- Vrealmatic
- Simulation
- Manufacturing simulation
Manufacturing simulation for a balanced line that meets takt
A simulation model of your production shows which station holds the line back, where work in progress piles up and what a change to the layout, staffing or plan will deliver. You choose the variant by the numbers.
Why simulate production
Line output is set by the slowest station. Which one it is only shows over time.
Average times in a spreadsheet ignore breakdowns, changeovers, breaks and the way orders meet at the stations. Simulation runs production through the model over time, variability included, and shows where and why the line loses output.
What manufacturing simulation solves
The questions we solve most often in production
We answer each one with a model of your production and your data. Variants are compared on the same inputs.
- 01
Does the line keep up with takt when demand grows?
We derive takt from demand and compare it with cycle times. We show which tasks to move so the line is balanced.
taktcycle time - 02
How big should the buffers between stations be?
A small buffer stops the line, a large one ties up money in work in progress. Simulation finds the size that is enough.
WIPblocking - 03
How to plan batches and changeovers with a wide product range?
We compare order sequences and batch sizes. You see how much time changeovers take and how lead time changes.
batcheschangeovers - 04
What does a machine breakdown do to output?
We add failure rates and repair times (MTBF, MTTR) to the model. We show the impact on the whole line and where a backup pays off.
MTBFMTTR - 05
Will a robot or another machine pay off?
We test the investment in the model before you order it. If the bottleneck is elsewhere, simulation shows it right away.
investmentthroughput - 06
How many people and shifts does the production plan need?
A parametric model recalculates the required staffing for different volumes and product mixes.
staffingshifts - 07
Does material supply keep up with the line?
We simulate supply routes and frequency (milk run, kanban) so stations never wait for parts.
supplyroutes - 08
Will a new line fit in the hall and work?
We design the layout at real dimensions and check material routes, buffer space and handling equipment.
layoutspace
What the model tells you
Every variant compared in numbers
The model collects data from every station for the whole run. You see results per shift, per week and over the full planning horizon.
- ThroughputHow many units the line produces per hour, shift or week, and whether it meets the plan.
- Takt and cycle timeThe cycle time of each station against the takt set by demand.
- UtilizationThe share of working, waiting and blocked time for machines and people. Overloaded and idle spots.
- Work in progress (WIP)How many parts wait between stations and how much space and money they tie up.
- Production lead timeHow long an order takes from material input to dispatch.
- LossesTime lost to changeovers, breakdowns and waiting for material or operators.
We first compare the baseline model with the actual output of your operation. Variants are evaluated only once the current state matches reality.
Lean and simulation
Lean reveals waste. Simulation verifies the fix.
A value stream map (VSM) captures production at one moment. Simulation adds time and variability, so you can verify proposed improvements before you implement them.
Data and outputs
What we need from you and what you get
You can start with incomplete data. We fill in missing times by measurement or a qualified estimate together with your process engineer.
Your inputs
- Hall layoutA drawing (DWG, PDF) or a sketch with dimensions, stations and routes.
- Process routingsThe sequence of operations and station times for each product.
- Production planVolumes, product mix and batch sizes over a representative period.
- Shifts and staffingShift calendar, breaks and who operates each station.
- Breakdowns and changeoversFrequency and duration of breakdowns, maintenance and changeovers between products.
- GoalWhat the simulation should decide. One clear question beats ten general ones.
Demo
Production flow model
The simulation model captures the flow of material and semi-finished products through every node of production. At any moment it knows the state of machines, people and parts in progress, so it reveals bottlenecks and points to a more efficient arrangement and setup of the process.
Process
From a question to a verified change
We build the model with the people who know the production: the process engineer, the foreman or the production manager. Every step ends with an output you sign off.
- 1
Goal and scope
We define the question, the metrics and the model boundaries: which line, which products, which period.
Output: model brief
- 2
Data and current state
We build a model of current production and compare it with the actual output of the operation.
Output: validated model
- 3
Variants
We add the proposed changes to the model: layout, staffing, batches or investments.
Output: set of scenarios
- 4
Evaluation
We compare the variants on the same data and recommend the best one.
Output: recommendation and action plan
- 5
Implementation
We help put the change into operation and compare the result with the model.
Output: verified benefit
Follow-up tools
The model can keep working after the project
A production model can be turned into tools for day-to-day planning and control. We build them to measure and connect them to your systems.
Planning a change in production?
Test it in the model first.
Tell us what you want to change or decide. We will tell you what data the simulation needs and what to expect from the result.
