Cycle time and OEE
The simulation shows whether the system reaches the required cycle time and the expected overall equipment effectiveness.
Find the bottlenecks
before the plant is built.
Material flow simulation examines how stations, buffers and transport routes work together over many cycles.
A single station reaches its target output while the overall system still waits. Varying processing times, faults and different order sequences change throughput and stock levels. Static calculations reproduce these interactions only to a limited degree. For a sound layout, realistic assumptions, scenarios and comparison figures have to be agreed so that the results can carry a planning decision.
Start now at no cost
In a free first conversation we clarify which question the simulation is meant to answer and which data has to be available for it.
What the analysis shows
The key figures are selected according to the system, the objective and the available data.
Throughput and utilisation
Stations and resources are assessed in the context of the whole line.
Waiting times and buffers
Buffer levels and waiting times show where handovers slow the system down.
Downtimes and bottlenecks
Faults become visible together with their later effect on the overall system.
Looking at events over many cycles
Material flow simulation models a system on an event basis and looks at it over many consecutive cycles.
Typical systems are large warehouses, conveyor and belt systems, airport baggage handling systems, distribution centres and parcel logistics. In such systems, handovers, buffers and faults decide the performance of the whole.
Because the runs can be accelerated considerably, many cycles and long operating periods are examined in a short time. States and faults that only occur after many repetitions in normal operation thus become visible before implementation.
For this, IQstruct Engineering uses Experior, a platform for 3D models, simulation and virtual commissioning that now belongs to Schneider Electric. If the concept holds, virtual commissioning tests the real control software in the next step.
Before the investment
Bottlenecks show up in the interplay of the stations
The simulation shows how handovers, buffers and faults determine the performance of the whole line.
Approach in the project
Ai1
Plan the material flow
Layout, conveyor lines, quantities and cycle times form the input data.
Ai2
Build the conveyor model
The data are used to build an event-based model of the system in Experior.
Ai3
Check the parcel flow
Process experts check the routes and assumptions of the model in the running simulation.
Ai4
Evaluate scenarios
Throughput, lead and cycle times of the agreed scenarios are set out in the results report.
Example scenario
Buffer sizes compared
A conveyor line connects several stations.
The model compares different buffer sizes and fault situations. Throughput, waiting times and utilisation are examined. The scenario describes a possible study and not a completed customer project.
Frequently asked questions
We are glad to answer your detailed questions in a personal conversation.
How reliable are the simulation results?
Simulation results apply to the underlying data and assumptions. Process experts check whether the model reflects the examined sequence plausibly.
Which data are needed?
Plant and system layouts, required quantities, process and cycle times, fault and failure data and the rules of the sequence. Restart and repair times refine the fault behaviour.
How much can the runs be accelerated?
Depending on the model, by a factor of roughly one hundred to one thousand. The achievable acceleration depends on the scope of the model, the level of detail, the computing effort and the couplings.
How does the simulation complement virtual commissioning?
Material flow simulation assesses whether a system concept reaches the desired performance. Virtual commissioning then tests, afterwards or in parallel, whether the real control software controls the plant correctly.
Further industry solutions
Every industry has its particularities. That calls for a reliable partner who knows the requirements and delivers suitable solutions.
- IntralogisticsConveyors, storage and retrieval machines and vehicles come from several manufacturers and speak different protocols.
- AutomotiveThe cycle time of a line is settled before it is built, and the buyer asks for proof that it is reached.
- Battery production and e-mobilityNew lines go into operation in quick succession, and their material flow changes with every product change.
First conversation
Arrange a free first conversation
Describe your task. We agree a date and discuss the possible project scope.
Ai1
You request an appointment
Ai2
We discuss your requirements
Ai3
You receive a quotation for the agreed scope
Tobias KuckBusiness Development ManagerTakes up new projects, coordinates offers and accompanies the cooperation from the first enquiry.
Free first conversation
Describe your task in the contact form. We come back with a proposed date.
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