Configure Your Product Package

A Production line can represent various types of manufacturing lines.

Examples of Production lines include:

• Machining line
• Assembly line
• Casting line
• Welding line
• Painting line

Capabilities and limitations in a Simple Flow :

• Parallel stations are supported.
• Complex branching is not supported (see Complex Flow ).
• Variant-specific flows are not supported (see Complex Flow ).

All our simulation models are built in 3D to ensure realistic visualization, which boosts both credibility and acceptance.

All variants are assigned randomly generated colors to help distinguish them visually.

To apply custom colors, this feature must be included in the order.

All static objects (e.g., stations, buffers) use a standard color by default.

To apply custom colors, this feature must be included in the order.

All static objects (e.g., stations, buffers) are displayed with a standard 3D graphic by default.

To appply custom graphic, this feature must be included in the order and the corresponding graphic files must be attached.

By default, all objects (except workers) are represented using static 3D graphics.

If animated graphics are required (e.g., a tool moving toward a part during processing), this feature must be included in the order.

Note! The animation of objects do NOT affect the simulation results.

The static objects included in the model, along with their connections, form a Line Configuration .

Typically, only one Line Configuration is needed. However, multiple configurations may be required – for example, when purchasing a new line and different machine or line suppliers propose alternative solutions.

Another case where multiple Line Configurations are needed is when simulations of several different flows are included in the same order.

Output values are various result data points, often determined by the simulation result.

Examples of Output values include:

• Throughput per hour (in the line)
• Lead time (in the line)
• Work in process (in the line)

Experiment parameters are input data points whose values vary between different experiments.

Examples of experiment parameters include:

• Cycle time in Station 1
• Capacity (number of places) in Buffer 1
• Set-up time in Station 2
• Batch size

Experiments represent different scenarios to be tested.

Examples:

• "What happens if availability increases by 5%?" – this is one experiment .
• "Which of the following three sequences gives the highest throughput per hour?" – this involves three experiments .
• "Which batch size (between 1 and 101, in steps of 5) gives the highest throughput per hour?" – this results in 21 experiments (1, 6, 11, ..., 101).

Another example, suppose you want to test the following:

• 2 line configurations
• 3 experiment parameters (for each configuration)
• 4 values per parameter

This results in a total of: 2 × 3 × 4 = 24 experiments .

A Station object is a location where a part is processed and value is added to it.

Examples of Station objects include: Station, Parallel Station, Assembly Station, and Dismantle Station.

A Buffer object is a location where a part can wait before continuing in the process flow.

Examples of Buffer objects include: Buffer and Store.

A Variant is a part type that differs from others in one or more defined ways, such as features, materials, dimensions, or configurations.

In flow simulation, it is only relevant to distinguish between Variants if they impact the flow in some way. This could include differences in cycle time, changeover time, scrap rate, or the specific path a variant follows through the production process.

A Shift calendar is used to define when different equipment and resources are operational.

• Configure shift times during the week (e.g., day, evening, or night shifts).
• Set up operational calendars across the year (e.g., holidays, maintenance periods, seasonal schedules).

Cycle time is the minimum time required to process a part in a station object, including loading and unloading, but excluding any waiting time.

Constant time refers to a fixed duration that repeats in every cycle.

Detailed (custom distribution) refers to a cycle time that varies for each cycle based on a specified statistical distribution.

Examples of supported distributions include:

• Uniform
• Normal
• Lognormal
• Negative Exponential
• Weibull
• Triangular

Per variant allows you to define a specific cycle time for each variant used in the simulation model.

This enables more accurate modeling when different variants require different processing times.

Stop data refers to the values that describe how frequently and how long an object is in a failed state.

With (AVB/MTTR) , failures are described using two metrics:

• Availability (AVB): The percentage of time an object is not in a failed state.
• MTTR (Mean Time to Repair): The average time it takes to repair an object after a failure.

Note:

• In simulation models, the relevant MTTR value typically reflects the entire stop duration , often referred to as MDT (Mean Down Time) . This includes all phases of a stop, such as:
  • Waiting for an operator
  • Waiting for maintenance
  • Waiting for spare parts
  • Restarting the station
  • Verifying the quality of produced parts
• An exception applies when repair resources (e.g., maintenance personnel) are modeled to simulate waiting times. In this case, the MWT (Mean Waiting Time) should be subtracted from MDT to obtain the correct MTTR.
• If needed for analysis, other parts of the stop duration can also be excluded, but this requires custom logic.

