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Logistic systems simulation (a presentation by SIMANDO)
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Logistic systems simulation (a presentation by SIMANDO)



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  • 1. Design and Optimization of Logistic Systems Think | Optimize | Succeed
  • 2. SIMANDO is a global management and technology consulting firm with a highfocus on decision support systems and operational excellence. We partner withclient organizations in all industrial sectors to address their most importantchallenges and develop complete solutions that will enable them to achievetheir objectives and make significant improvements in their performance. Ourcustomized approach combines innovative technology, systems thinking andpassion for operational excellence. This ensures that our solutions enable ourclients to achieve sustainable competitive advantage by optimized operationsand responsiveness to the current dynamic business environment.Founded in 2009, SIMANDO is a private company with its headquarters inTimisoara, Romania. For more information, please visit:www.simando.com
  • 3. Outline About SIMANDO Services and Products Simulation Modeling Simulation of logistic systems  Order Picking Systems  Warehouse Operations 2011 3/35
  • 4. About SIMANDOCompany founded in 2009Privately owned, LLCHeadquarters: Timisoara, ROMANIAMissionAt SIMANDO, our primary mission is to help our clients make substantial, continuous improvement in their performance. Weaccomplish this by providing them with outstanding technology solutions and consulting services to increase their excellencedegree at all levels.VisionWe strive to be the company that understands perfectly its clients objectives, always delivers quantifiable results andmaximizes the financial and trust investments made by its clients.Our Certifications Certified Six Sigma Black Belt Project Management Professional (American Society for Quality) (Project Management Institute) Certificate in Finance Oracle Certified Professional Java (New York Institute of Finance) Programmer (Oracle Corporation) 2011 4/35
  • 5. ExpertiseModeling and Simulation Operational Excellence Systems modeling, simulation and optimization  Lean Six Sigma Transformation All simulation paradigms - discrete events, agent-  Design for Six Sigma based and system dynamics  Toyota Production System Statistics  Theory of Constraints  Product DevelopmentSoftware Applications Development Industrial Advanced algorithms and design patterns  Project and product development management Software architecture  Computer Integrated Manufacturing Software development lifecycle methodologies  Industrial engineering and factory planning Functional and object oriented programming  Manufacturing, logistics, supply chain design Database Management Systems  Transport and distribution systems MRP/ERP Systems 2011 5/35
  • 6. 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 2011 6/35
  • 7. P&L Systems Performance Optimization Industrial Engineering Information Six Sigma Technology Production & Logistic Systems Performance TRIZ Lean Theory of ConstraintsSynergistic framework for continuous significant improvement of production and logistics 2011 7/35
  • 8. Logistic Systems Leverage Points 1st Dimension 1st Dimension Products and processes selection Warehouse location, size and layout 2nd Dimension Warehouse or DC personnel Material handling systems Degree of automation 2nd Dimension 3nd Dimension Jobs scheduling Preventive maintenance protocols Personnel allocation protocols Batching protocols Waste reduction programsThe 3 Dimensions of Logistics 3rd Dimension Investment Logistic System Performance 2011 8/35
  • 9. Why Simulation ? What? Where? Who? The future is of greater interest to me than the past, since that is where I intend to spend the ! rest of my life. When? Why? ~ Albert Einstein How?BECAUSE … SIMULATION GIVES US ANSWERS! 2011 9/35
  • 10. Simulation Study Types Simulation StudiesSystem Design Problem Solving Continuous Improvement  New processes  Diagnosis  Opportunity definition New facilities  Problem definition  Performance measurement New concepts  Solution finding  Performance improvement Structural Design Diagnosis Opportunity Definition  Elements  Problem definition  Benchmarking  Layout  Logic Logical Design Testing Schemes Test Plans  Flow logic  What-if scenarios analysis  Feasibility check  Operations sequences  Priority rules Parametric Design Solution Validation Plan Validation  Cycle times  Sensitivity analysis  Sensitivity analysis  Reliability requirements  Velocities, rates 2011 10/35
  • 11. Simulation Benefits Analyze the behavior of Experiment and get complex systemsMake prompt and fast feedback correct decisions Convince clients of your operational capabilities Communicate ideas efficiently and credibly Teach new Test fast, fail fast, adjust fast. concepts easily ~ Tom Peters Discover alternatives to unexpected roadblocks Save money in short and medium term Safely analyze dangerous scenarios Implement your decisions with confidence 2011 11/35
