simulation in logistics - simando

2011 1/24

Think | Simulate | Succeed

Simulation in Logistics

2011

Outline

Company overview

Expertise

Products and services

Modeling and simulation

Simulation in Logistics Order Fulfillment Systems

Warehouse Operations

2011 2/24

Company Overview

Founded 2009

Limited Liability Company

Headquarters: Timisoara, ROMANIA

2011 3/24

Our mission:

Our vision:

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.

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.

Expertise

Software Applications Development

Advanced algorithms and design patterns

Software architecture

Software development lifecycle methodologies

Functional and object oriented programming

2011

Industrial

Project and product development management

Computer Integrated Manufacturing

Industrial engineering and factory planning

Manufacturing, logistics, supply chain design

Transport and distribution networks

Continuous Improvement

Lean principles implementation

Six Sigma/Design For Six Sigma

Modeling and Simulation

Systems modeling, simulation and optimization

All simulation paradigms - discrete events, agent-based and system dynamics

4/24

Expertise

2011 5/24

Our certifications Certified Six Sigma Black Belt American Society for Quality

Project Management Professional Project Management Institute

Certificate in Finance New York Institute of Finance

Oracle Certified Professional Java Programmer Oracle Corporation

Our clients’ benefits

Rapid understanding of their environment and

problems to solve

Solutions based on proven methods and technology

Efficient communication and professional project management

Consideration for a mix of aspects that impact the proposed solutions

Flexible, timely and cost efficient solutions

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 6/24

Why Simulation ?

SIMULATION GIVES YOU ANSWERS!

2011 7/24

The future is of greater interest to me than the past, since that is where I intend to spend the rest of my life. ~ Albert Einstein

When?

Where?

What?

Who?

Why?

How?

!

Simulation Study Types

Simulation

Studies

System Design

New processes

New facilities

New concepts

Structural Design

Elements

Layout

Logic

Logical Design

Flow logic

Operations sequences

Priority rules

Parametric Design

Cycle times

Reliability requirements

Velocities, rates

Problem Solving

Diagnosis

Problem definition

Solution finding

Diagnosis

Problem definition

Testing Schemes

What-if scenarios analysis

Solution Validation

Sensitivity analysis

Continuous Improvement

Opportunity definition

Performance measurement

Performance improvement

Opportunity Definition

Benchmarking

Test Plans

Feasibility check

Plan Validation

Sensitivity analysis

2011 8/24

Simulation Benefits

2011 9/24

Convince clients of your operational capabilities

Safely analyze dangerous scenarios Implement your decisions

with confidence

Make prompt and correct decisions

Experiment and get fast feedback

Analyze the behavior of complex systems

Communicate ideas efficiently and credibly

Discover alternatives to unexpected roadblocks

Teach new concepts easily

Save money in short and medium term

Test fast, fail fast, adjust fast. ~ Tom Peters

Applicability Areas

Manufacturing

Key Performance Indicators FMEA Production flow design Planning and scheduling Resource estimation Capacity planning Total cost of ownership

2011 10/24

Lean Six Sigma

Stochastic process simulation Statistical analysis Variability elimination Pull mechanism design QOS metrics Dynamic VSM Benchmarking

Logistics and Supply Chain

Transport networks design Fleet planning & maintenance Warehouse design Operations optimization Supply chain planning

IT & Telecom

Wireless networks topology

Protocols design

Agent-based emergent behaviour analysis

QOS

Urban Development

Public utilities planning

Evacuation plans creation

Disaster recovery

Anti-terrorist measures

Healthcare

Resource estimation

QOS

Epidemics dynamics

Operations optimization

How we do it ?

Problem formulation

Objectives and plan definition

Model development

Data collection

Model conceptualization

Code verification

Model validation

Control

Implementation

Reporting

Experiments run and analysis

Design of experiments

Your trajectory to success with simulation

2011 11/24

Continuous improvement is better than delayed perfection. ~ Mark Twain

Modeling

2011 12/24

Specialized component libraries

Domain specific library components

2D/3D customizable animation

Fast and easy drag-and-drop layout modeling

Reusable models and components encourage continuous improvement!

Simulation models input/output data

2011 13/24

Text

Excel

Database

Webservice

XML

Text

Excel

Database

Webservice

XML

Run-time Charts

Simulation Model

Input Data

Output Data

CAD


2011 14/24

E.g. Order Fulfillment & Packaging System (simulation application developed by SIMANDO)

Creativity is thinking up new things. Innovation is doing new things. ~ Ted Levitt


2011 15/24

Pallets with different types of

goods

Operators loading from pallets into the storage zone

Packaging equipment

Equipment runtime statistics Storage zones

filled with goods

Pickers & weigh stations

Pickers & zones runtime statistics

End of line & delivery pallet


2011 16/24

• Highly detailed behavior of pickers (states: IDLE, PICKING,

MOVING_BUSY, MOVING_FREE, WAITING, and any other custom state according to needs)

• Support for complex interactions among personnel (pickers, operators), equipment and items

• Picking time based on item weight, dimension, appedices, wrapping, picker dexterity, tiredness etc.

• Personnel have dexterity levels, moving speeds, max load capacity etc.

• Dynamically configurable layout, number of resources, animation, animation/speed ratio

• Any type of KPI can be tracked, reported and analyzed

• Detailed modeling of equipments (e.g. conveyors, offloaders,

strapping, plastic foil application, foil heating, weight checker, storage zones, carousels, mini-loads, stacker cranes, labeling)

• Probabilistic/deterministic events for breakdowns, maintenance, change of consumables, setup, assistance etc.

• Tracking/evaluation of energy use, consumables, spare parts according to operation scenarios

• Support for any type of items, picking strategies used (single, batch, baskets, tote boxes, sorting etc.)

• Customizable animation, behavior and parameter set for any component


IT’S MORE THAN A SIMULATION MODEL, IT’S AN APPLICATION!

2011 17/24

Production plan (ERP/WMS/WCS)

Feedback

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!


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 18/24


2011 19/24

E.g. Warehouse Operations (simulation application developed by SIMANDO)

Receiving docks

Conveyor system

Forklifts

Receiving docks

S/R machine

Multi-depth/level storage racks

Trucks arrival according to deterministic or probabilistic schedule


2011 20/24

S/R machine with acceleration and deceleration for all types of movements; single/multi cycle

Innovative and revealing customized animation based on large data visualization techniques

Extensive and easily configurable simulation parameter set

Runtime and post-simulation statistics and charts for inflows, outflows, stocks, equipment utilization, energy consumption, spare parts etc.


2011 21/24

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 22/24

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)


Design Produce/Build Deliver Support

Time

Cost vs. Impact

Impact

Potential is positive

(Impact > Cost)

Cost

Potential is negative (Impact < Cost)

2011 23/24

Impact of design stages on life cycle

SIMANDO Team

Thank you for your attention!

SIMANDO 9 Republicii Blvd Timisoara, TM 300159 ROMANIA Tel: + 40 356 172 021 Fax: + 40 356 172 017 [email protected] www.simando.com

2011 24/24

simulation in logistics - simando

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