Simulation Modelling and Planning in Industry
Oil and Gas
The oil and gas industry is characterised by large scale investments in complex, multi-stage value chains. Return on investment is heavily dependent on effective decisions made in the design and operational stages of the project life cycle.
Simulation modelling overcomes the limitation of spreadsheets and other static tools by incorporating the real-life complexities of these value chains. The impact of alternative investment strategies and operating practices can be accurately tested in a low risk modelling environment, with the visual nature of simulation providing insight as to why some approaches work better than others.
Defence & Aerospace
Maintaining capability whilst living within the bounds of affordability is key to success in the defence and aerospace sector.
Simulation modelling helps by testing alternative maintenance strategies, evaluating alternative working practices and designing new factories all in a low risk modelling environment. It accurately predicts the effect on key metrics such as lead time, OEE, cost and throughout.
Used in conjunction with our shift pattern design software, XIMES, simulation can be used to examine the impact of operating 5,6 or 7 days a week, running 24 hours a day or less. In this way, capital expenditure, plant size and impact on the overall supply chain of different strategies can be tested in a low risk modelling environment.
Food & Drink
We use simulation modelling in the food and drink industry optimise the design and operation of production processes. Examples include designing new factories, streamlining the interface between automated and manual processes and testing alternative production strategies.
Optimising the overall supply chain requires having the right capacity available at the right time to meet demand. Rather than shoehorn our client’s business into one product, we have the capability to rapidly develop bespoke planning solutions that incorporate the parameters critical to our clients’ businesses.
In conjunction, these two capabilities enable our clients to benefit from reduced (or justified) capital expenditure, improved lead times, more on time delivery and reduced operating cost.
XIMES helps AEC improve throughput
Aero Engine Controls worked with Process Evolution to help design new shift patterns for its Birmingham-based manufacturing sites. This provided a firm evidence-based foundation for discussing options with employees. Output in some production areas is now up by more than 10% since implementation of the new shift patterns.
“There were two main benefits of working with Process Evolution. First, they enabled the leadership team to understand with confidence how we could cover our business working hours requirements based on proven, deployed working patterns in other private and public sector organisations. Second, we asked PE to work with our trade union representatives so that they could understand in an objective way, the options for covering the new working hours requirements. In practice, this meant that PE consultants worked with the reps without the leadership teams involvement and this resulted in the reps getting to an understanding of the limits of what was and what was not possible, much more quickly and effectively than had we tried to work through working pattern options in negotiation.”Mike Moran
Our evidence-based consulting service
1. Scope: what needs to be done? We meet with stakeholders so that we can establish a single-team approach and a shared understanding of objectives, priorities and context. This is crystallised in the scoping report.
2. Baseline and diagnose: where are you now? We capture data from client systems and using our powerful analytical tools are able to show clients what is really happening rather than what they think is happening. With a baseline for current processes, performance and workload, we can clarify the rationale for change and identify areas of opportunity.
3. Model, evaluate & optimise: what are the options for handling demand? With our suite of modelling software, we can use our client data to run a series of accurate 'what-if?' scenarios. These allow you to determine the consequences and costs of, say, adjusting performance targets, the number and categories of vehicles and staff and changes in organisation structures - without the risk and cost of real-life experiments.
4. Report and recommend: what do you need to do?We work with our clients to agree the clear evidence-based options. They are then equipped to make sound decisions about how best to maximise performance and make savings.
5. Support implementation: how do you adapt? We continue to support clients throughout the implementation phase, helping to keep the programme on-track by monitoring the realisation of benefits, responding to real-world change and carrying out on-going analysis.
The software suite for industry
Transforming data held on operational systems into meaningful management information
Aligning assets and resources to where demand occurs
Design of working time compliant shift patterns that align resources to when demand occurs