In some scenarios, Stop data follows two or more statistical distributions rather than just one.

This typically occurs when there are multiple sources of stops, such as:

• Breakdowns: Failures where something is physically broken and requires replacement or special handling (often involving specialized personnel).
• Small stops: Minor interruptions where the object can usually be restarted without major intervention.

The presence of multiple error types can often be identified by observing that the input data aligns with more than one distribution pattern.

Stop data can be defined in two ways:

1. Using Availability and MTTR , see (AVB/MTTR)

   Note: With this approach, the interval and duration are calculated from the Availability and MTTR values. The simulation uses a Lognormal distribution for the interval and a Weibull distribution for the duration.

2. Using interval and duration directly:
   • Interval: Mean time between stops
   • Duration: Mean time for each stop

   This method allows you to specify a custom distribution for both the interval and the duration.

   Examples of supported distributions include:

   • Uniform
   • Normal
   • Lognormal
   • Negative Exponential
   • Weibull
   • Triangular

The feature Detailed stop data (custom distribution) enables the second approach.

A station that requires Set-up needs preparation time before it can begin processing. This typically includes activities such as changeovers between variants or tool changes.

In the simulation model, Set-up can be defined according to two main principles:

1. Set-up due to change of variant: Triggered when the incoming part differs from the previous one.
2. Set-up after a certain number of processed parts: Triggered periodically, based on quantity thresholds.

Detailed set-up time (custom distribution) allows the set-up duration to vary randomly according to a specified statistical distribution.

This makes it possible to more accurately represent the variability in set-up times within the simulation model.

Set-up time (per variant) allows you to define different set-up durations between specific variant transitions using a variant-to-variant matrix.

For example, the Set-up time can be specified individually for transitions such as:

• A → B
• A → C
• B → A
• B → C
• C → A
• C → B

This enables more accurate modeling of changeover times between different product variants.

Set-up settings allow you to define more precisely when a set-up should occur.

Available options include:

• Only perform set-up when the station is empty – ensures that set-up is triggered only when no parts are present at the station.
• Perform set-up "Before Next Part" or "After Last Part" – applicable only for Set-up after a certain number of processed parts: , not for Set-up due to change of variant .

The Scrap rate is a percentage that defines how much of the processing at a station results in parts being scrapped.

A part marked as scrap may either continue through the process flow to the end or be removed from the flow at a designated point.

In analysis, scrap is treated as a quality loss .

Scrap settings allow you to define the specific positions in the process flow where parts marked as Scrap should be removed from the flow.

Workers in the simulation model make it possible to simulate the impact of different numbers of available workers on the process.

When using workers in the model, it is important to exclude any pre-existing worker-related waiting times from the input data. Instead, let the simulation dynamically generate waiting times based on actual worker availability during runtime.

There are three default worker types in the simulation model: Operator , Set-up Staff , and Maintenance .

• Operator: Performs the actual processing at a station, such as assembly tasks.
• Set-up Staff: Handles set-up activities, indicating that these tasks require separate personnel.
• Maintenance: Responsible for repairing objects when they fail.

Adding Electrical and Mechanical maintenance categories allows you to split maintenance tasks into two distinct types. This enables a more precise analysis of how waiting times impact the overall process flow.

When Shift calendars are included, you can always choose from 12 predefined Shift Times (1–6 shifts, each available with or without breaks ).

To apply customized shift times, this feature must be included in the order.

Note: It is quite common to exclude Calendars in a Flow Simulation model.

However, if a Calendar is required, both a Swedish and an American Calendar for the current year are automatically included when Shift calendars are enabled.

To use a Customized calendar , this feature must be included in the order.

The Bottleneck analysis is the primary tool for analyzing flow effectiveness and identifying losses in the system.

Functions of the Bottleneck analysis includes:

• Calculates the mean cycle time for each station during the simulation run and can therefor present statistics as parts/hour in charts.
• Allows grouping of two or more station objects into a single operation step for combined analysis.
• Identifies the bottleneck operation in the system and enables it to be highlighted.
• Displays loss charts from three time perspectives:
  • OEE – based on Planned Production Time
  • OOE – based on Total Operations Time
  • TEEP – based on All Time
• Supports input of an ideal cycle time to distinguish speed loss from working time, and are therefor able to recalculating statistics accordingly.
• Enables identification of quality loss due to scrapped parts.
• Allows separation of waiting time into:
  • Waiting for parts
  • Waiting for resources
  This helps identify line constraint losses in the analysis.

