Dynamic simulation and modelling of production systems

Dynamic simulation is a powerful tool for planning, design, optimization and reengineering of real production/manufacturing, logistic or service provision systems. Using a computer model, which takes into account existing constraints, capacities, failure rates, shift patterns, and other factors affecting the total performance and efficiency of production, it is possible to simulate planned function and load of the system, change parameters affecting system performance, carry out extreme-load tests, verify by experiments the proposed solutions and select the optimal solution alternative.

Dynamic discrete simulation provides unambiguous and concrete results and proofs - information on how will the designed or optimized production system actually function. The outputs of simulation are "hard data", values and statistics of performance parameters and metrics of the production system. Simulation allows you to carry out experiments, compare various alternatives of the proposed solution and basing on the experimental results select the optimal/best alternative.

Simulation proved to be an outstanding tool for support of decisionmaking in projects of reengineering and optimization of production processes and systems. Applications of simulation methods are not limited solely to the field of production and manufacturing - similar benefits can be achieved when simulating administrative processes, workflow od processed documents, service provision systems (eg banking tellers servicing clients or receiving customer calls at callcenters.

Using dynamic simulation you can design, balance, finetune and test your assembly line even before any investment is made. You can monitor, analyse and visualize results and metrics such as workload and utilization of production equipment, waiting times, utilization of resources (workers) or process times.

Typical inputs to simulation models

  • cycle times
  • production takt
  • capacities of production equipment
  • arrival/order rates
  • production rates of production equipment
  • statistics of production equipment failures

Typical outputs of simulation models

  • utilization of production equipment
  • identification of bottlenecks
  • production system performance
  • inventory levels

Examples of simulation models created in SIMUL8


Simulation of distribution and replenishment of fasteners in manufacturing
Model of soft drinks production used for production planning and scheduling

Simple model of material handling
Verification of troughput and utilization of input and output bays in a warehouse

Visualization of buffer inventory level in time
Verification of logistic conception of a production plant (warehouse, manufacturing, expedition, material handling)

Simulation of utilization of warehouse expedition bays
Model of production and logistic system of an automotive supplier

Simulation of soft drinks production
Model of soft drinks production system

Example model of simple manufacturing system with visualization of inventory levels and waiting times in buffers