2. Outline
Company overview
Expertise
Products and services
Modeling and simulation
Simulation in manufacturing
Simulation in Lean Six Sigma/Design For Six Sigma
2011 2/32
3. Company Overview
Our mission: SIMANDO delivers outstanding simulation, analysis and optimization
software applications and services that enable its clients to better
understand, design and run their processes and systems.
Our vision: At SIMANDO, simulation is viewed as an important, multi-purpose
component of the value chain. By this approach, we offer to our clients
the most effective simulation-based tools and services that will enable
them to maximize the results of their enterprises.
Founded 2009
Limited Liability Company
Headquarters: Timisoara, ROMANIA
2011 3/32
4. Expertise
Modeling and Simulation Continuous Improvement
Systems modeling, simulation and optimization Lean principles implementation
All simulation paradigms - discrete events, agent- Six Sigma/Design For Six Sigma
based and system dynamics
Software 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
Transport and distribution networks
2011 4/32
5. Expertise
Our certifications Our clients’ benefits
Rapid understanding of their environment and
Certified Six Sigma Black Belt problems to solve
American Society for Quality
Solutions based on proven methods and
technology
Project Management Professional
Project Management Institute Efficient communication and professional
project management
Certificate in Finance Consideration for a mix of aspects that impact
New York Institute of Finance the proposed solutions
Flexible, timely and cost efficient solutions
Oracle Certified Professional Java Programmer
Oracle Corporation
2011 5/32
6. Products and Services
Products
Modeling and simulation component libraries
MANSIM™ - general manufacturing
SOLSIM ™ - photovoltaics manufacturing
LOGSIM ™ - warehousing and logistics
Specialized components for Lean Six Sigma applications
Services
Production, logistics, supply chain, healthcare, financial modeling and simulation
Training and assistance in simulation platforms and paradigms
Lean Six Sigma/Design For Six Sigma training and implementation
Product development and project management
Computer Integrated Manufacturing
Facilities planning
2011 6/32
7. 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?
SIMULATION GIVES YOU ANSWERS!
2011 7/32
8. Simulation Study Types
Simulation
Studies
System 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 8/32
9. Simulation Benefits
Analyze the behavior of
Experiment and get complex systems
Make 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 9/32
11. How we do it ?
Continuous improvement is better
than 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 11/32
12. Modeling
Reusable models and components encourage continuous improvement!
Specialized
component
libraries
2D/3D
customizable
animation
Domain specific
library components
Fast and easy
drag-and-drop
layout modeling
2011 12/32
13. 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 13/32
14. Simulation in Manufacturing
Creativity is thinking up new things.
Innovation is doing new things.
Assembly line simulation model
~ Ted Levitt
2011 14/32
18. Simulation in Manufacturing
Total Cost of Ownership
������������������������������ ������������������������������ ($)
������������������ =
������������������������������ ������������������������������������ ������������ ������������������������ ������������������������������������������������ ������������������������ ������������������������������������′ ������ ������������������������
������������������������������ ������������������������������($) = ������($) + ������($) + ������($) + ������($)
Where:
F ($) = fixed costs for purchasing the system
L ($) = fully burdened labor cost
R ($) = recurring costs (consumables, maintenance, specialized support etc.)
Y ($) = yield loss cost
������($) = ������ ∗ ������($)
Where:
N = number of defective product entities
P ($) = value of the product entities in the specific production stage
2011 18/32
19. Simulation in Manufacturing
Total Cost of Ownership
������������������������������ ������������������������������������ ������������ ������������������������ ������������������������������������������ ������������������������������������������������ = ������ ∗ ������ ∗ ������ ∗ ������
������������������������������������������������ ������������������������ ������������������ ������������������������������������′ ������ ������������������������
Where:
L = lifetime of the production system
T = throughput rate
Y = composite yield
U = equipment utilization
Where:
SM = scheduled maintenance
USM = unscheduled maintenance
A = assist time
S = standby time
Q = qualification time ������������ + ������������������ + ������ + ������ + ������
������ = ������ −
H = total number of scheduled ������
production hours per week
2011 19/32
20. Simulation in Manufacturing
Total Cost of Ownership
������ $ + ������ $ + ������ $ + ������($)
������������������ =
������ ∗ ������ ∗ ������ ∗ ������
All variable/probabilistic elements in the formula can be tracked
and calculated by simulating realistically the system under study.
