This document discusses the latest trends in manufacturing simulation. It outlines important themes in continuous improvement, personnel and leadership, sustainability, emerging markets, and investment climate. It also discusses trends seen in projects, including interest in serious games for training. Additionally, it examines the lifecycle of production assets and models from design through operation and replacement. It notes challenges in keeping models alive over the long term.

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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12. Production assets lifecycle
Replace Design
Brownfield terminal:
-simulation modeling-
-lean six sigma-
Improve Build
Maintain Operate
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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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