  • 12. Applicability AreasManufacturing Lean Six Sigma Logistics and Supply Chain Key Performance Indicators  Stochastic process simulation FMEA  Statistical analysis  Transport networks design Production flow design  Variability elimination  Fleet planning & maintenance Planning and scheduling  Pull mechanism design  Warehouse design Resource estimation  QOS metrics  Operations optimization Capacity planning  Dynamic VSM  Supply chain planning Total cost of ownership  BenchmarkingHealthcare IT & Telecom Urban Development Resource estimation  Wireless networks topology  Public utilities planning QOS  Protocols design  Evacuation plans creation Epidemics dynamics  Agent-based emergent  Disaster recovery Operations optimization behaviour analysis  Anti-terrorist measures  QOS 2011 12/35
  • 13. How We Do It ?Continuous improvement is betterthan delayed perfection. ~ Mark Twain Problem formulation Objectives and plan definition Control Model conceptualization Data collection Your trajectory to success Implementation with simulation Reporting Model development Experiments run and analysis Code verification Design of experiments Model validation 2011 13/35
  • 14. ModelingReusable models and components encourage continuous improvement!Specializedcomponentlibraries 2D/3D customizable animationDomain specificlibrary components Fast and easy drag-and-drop layout modeling 2011 14/35
  • 15. Simulation Models Input/Output Data CAD Run-time Charts Text Text Excel Excel XML Simulation Model XML Input Output Database Database Data Data Webservice Webservice 2011 15/35
  • 16. Simulation of Order Picking/Packaging Creativity is thinking up new things. Innovation is doing new things. ~ Ted Levitt E.g. Order Picking & Packaging System (simulation application developed by SIMANDO) 2011 16/35
  • 17. Simulation of Order Picking/Packaging Pickers & zones Pickers & weigh runtime statistics stations Equipment Storage zones runtime statisticsfilled with goodsOperators loadingfrom pallets intothe storage zone Pallets withdifferent types of goods Packaging End of line & equipment delivery pallet 2011 17/35
  • 18. Simulation of Order Picking/Packaging• Highly detailed behavior of pickers (states: IDLE, PICKING, • Detailed modeling of equipments (e.g. conveyors, offloaders, MOVING_BUSY, MOVING_FREE, WAITING, and any other strapping, plastic foil application, foil heating, weight checker, custom state according to needs) storage zones, carousels, mini-loads, stacker cranes, labeling)• Support for complex interactions among personnel (pickers, • Probabilistic/deterministic events for breakdowns, operators), equipment and items maintenance, change of consumables, setup, assistance etc.• Picking time based on item weight, dimension, appedices, • Tracking/evaluation of energy use, consumables, spare parts wrapping, picker dexterity, tiredness etc. according to operation scenarios• Personnel have dexterity levels, moving speeds, max load • Support for any type of items, picking strategies used (single, capacity etc. batch, baskets, tote boxes, sorting etc.)• Dynamically configurable layout, number of resources, • Customizable animation, behavior and parameter set for any animation, animation/speed ratio component• Any type of KPI can be tracked, reported and analyzed 2011 18/35
  • 19. Simulation Order Picking/Packaging IT’S MORE THAN A SIMULATION MODEL, IT’S AN APPLICATION! FeedbackProduction plan(ERP/WMS/WCS) 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! 2011 19/35
  • 20. Simulation of Order Picking/Packaging 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) 2011 20/35
  • 21. Simulation of Warehouse Operations Multi-depth/level Forklifts storage racksTrucks arrival accordingto deterministic orprobabilistic schedule Conveyor systemReceiving docks S/R machine E.g. Warehouse Operations (simulation application developed by SIMANDO) 2011 21/35
  • 22. Simulation of Warehouse Operations Innovative and revealing customized animation based on large data Extensive and easily configurable visualization techniques simulation parameter set Runtime and post-simulation statistics and charts for inflows, outflows, stocks, equipment S/R machine with acceleration utilization, energy consumption, and deceleration for all types of spare parts etc. movements; single/multi cycle 2011 22/35
  • 23. Simulation of Warehouse Operations 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 2011 23/35
  • 24. Simulation of Warehouse Operations 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) 2011 24/35
  • 25. Logistic Systems Life Cycle Cost vs. Impact Cost Potential is negative (Impact < Cost) Potential is positive (Impact > Cost) Impact Time Design Produce/Build Deliver Support Impact of design stages on life cycle 2011 25/35
  • 26. Thank you for your attention! SIMANDO Team SIMANDO LLC 9 Republicii Blvd Timisoara, TM 300159 ROMANIA Tel: +40 356 172 021 Fax: +40 356 172 017 E-mail: info@simando.com Web: www.simando.com