Due to variable costs and probabilistic events associated with complex
production systems, only simulation-based methods of calculating the TCO can
provide correct and accurate estimates therefore.
2011 20/32
21. Simulation in Manufacturing
Detailed modeling of components and manufacturing scenarios
Accurate timing and behavior of the modeled systems
Manual work, worker-machine and fully automated manufacturing modeling possibilities
Any type of production environment: jobbing, intermittent, mass production
Resources behavior described by state machines according to client/industry standards
Any type of Key Performance Indicator can be defined and tracked
Maintenance planning support
Ramp-up scenarios analysis
Inbound/outbound logistics and supply chain analysis and integration
2011 21/32
22. Simulation in Manufacturing
Line balancing and materials handling
Dispatching rules:
critical ratio, shortest processing time, FIFO, due date, etc.
Conveyors vs. Automated Guided Vehicles vs. Humans
Material flow optimization
Buffers capacities & policies (FIFO, LIFO, FEFO, custom)
2011 22/32
23. Simulation in Manufacturing
Lean manufacturing speed and quantity control and Six Sigma quality
Simulation offers support in reducing:
Transport times
Inventory and buffers
Employee motion
Waiting
Overproduction
Defects
2011 23/32
24. Simulation in Manufacturing
Optimization of Key Performance Indicators
Work in process (WIP)
Manufacturing lead time
Equipment cycle times
Queuing, blocking, waiting, transport time
Throughput
Takt time
Equipment and human resources utilization
Energy, consumables, spare parts, waste
2011 24/32
25. Simulation in Manufacturing
Design and optimization of complex equipment
Utilization, throughtput, cycle time for cluster tools
Equipments with M:N mapping of process resources to handling units
Optimization of handling units movement and process resources allocation
Process Process Process Chambers
Chamber Chamber
Process
Chamber
Multiple handling
units on the same rail IO Ports
Process
Chamber
Process Process
Chamber Chamber
2011 25/32
26. Simulation in Manufacturing
Production planning and scheduling
Feedback
Simulation
Production Forecast
Planning
2011 26/32
27. Simulation in Lean Ops Implementation
Static Value Stream Map
Nature does constant value stream
mapping – it's called evolution.
~ Carrie Latet
Dynamic Value Stream Map (Simulation)
2011 27/32
28. Simulation in Lean Ops Implementation
Single piece flow vs. batch processing analysis
Kanban (pull) mechanism design
Production leveling (heijunka)
Cycle, safety and buffer stocks calculation
Just In Time (JIT), Just in Sequence (JIS) inventory strategy design
Cellular operations design
Overall Equipment Effectiveness (OEE) calculation
Relation between demand and takt time analysis
2011 28/32
29. Simulation in Lean Six Sigma
Define Define Define
Define Project
Scope
Lean
Measures
Structure
and Variables
Develop Develop Identify Sources
Measure Current State
VSM
Develop
Simulation Model
Dynamic
VSM
of Variation and
Waste
Analize Develop DOE Plan
Run Simulation
Experiments
Analyze Process
Flow
Apply Develop
Improve Optimize Process
Parameters
Lean
Techniques
Validate
Improvement
Future State
VSM
Test Implement Monitor
Control Develop Control
Strategy
Control
Plans
Control
Plans
Performance Over
Time
Simulation-based Lean Six Sigma Project Roadmap
2011 29/32
30. Simulation in Design For Six Sigma
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 30/32
31. Simulation in Design For Six Sigma
Identify Simulation-based DFSS Project Roadmap
Model building Data collection
Conceptualize Simulation model
No
Verified ?
Optimize No
Yes
Valid ?
Model analysis
Validate Conclusions and reporting
2011 31/32
32. Thank you for your attention!
SIMANDO Team
SIMANDO
9 Republicii Blvd
Timisoara, TM 300159
ROMANIA
Tel: + 40 356 172 021
Fax: + 40 356 172 017
engineering@simando.com
www.simando.com
2011 32/32
