scope, precedence, rates, and conversion ratios—in a single model. This is the structural skeleton everything else depends on.
A graph without failure behavior is just a flowchart. Production interrupts are where the system's true statistical character lives—and where traditional analysis goes wrong by treating each event as independent.
Run your model as-is, with no changes. Watch how production behaves through time—where flow stalls, where buffers empty, where throughput is lost before it ever appears in your Loss Tree.
Simulation is only as valuable as its credibility. Validation closes the gap between model output and historical reality—giving you the confidence to act on predictions rather than hedge against them.
This is where traditional analysis fails and ReliaSim shines. With a validated model, you can test changes before spending a dollar—and discover that your true leverage points are rarely where your Loss Tree says they are.
The sequence ends where the business begins. Armed with validated predictions and ranked experiments, you move from strategic uncertainty to strategic intelligence—committing capital where the model says it belongs.
Manufacturing systems exhibit emergent behavior—cascade effects that never appear under the original problem's name in your Loss Tree. The sequence is designed to surface them.
"Eliminating 120 one-minute problems recovers 220 minutes—because you're changing how the entire system operates under stress, not just removing 120 minutes of direct downtime."— The 120-Minute Paradox, ReliaSim core methodology
Loss Trees record what happened as independent events. Competing risk modeling reveals they're statistically interdependent—the jam at 10:23 was precipitated by system stress from prior interruptions.
A model you experiment on before validation is a model you can't trust. The sequence enforces the discipline that separates confident investment from costly guesswork.
Fortune 500 manufacturers consistently find that frequent small interruptions deliver 3× more improvement than the headline bottleneck—because of how they stress the entire competing risk system.
The six-step sequence is how Fortune 500 manufacturers validate capital decisions before committing.
ReliaSim gives plant managers the tools to run every step—from production graph to confident decision—without needing a simulation expert in the room.