Logistic systems simulation (a presentation by SIMANDO)
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Design and Optimization of Logistic Systems Think | Optimize | Succeed
Transcript of Logistic systems simulation (a presentation by SIMANDO)
Design and Optimization of Logistic Systems
Think | Optimize | Succeed
SIMANDO is a global management and technology consulting firm with a high focus on decision support systems and operational excellence. We partner with client organizations in all industrial sectors to address their most important challenges and develop complete solutions that will enable them to achieve their objectives and make significant improvements in their performance. Our customized approach combines innovative technology, systems thinking and passion for operational excellence. This ensures that our solutions enable our clients to achieve sustainable competitive advantage by optimized operations and responsiveness to the current dynamic business environment. Founded in 2009, SIMANDO is a private company with its headquarters in Timisoara, Romania. For more information, please visit: www.simando.com
About SIMANDO
Services and Products
Simulation Modeling
Simulation of logistic systems
Order Picking Systems
Warehouse Operations
2011 3/35
Outline
About SIMANDO
2011 4/35
Mission
Vision
At SIMANDO, our primary mission is to help our clients make substantial, continuous improvement in their performance. We accomplish this by providing them with outstanding technology solutions and consulting services to increase their excellence degree at all levels.
We strive to be the company that understands perfectly its clients' objectives, always delivers quantifiable results and maximizes the financial and trust investments made by its clients.
Certified Six Sigma Black Belt (American Society for Quality)
Project Management Professional (Project Management Institute)
Oracle Certified Professional Java Programmer (Oracle Corporation)
Certificate in Finance (New York Institute of Finance)
Our Certifications
Company founded in 2009
Privately owned, LLC
Headquarters: Timisoara, ROMANIA
Expertise
Software Applications Development Advanced algorithms and design patterns
Software architecture
Software development lifecycle methodologies
Functional and object oriented programming
Database Management Systems
MRP/ERP Systems
2011
Industrial
Project and product development management
Computer Integrated Manufacturing
Industrial engineering and factory planning
Manufacturing, logistics, supply chain design
Transport and distribution systems
Operational Excellence
Lean Six Sigma Transformation
Design for Six Sigma
Toyota Production System
Theory of Constraints
Product Development
Modeling and Simulation
Systems modeling, simulation and optimization
All simulation paradigms - discrete events, agent-based and system dynamics
Statistics
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Services and Products
Services
Production, logistics, supply chain, healthcare engineering , modelling and simulation
Operations optimization
Lean Six Sigma/Design For Six Sigma training and implementation
Training and assistance in simulation models development
Product development and project management
Computer Integrated Manufacturing
Products
Modeling and simulation component libraries
MANSIM™ - general manufacturing
SOLSIM ™ - photovoltaics manufacturing equipment
LOGSIM ™ - warehousing and logistics
Specialized software applications for Lean Six Sigma, planning and scheduling
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P&L Systems Performance Optimization
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Production & Logistic Systems
Performance
Industrial Engineering
Six Sigma
Lean
Theory of Constraints
TRIZ
Information Technology
Synergistic framework for continuous significant improvement of production and logistics
Logistic Systems Leverage Points
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The 3 Dimensions of Logistics
1st Dimension Products and processes selection Warehouse location, size and layout
2nd Dimension Warehouse or DC personnel Material handling systems Degree of automation
3nd Dimension Jobs scheduling Preventive maintenance protocols Personnel allocation protocols Batching protocols Waste reduction programs
Investment
Logistic System Performance
1st Dimension
2nd Dimension
3rd Dimension
Why Simulation ?
BECAUSE … SIMULATION GIVES US ANSWERS!
2011 9/35
The future is of greater interest to me than the past, since that is where I intend to spend the rest of my life. ~ Albert Einstein When?
Where?
What?
Who?
Why?
How?
!
