Production simulation

Production system planning and development with simulation

Delfoi delivers to its customers simulation and development services of new and existing factories, production cells and lines. Our main application for factory simulation is FlexSimTM, which is the most advanced and flexible software available for Discrete-event-simulation with 3D-interface. We also can use Delmia Quest for those customers, that have existing Quest software in their own use.

The main benefit of simulation is that our customers can minimize risk by using simulation. The efficiency and service-level of operations operability can be simulated in advance. The layout of the planned system can be planned to meet both production and financial requirements. Important guidelines for the production system can be selected in advance.

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Picture: Valio, Simulated model of the production plant in Seinäjoki

With the help of computer simulation, existing production systems can be better understood. By analyzing dependencies between production factors, the effect that changes will have on the operations of an existing production plant, can be verified. And if a new factory or a new site for a service provider to be constructed –  the functioning of production, service and logistics processes can be verified before the first product has been manufactured or before the first customer has entered the site. With 3d-simulation, the layout can be optimized to support the target process.

In addition to production or service facilities, simulation can also be used to support the company’s strategic and operational planning. There is no limit to the size of the system being simulated. Simulation can be used to model world-wide supply chains, or it can also be used to analyze and develop back-office processes, e.g. administration, product development, customer support or IT-processes.

Simulation model of a plant

Simulation is an inexpensive, quick and safe way to examine the performance of production systems. Computer simulation of production systems means modelling of the actual or planned system, such as a plant, as time advances in discrete-events (e.g. hours, minutes, or seconds). Simulation model can be used to generate technical and economic requirements for products, processes, equipment, personnel and production planning and control. In addition to numerical simulation, the changes and updates are presented graphically with 3D animation. This accelerates learning and facilitates easy interpretation of the results. The same model is understood by employees as well as marketing and operational management.

The simulation shows bottlenecks, calculates the availability of the workforce and machines, the impact of a machine breakdown on production as well as the level of work-in-process (WIP)). The software allows for production planning and scheduling. Simulation can be used to examine and plan both push- and pull production control methods, and how each technique and their combinations fit the company’s operations.

Teamwork with our customers

Delfoi’s experience covers more than 1000 succesfull simulation and development projects. The success is based on good teamwork with our team and customers team. Recommendations and actions are based on the simulation of customers’ real production and order-delivery process, and validity of the findings can be assessed in different scenarios. The simulation run in each scenario can include different starting values, product mixes and orders. The simulation model is based on the accurate information, about the layout of the plant, products and resources. In addition, employees, their skills and different labor shifts as well as information on the plant’s control system are included. Resources in the model include information on capacities and takt-times.

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