A process model can be a simple spreadsheet or a complex model encompassing all aspects of a real-world manufacturing plant. However, even the best model cannot include everything. It only includes what is necessary to answer the questions.
The question to consider is: Under what circumstances are model and simulation projects most likely to add value? Let’s look at 10 reasons to build process models.
10 Reasons Why You Should Build a Process Model. Image Source: CRB
1. Determine the number and scale of the equipment design. For example, how many bioreactors and purification tracks are needed to meet anticipated demand over the next 10 years?
2. Identify process bottlenecks. Most processes involve highly complex techniques, such as those involving numerous devices and facilities. Sometimes, process bottlenecks change over time or function as a function of process variability. Understanding where the bottlenecks are and how to limit them helps improve productivity.
3. Configure utility systems. Manufacturing plants typically have numerous utility needs, some of which may not be well-differentiated. Factors such as sanitation schedules and preventative maintenance can impact the delivery of critical items. Production volume and product quality can be affected if these utilities are not available when needed. Simulation allows for the quantification and correction of over-design levels, rather than guessing at a numerical value.
4. Optimize layout. The available layouts can be quantitatively compared with the model to select the layout that is optimal in terms of operability and cost.
5. Determine personnel. Consider when it would make sense to add another operator or another shift.
6. Optimize the laboratory. This may mean changing the layout, increasing the correct number of testing devices, or simplifying operations.
7. Cleaning pipes. In complex pipe networks, cleaning each section of pipe on-site can be a troublesome task.
8. Transporting materials to large equipment. Raw materials must be moved from the warehouse, weighed, and dispensed before entering the solution preparation stage. If they do not arrive on time, buffering may be delayed, potentially affecting product batches. Conversely, if materials arrive too early or the buffer preparation plan is too conservative, it may result in additional inventory and related costs.
9. Reduce costs. Understand all elements of the cost structure. Where should attention be focused to reduce costs? Is it on simple methods like changing elements, or on the elements with the greatest impact?
10. Learn more about the modeling process. This insight often leads to unexpected improvements. For example, one client was pleased to learn how to increase capacity by 25% without incurring costly capital projects.
If any of the reasons above describe your manufacturing plant, process modeling and simulation are recommended as a new and effective way to learn and improve processes and operations.
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