Simulation Study Types
Simulation
Studies
System Design
New processes
New facilities
New concepts
Structural Design
Elements
Layout
Logic
Logical Design
Flow logic
Operations sequences
Priority rules
Parametric Design
Cycle times
Reliability requirements
Velocities, rates
Problem Solving
Diagnosis
Problem definition
Solution finding
Diagnosis
Problem definition
Testing Schemes
What-if scenarios analysis
Solution Validation
Sensitivity analysis
Continuous Improvement
Opportunity definition
Performance measurement
Performance improvement
Opportunity Definition
Benchmarking
Test Plans
Feasibility check
Plan Validation
Sensitivity analysis
2011 10/35
Simulation Benefits
2011 11/35
Convince clients of your operational capabilities
Safely analyze dangerous scenarios Implement your decisions
with confidence
Make prompt and correct decisions
Experiment and get fast feedback
Analyze the behavior of complex systems
Communicate ideas efficiently and credibly
Discover alternatives to unexpected roadblocks
Teach new concepts easily
Save money in short and medium term
Test fast, fail fast, adjust fast. ~ Tom Peters
Applicability Areas
Manufacturing
Key Performance Indicators FMEA Production flow design Planning and scheduling Resource estimation Capacity planning Total cost of ownership
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Lean Six Sigma
Stochastic process simulation Statistical analysis Variability elimination Pull mechanism design QOS metrics Dynamic VSM Benchmarking
Logistics and Supply Chain
Transport networks design Fleet planning & maintenance Warehouse design Operations optimization Supply chain planning
IT & Telecom
Wireless networks topology
Protocols design
Agent-based emergent behaviour analysis
QOS
Urban Development
Public utilities planning
Evacuation plans creation
Disaster recovery
Anti-terrorist measures
Healthcare
Resource estimation
QOS
Epidemics dynamics
Operations optimization
How We Do It ?
Problem formulation
Objectives and plan definition
Model development
Data collection
Model conceptualization
Code verification
Model validation
Control
Implementation
Reporting
Experiments run and analysis
Design of experiments
Your trajectory to success with simulation
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Continuous improvement is better than delayed perfection. ~ Mark Twain
Modeling
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Specialized component libraries
Domain specific library components
2D/3D customizable animation
Fast and easy drag-and-drop layout modeling
Reusable models and components encourage continuous improvement!
Simulation Models Input/Output Data
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Text
Excel
Database
Webservice
XML
Text
Excel
Database
Webservice
XML
Run-time Charts
Simulation Model
Input Data
Output Data
CAD
Simulation of Order Picking/Packaging
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E.g. Order Picking & Packaging System (simulation application developed by SIMANDO)
Creativity is thinking up new things. Innovation is doing new things. ~ Ted Levitt
Simulation of Order Picking/Packaging
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Pallets with different types of
goods
Operators loading from pallets into the storage zone
Packaging equipment
Equipment runtime statistics Storage zones
filled with goods
Pickers & weigh stations
Pickers & zones runtime statistics
End of line & delivery pallet
Simulation of Order Picking/Packaging
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• Highly detailed behavior of pickers (states: IDLE, PICKING,
MOVING_BUSY, MOVING_FREE, WAITING, and any other custom state according to needs)
• Support for complex interactions among personnel (pickers, operators), equipment and items
• Picking time based on item weight, dimension, appedices, wrapping, picker dexterity, tiredness etc.
• Personnel have dexterity levels, moving speeds, max load capacity etc.
• Dynamically configurable layout, number of resources, animation, animation/speed ratio
• Any type of KPI can be tracked, reported and analyzed
• Detailed modeling of equipments (e.g. conveyors, offloaders,
strapping, plastic foil application, foil heating, weight checker, storage zones, carousels, mini-loads, stacker cranes, labeling)
• Probabilistic/deterministic events for breakdowns, maintenance, change of consumables, setup, assistance etc.
