latest trends in manufacturing simulation
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TRANSCRIPT
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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
3 Latest trends in manufacturing simulation November 8, 2011
• Continuous improvement
• Personnel & leadership
• Sustainability
• Emerging markets
• Investment climate
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Continuous improvement
4 Latest trends in manufacturing simulation November 8, 2011
• Lean manufacturing
• Operational excellence
• Six sigma
• Value stream mapping
• TPM (Total productive maintenance)
• TQM (Total quality management)
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Personnel and leadership
5 Latest trends in manufacturing simulation November 8, 2011
• Leadership skills
• Change management
• Training personnel
• Flexibility of personnel
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Sustainability
6 Latest trends in manufacturing simulation November 8, 2011
• 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
7 Latest trends in manufacturing simulation November 8, 2011
• Strategic choice of production locations
• Roll of the supply chain
• Local legislation
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Investment climate
8 Latest trends in manufacturing simulation November 8, 2011
• 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
9 Latest trends in manufacturing simulation November 8, 2011
• 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
10 Latest trends in manufacturing simulation November 8, 2011
Design
Build
Operate Maintain
Improve
Replace
Greenfield: - simulation modeling-
- emulation- -vertical startup-
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Production assets lifecycle
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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Production assets lifecycle
12 Added value of simulation in the design of terminals November 8, 2011
Design
Build
Operate Maintain
Improve
Replace
Brownfield terminal: -simulation modeling-
-lean six sigma-
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Added value of modeling
13 Added value of simulation in the design of terminals November 8, 2011
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
16 Latest trends in manufacturing simulation November 8, 2011
Model building
Model testing
Model experimenting Project complete
Model death
Model running
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Why do models die?
17 Latest trends in manufacturing simulation November 8, 2011
• 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?
18 Latest trends in manufacturing simulation November 8, 2011
• 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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20 Added value of simulation in the design of terminals November 8, 2011
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