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An interruption at a workstation is a major cause of production downtime, which has negative effects on performance, cost, consumer-centric value, and efficiency. Blockage and starvation brought on by broken workstations have a domino effect on the entire production line. To allocate resources effectively and minimize downtime, it is crucial to thoroughly analyze each disruption's effects. Quantitative analysis of disruption at a single workstation and its effects on neighbouring workstations are performed in the work presented. Faulty workstations have an additional threshold value added to the Alarm Trip Point (ATP), depending on their current state. This one significantly improves upon downtime mitigation and batch rejection reduction compared to previous approaches. A more general model based on multiple workstations has been developed by expanding the analysis for a single workstation. The proposed work is demonstrated in an experimental case study, an Asphalt-Processing Plant. It is applied in addition to developing a theoretical model to reduce downtime, multiple starts and stops, and numerous rejections. The proposed method reduces start-stop events by 60%, reducing rejections and downtime while increasing consumer-centric value and efficiency.

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