• Tracking/evaluation of energy use, consumables, spare parts according to operation scenarios
• Support for any type of items, picking strategies used (single, batch, baskets, tote boxes, sorting etc.)
• Customizable animation, behavior and parameter set for any component
Simulation Order Picking/Packaging
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IT’S MORE THAN A SIMULATION MODEL, IT’S AN APPLICATION!
Production plan (ERP/WMS/WCS)
Feedback
The simulation model resulted is a Java stand-alone application that is utilized by the end-user daily after the system is installed, to simulate production scenarios and make fine-tunings
Extremely fast - 1 week production scenario for an average order fulfillment and packaging system simulated on a regular laptop in less than 3 minutes!
Simulation of Order Picking/Packaging
2011 20/35
Simulation model/application benefits (order fulfillment systems specific)
Great support for system design activities: system layout, equipment selection, value engineering, FMEA, KPIs Work dispatching and scheduling alternatives efficiency Order batching and picking strategies Zoning and slotting of products Zone balancing and labor required to meet schedule Zone reconfiguration recommendations System bottlenecks detection and management Sales tool to convince your clients of your capabilities and abilitiy to deliver in time Cost effective optimizations
Features Labor, zones, and system productivity KPIs Runtime charts Reports and statistics available in PDF format following a simulation run Integration with ERP, WMS, WCS or other software applications Great visualization tool Extremely fast simulation Platform independent application (Windows, Linux, Mac OS)
Simulation of Warehouse Operations
2011 21/35
E.g. Warehouse Operations (simulation application developed by SIMANDO)
Receiving docks
Conveyor system
Forklifts
Receiving docks
S/R machine
Multi-depth/level storage racks
Trucks arrival according to deterministic or probabilistic schedule
Simulation of Warehouse Operations
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S/R machine with acceleration and deceleration for all types of movements; single/multi cycle
Innovative and revealing customized animation based on large data visualization techniques
Extensive and easily configurable simulation parameter set
Runtime and post-simulation statistics and charts for inflows, outflows, stocks, equipment utilization, energy consumption, spare parts etc.
Simulation of Warehouse Operations
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Simulation models/applications utility
Long term planning
Dimensioning of storage areas and warehouse technology/MH equipment selection Preparation of the warehouse layout (storage & access pathways) Development of fundamental operating strategies and proof of functionality Input for the implementation of WMS/WCS functions Staging protocols
Medium term planning
Planning the asortment and range of items to be kept in stock to react to seasonal/market influences
Manpower requirement planning, preparation of shift models and work schedules Reorganization of stocks Planning of transport routes within the warehouse
Simulation of Warehouse Operations
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SIMANDO simulation models/applications benefits
All aspects of warehousing operations (receiving, cross-docking, storing, picking, packing, shipping) are covered, thus local optimizations to the detriment of the whole system are avoided
Calculation of a realistic Total Cost of Ownership (TCO) based on stochastic models
The built-in flexibility enables you to run any type of scenario imaginable
The end-result is a stand-alone Java application that can be used for planning and optimizing operations daily
Great tool to make decisions in reverse-logistics (which have a high degree of variability/uncertainty)
Features Simulation/application developed with AnyLogic platform 2D/3D customizable animation Runtime charts Reports and statistics available in PDF format following a simulation run Integration with ERP, WMS, WCS or other software applications Extremely fast simulation models/applications compared to other fixed-library simulation platforms Platform independent application (Windows, Linux, Mac OS)
Logistic Systems Life Cycle
Design Produce/Build Deliver Support
Time
Cost vs. Impact
Impact
Potential is positive
(Impact > Cost)
Cost
Potential is negative (Impact < Cost)
2011 25/35
Impact of design stages on life cycle
SIMANDO Team
Thank you for your attention!
SIMANDO LLC 9 Republicii Blvd Timisoara, TM 300159 ROMANIA Tel: +40 356 172 021 Fax: +40 356 172 017 E-mail: [email protected] Web: www.simando.com
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