Why Use Simulation ?
We at Production Modelling are often asked "How
can I best run the factory to achieve my business objectives yet
at the same time, meet customer demands?" Manufacturers are
continually being asked to increase production volumes in less time
with less people and for less money. Trying new ideas out in the
factory are all very well, but they can take time, be disruptive,
very costly, and you may not get it right first time. Today’s
managers can’t afford to take such risks when implementing
change.
Experimenting with new ideas on a computer model
before you make changes for real is simple common sense. It takes
the risk out of change. This is where ProModel simulation users
have gained a competitive edge, an advantage that results in bottom-line
benefits to their business.
Why not flowcharts or process
mapping?
Many organisations use static modelling tools, such as flowcharts,
process mapping, and spreadsheets. Flowcharts and process mapping
tools have their place, but on their own, they merely show relationships
between processes and generally don’t provide any quantitive
performance measures.
Why not spreadsheets?
Spreadsheets are very useful, and do have their place, but also
have serious limitations.
Firstly, they are static models. This means that they cannot represent
changes that occur with respect to time.
Secondly, they are deterministic – using
constant values, approximations or averages rather than the variability
that exists in real life.
Thirdly, they can’t represent interdependencies.
In other words, process steps are independent of each other. Again,
a serious deficiency, as this limits the validity of the models.
At best, spreadsheets can give misleading results,
and in many cases wildly inaccurate predictions. At worst, business
decisions can be made on entirely inaccurate information. It’s
no surprise that companies often wonder why the results from their
spreadsheet models don’t match reality.
Here’s a simple illustration to prove why
simulation is so important:
Picture a small cell where
parts arrive on average every 30 seconds, queue for Machine1 or
Machine 2, each of which takes on average of 1 minute to process
A spreadsheet model of
this would show no queuing, 100% utilisation of the workstations,
and average lead-time of 1 minute. In other words, a nicely balanced
system.
Look what happens if we
use variability. A normal, (bell-shaped), distribution of the
same averages would be a more realistic way of representing the
variability that exists in the real world.
Using a ProModel simulation,
running the process for just 8 hours, the results show a completely
different (but more accurate) story. The machine utilisation is
less than 100%, there a 11 jobs queuing for the machines, and
the average lead time is over 10 minutes!!!
Imagine the difference
in a more complex process, or if the process runs for a week or
a month.
Click here to request
a copy of this Model.
This is why simulation is so important. Simulation,
and only simulation, takes into account the combined effect of variability,
uncertainty, and complex interdependencies between processes
ProModel simulation is helping companies improve their businesses
and become more competitive. Increasingly competitive markets bring
new challenges and customers' demands are constantly changing. As
a result, manufacturers need to become more responsive, more quickly,
more efficiently, yet often within tighter budgets and timescales.
ProModel is helping them to visualize, analyse
and optimise their processes to achieve these business performance
improvements.
Furthermore, ProModel is often used to help “sell”
ideas to others to gain their commitment to change and show why
one method will work better than another. The visual accuracy and
animation of the model can provide a powerful communications tool.
It can help speed up decisions affecting changes in the factory,
and get people from the shop floor through to senior management
all committed to the same ideas. |
