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Test Line Design with Dynamic Simulation

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Test the static calculations and the conceptual line layout using a Dynamic Simulation Modeling tool. Ensure that the conceptual design can meet the performance goals for project with a special focus on Throughput and Productivity. The team must test changes to mix and volume based on known or expected Customer demand fluctuations.

Collect Simulation Data

Gather and review all work to-date, including conceptual layout, the Standard Time process matrix, resource calculations, and workstation definitions. Additional data includes estimates of process variability.

Select Simulation Software

Decide which software application will be used. There are many choices, but expertise in the software is a requirement, and often the deciding factor. You will have to make your choices based on price, learning curve, and immediacy of results.

Enter Data and Test Based Model

Build the Mixed Model Line’s simulation model and populate it with the required information. Perform the baseline tests to debug the simulation the model. Compare model’s output to current actual performance as an initial sanity check.

Meet Target Volume and Mix

Experiment with the model once the original line design data has been entered and the model is running without basic errors. Test the model to meet the desired throughput goals as originally designed. Identify constraints and make real time changes to improve performance. Document all scenarios on every iteration to keep track of the changes you made. All these experiments must be made with the Forecasted Daily Volume used in the Resource Calculations. Do not make changes to volumes yet.

Test Changes in Mix

Simulate different mix scenarios to test the strengths of the Mixed Model line. You are now in the next level of experimentation by making reasonable changes to the mix of products. If possible, use historical mix and volumes that have occurred in the past. Continue to make changes to improve performance.

Perform Sanity Check

Review your results with the aid of line staff. Once the model can meet performance goals, including changes to mix and volume, it is advised to review model with Operators and other Team Members and incorporate their feedback.

Perform Final Simulation Review

Perform a final review of the model’s performance data, and collect all changes made to the original design. Invite stakeholders to review the line and provide their feedback. Evaluate the impact to the original budget if necessary.

Document Simulation Results

Create a written report on the simulation project, with a high focus on the changes that were made from the original design. Provide for input to the CAD layout. This should also be used as a feedback loop to the MMLD data gathering team to see of the information they developed for the line design could be improved on future projects.