Latest trends in manufacturing simulation

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Latest trends in manufacturing

(simulation)

Rienk Bijlsma

November 8, 2011 1 Latest trends in manufacturing simulation

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Contents

• Important themes

• Project findings

• Production assets lifecycle

• Lifecycle of models

2 Latest trends in manufacturing simulation November 8, 2011

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Important themes


• Continuous improvement

• Personnel & leadership

• Sustainability

• Emerging markets

• Investment climate

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Continuous improvement


• Lean manufacturing

• Operational excellence

• Six sigma

• Value stream mapping

• TPM (Total productive maintenance)

• TQM (Total quality management)

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Personnel and leadership


• Leadership skills

• Change management

• Training personnel

• Flexibility of personnel

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Sustainability


• How to eliminate waste

• Cradle to cradle

• Carbon footprint reduction

• Reduce energy consumption

• Using raw materials as efficient as possible

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Emerging markets


• Strategic choice of production locations

• Roll of the supply chain

• Local legislation

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Investment climate


• How can we cut cost and maintain quality

• How can we increase production volume with our existing assets

• How to respond to changing market conditions

• Product innovation

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What do we see in our projects


• Interest in serious games for training – HSE, management, operators

• Limited interest in supply chain/market model

• Easy user interfaces to models

• Drive away from local installations

• Planning/scheduling, business analytics

• Emerging applications – Wind farms, Biofuels, Lean six sigma

• New model KPI’s – Emissions, energy/utility consumption,

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Production assets lifecycle


Design

Build

Operate Maintain

Improve

Replace

Greenfield: - simulation modeling-

- emulation- -vertical startup-

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11 Added value of simulation in the design of terminals November 8, 2011

Design

Build

Operate Maintain

Improve

Replace

Brownfield: - scheduling/planning -

-serious gaming – -Safety culture -

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Design

Build

Operate Maintain

Improve

Replace

Brownfield terminal: -simulation modeling-

-lean six sigma-

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Added value of modeling


Design

Build

Operate Maintain

Improve

Replace

2 or 3 cranes? Enough packaging lines?

12.45 pm – MB SLK white– Line1 14.30 pm – MB S500 Black– Line1

------------------------------- (How) Can we handle this

new order?

What if we change our paintshop configuration? Should we add more ....?

Lower CAPEX

Better service

Higher efficiency

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Lifecycle of models


Model building

Model testing

Model experimenting Project complete

Model death

Model running

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Why do models die?


• Model build to support onetime investment decision – New (air)port, new petrochemical complex, new terminal ...

• Original model builder not available – Left company, other project, career move, retirement ...

• Modeled system changes – Data no longer correct, process changes ...

• Time for model resurrection too long – Model results expected in hours/days not weeks/months

• System no longer running – IT support, installation, model versions, software versions ...

• Decision maker cannot run experiments – No user interface, no training, no documentation no support

...

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How to keep models alive?


• Design model to support operational and tactical decisions – Airport: new runway, new flight schedule, new gate allocation...

• User interface for decision makers – Ease of use, scenario creation, results, analysis

• System available on internet or intranet – No installation, available anywhere, no version problems ...

• Support from professional organization – User support & training, model updates, IT integration ...

• Document & demonstrate the delivered value!

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Models on the internet

November 8, 2011 Added value of simulation in the design of terminals 19

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Visit our website: www.systemsnavigator.com

Systems Navigator B.V.

Delftechpark 38

2628 XH Delft

The Netherlands

Thanks for your attention…

Latest trends in manufacturing simulation

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