1. Latest trends in manufacturing
(simulation)
Rienk Bijlsma
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November 8, 2011 Latest trends in manufacturing simulation 1

2. Contents
• Important themes
• Project findings
• Production assets lifecycle
• Lifecycle of models
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3. Important themes
• Continuous improvement
• Personnel & leadership
• Sustainability
• Emerging markets
• Investment climate
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4. Continuous improvement
• Lean manufacturing
• Operational excellence
• Six sigma
• Value stream mapping
• TPM (Total productive maintenance)
• TQM (Total quality management)
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5. Personnel and leadership
• Leadership skills
• Change management
• Training personnel
• Flexibility of personnel
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6. Sustainability
• How to eliminate waste
• Cradle to cradle
• Carbon footprint reduction
• Reduce energy consumption
• Using raw materials as efficient as possible
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7. Emerging markets
• Strategic choice of production locations
• Roll of the supply chain
• Local legislation
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8. Investment climate
• How can we cut cost and maintain quality
• How can we increase production volume with
our existing assets
• How to respond to changing market conditions
• Product innovation
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9. What do we see in our projects
• Interest in serious games for training
– HSE, management, operators
• Limited interest in supply chain/market model
• Easy user interfaces to models
• Drive away from local installations
• Planning/scheduling, business analytics
• Emerging applications
– Wind farms, Biofuels, Lean six sigma
• New model KPI’s
– Emissions, energy/utility consumption,
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10. Production assets lifecycle
Greenfield:
- simulation modeling-
- emulation-
-vertical startup-
Replace Design
Improve Build
Maintain Operate
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11. Production assets lifecycle
Replace Design
Improve Build
Brownfield:
Maintain Operate - scheduling/planning -
-serious gaming –
-Safety culture -
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November 8, 2011 Added value of simulation in the design of terminals 11

12. Production assets lifecycle
Replace Design
Brownfield terminal:
-simulation modeling-
-lean six sigma-
Improve Build
Maintain Operate
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November 8, 2011 Added value of simulation in the design of terminals 12

13. Added value of modeling
2 or 3 cranes?
Enough packaging lines?
Replace Design
What if we change our
paintshop configuration? Lower CAPEX
Should we add more ....?
Improve Build
Higher efficiency
12.45 pm – MB SLK white– Line1
14.30 pm – MB S500 Black– Line1
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(How) Can we handle this
new order?
Maintain Operate
Better service
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14. Lifecycle of models
Model building
Model death
Model testing
Model running
Project complete Model experimenting
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15. Why do models die?
• Model build to support onetime investment decision
– New (air)port, new petrochemical complex, new terminal ...
• Original model builder not available
– Left company, other project, career move, retirement ...
• Modeled system changes
– Data no longer correct, process changes ...
• Time for model resurrection too long
– Model results expected in hours/days not weeks/months
• System no longer running
– IT support, installation, model versions, software versions ...
• Decision maker cannot run experiments
– No user interface, no training, no documentation no support
...
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16. How to keep models alive?
• Design model to support operational and tactical decisions
– Airport: new runway, new flight schedule, new gate allocation...
• User interface for decision makers
– Ease of use, scenario creation, results, analysis
• System available on internet or intranet
– No installation, available anywhere, no version problems ...
• Support from professional organization
– User support & training, model updates, IT integration ...
• Document & demonstrate the delivered value!
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17. Models on the internet
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18. Thanks for your attention…
Visit our website: www.systemsnavigator.com
Systems Navigator B.V.
Delftechpark 38
2628 XH Delft
The Netherlands
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