Production optimization with the help of plant simulation using Flexsim & GA wizard tools
Challenge
The success of the company’s production process hinges on the employees’ expertise in scheduling. While this approach has been effective in the past, the increasing number of demand requests necessitates the adoption of more decisive evidence-based planning methods.
One of the primary challenges faced by the company’s production scheduling is the difficulty in predicting long-term demand. As the company caters to numerous customers, the influx of orders has reached unprecedented levels. All orders must be produced and delivered within the subsequent month, posing obstacles to achieving long-term production planning. Consequently, there is a significant disparity in production volume across different months. So, they approached us to find the solution
Our Solutions
- Gathered essential data such as monthly production records from the past year, material flow information, data pertaining to batch production equipment, processing times for different product types in various weaving processes, setup times, changeover times, scrap percentages, and more.
- Constructed a simulation model using the collected data and verified and validated the model against actual production scenarios.
- Improved the production sequence/mix to minimize overall production time.
- Assessed different options related to the variables in the model and ultimately proposed the most favourable production mix alternative.
Results
- Following the implementation of the optimization process, a new production sequence was generated, resulting in a reduction of time waste. As a result, there was a decrease in the requirement for overtime work to fulfil demand during critical months.
- The outcomes demonstrated substantial cost savings even during the peak season
Client
Industry
