2009 February: Success story: Planning a production plant

How to establish the scale of a production plant and need for storage, as well as balance the production line to minimize the time when storage units are either full or empty.


The challenge
During the past year, one of our customers has used Studio 7 to plan the dimensions of a production plant to set up a new product line. The challenge for this company was twofold; to establish the scale of the production plant and need for storage, as well as balance the production line to minimize the time when storage units are either full or empty.

The Powersim Approach
There are several phases within their production, where the product of one phase may be used as raw material for the next phase, and in some cases for several parallel phases. Also waste from one phase may be used as raw material for a previous phase, which gives circular flows of material to some extent. Between each phase there is a need for storage of both products and raw materials.

The Simulation
Since the different process phases are quite similar to each other, building the model were done with the sub model concept in Studio 7. A general component handles the processes, containing the entire functionality of the process where the sub model's interface handles input of planned and sudden maintenance. The sub models are connected through a singe flow and thus the big challenge is to manage all of the processes running simultaneously.

The Powersim Solution
Through this project, the company was able to fine-tune each process of the product line, thus avoiding surprises and unexpected cost increase during the detailed planning and preparation for constructing their plant.


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