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Flexsim and Excel Comparison for Manufacturing Layout Analysis

Given below is a comparison between Flexsim and Excel for manufacturing layout analysis:

Criteria Flexsim Excel

Change in State Flexsim is a discrete event simulation software that captures changes in state over time making it a far more accurate system to assess the layout of a manufacturing process. This is all the more true, because manufacturing processes are inherently discrete event processes and therefore mandate the use of a discrete event software application. For instance, a machine undergoes several changes in its state during the manufacturing process, from processing, to idle, to breakdown, to setup and sometime repair. Similarly, other parts of operation also undergo different set of states – all of which occur over time.

Excel is a calculating system that does not have a real time clock or any mode of capturing changes in state over time, which results in highly inaccurate assessment of complex manufacturing processes.

Geometry Flexsim is a 3d system that captures the movement of operators and material handling machinery across x, y and z axis taking into consideration distance, speed, acceleration and de acceleration. Furthermore, a user can import CAD layout to precisely layout the machines taking into consideration the distance and speed of material and man movements.

It is very difficult to create a simulation model in Excel where distance and speed calculation are incorporated in assessing the impact to the overall manufacturing process. Even if this were done it would be difficult to explain the results to a non-Excel user.

3d Visualization Flexsim uses powerful 3d video gaming technology to create a real life like simulation model that represents the true situation to a high measure of degree resulting in accurate representation of the manufacturing process. This makes it easy for a non technical user to understand clearly the nature of the manufacturing process behavior in real time.

Excel does not have this capability.

Ease of use Flexsim uses drag and drop technology enabling users to use readily available objects in the Flexsim library, such as queues, processors, operators, conveyors, cranes etc, to build complex manufacturing models with little or no programming.

Excel does not have this capability, which means a user will have to start from scratch for every model that they want to create.

Experimentation Flexsim has a built in Experimenter, wherein a user can configure a simulation experiment to view several scenarios simultaneously to optimize the manufacturing process.

Excel does not have this readymade capability.

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Stochastic capability

Flexsim can model any stochastic process. Since, all manufacturing processes are stochastic in nature, a user can determine the nature of the distribution via an estimation of times gathered or assumed. Flexsim contains a full library of all statistical distributions.

Excel math library has this capability to generate random events based on a statistical distribution. However, its use in creating a simulation model is very limited and difficult for the user. As a result, almost all Excel based estimation assumes a deterministic approach to the process times.

Capturing Complexity

Flexsim has a built in set of pick lists, that make it easy for an average user to capture manufacturing requirements, such as routing logic, priority in processing, use of material handling equipment, task sequences, machine break downs, shift timings, differing product types, communication between differing processors, and a lot more. Additionally, advanced user can program in Flexsim using C++ or Flexscript to deal with any difficult situation that needs to be addressed. Flexsim models, because of its versatility and immense power can give results with almost 99% or more accuracy.

Excel is too basic a tool for capturing varied manufacturing logic. As a result, the Excel user makes broad assumptions, resulting in large errors in assessing the manufacturing layout, resulting in values, where there is a big difference between the actual situation and the Excel model results. Because, Excel has a large risk of error in estimation, the risk of moving forward with a layout design based on Excel based estimation can result in losses in millions of dollars.

Customization Flexsim users can create custom objects that can mimic the behavior of special machines, such as a robots, special purpose machines, special delivery vehicles, where users can create custom properties for the custom object and thus create their own custom library if needed etc. In addition, a user can create custom GUI, wherein a user can input data directly into the Flexsim model with ease to determine the performance of the system, thus creating a ‘What if’ capability for the average user.

Excel does not have this capability.

Reports Flexsim has a wide range of reporting capabilities. A user can create Excel based reports, real time dashboard reports, MS Access based report and can also be integrated with external reporting tools, if required.

Excel has basic reporting capabilities. Furthermore, Excel cannot provide any real time reporting as it is not a state based software that captures changes in state behavior.