Level 2 is the standard analysis level in Flow Simulation software. At this level, the different states of station objects form the basis of the statistical output.

States in Level 2 include:

• Working
• Setting-up
• Waiting
• Blocked
• PoweringUpDown (start-up and shut-down time)
• Stopped
• Failed
• Paused (unplanned production time)
• Unplanned (non-operating time)

The Bottleneck analysis feature enhances Level 2 by adding the following states:

• Working (Possible bottleneck)
• Waiting for resources
• Quality loss
• Speed loss

Level 1 provides an aggregated view of losses using standardized categories:

• Working (OEE / OOE / TEEP)
• Quality losses
• Performance losses
• Line constraints
• Availability losses
• Planned losses (used only in OOE/TEEP calculations)
• Non-operating losses (used only in TEEP calculations)

Level 3 provides an in-depth analysis by breaking down key loss categories into detailed subcategories.

Quality Losses:

• Scrap
• Processing scrap
• Rework

Waiting for Resources:

• Waiting for operator
• Waiting for set-up staff
• Waiting for maintenance

Setting Up:

• Setting up for variant
• Setting up after n parts
• (Tool change)

Start-up / Shut-down Losses:

• Start-up loss
• Pause down loss
• Shut-down loss

Stopped By (dynamic loss categories from user input) :

• Stopped by Failure (failure name)
• Stopped by Failure (failed object + failure name)
• Stopped by Object (StoppedBy object name)
• Stopped by Object (other failed object name)

Failed (dynamic loss categories from customer input) :

• Failure group name

Planned Loss (dynamic loss categories from customer input) :

• Label of unplanned shift times in the ShiftCalendar object

Non-operating Losses:

• Weekly non-operating loss
• Label of non-operating shift times in the ShiftCalendar object (dynamic loss categories from customer input)
• Yearly non-operating loss
• Label of non-operating days in the ShiftCalendar object (dynamic loss categories from customer input)

Choose setting Level 1-2 makes it possible to choose from a set of predefined configurations.

Available options for Level 1:

• SP STD
• APQ Pl N
• APQ Pl (not recommended)
• APQ (not recommended)

Available options for Level 2:

• SP STD
• PlantSim default

Choose setting Level 3 makes it possible to choose from a few predefined configurations:

• SP STD (affected)
• SP STD (causing)

Custom settings Level 1-2 enables the following configuration options:

For Level 2:

• Activate or deactivate additional states:
  • Working (Possible bottleneck)
  • Quality losses
  • Speed losses
  • Waiting for resources
• Rename losses
• Sort losses
• Assign colors to losses

For Level 1:

• Re-categorize Level 2 losses into Level 1 categories
• Sort losses
• Assign colors to losses

Custom settings Level 3 enables the following configuration options:

• Re-categorize Level 3 losses into corresponding Level 2 categories
• Rename losses
• Deactivate dynamic losses for the following categories:?
  • Failures
  • Yearly non-operating losses
  • Weekly on-operating losses
  • Planned stops
  • Stopped by

Help with input data

An included bank of support hours dedicated to helping you prepare, structure, and quality-assure your input data. This support is provided after your order is completed, but before the actual simulation work begins.

The values in the table for this service are specified in hours (h).

All support and walkthroughs are conducted digitally via screen sharing in Microsoft Teams . This is our standard option, optimized for speed and efficiency.

Expert Analysis & Recommendations

In addition to the quantitative baseline analysis, one of our specialists conducts a qualitative deep dive. The specialist interprets the data-driven results, identifies strategic insights, and provides tailor-made recommendations based on their experience.

The values in the table for this service are specified in hours (h).

An interactive meeting with one of our specialists where we review your results, explain the reports, and answer your questions so you can act on the insights.

Depending on your chosen package, the walkthrough can also include:

• For the Basic package & up: A demonstration of your simulation model, how to run it, and an explanation of its different components.
• For Pro & Premium: A deeper discussion about the conclusions from your Expert Analysis & Recommendations .

The values in the table for this service are specified in hours (h).

A Simulation Report is included with all deliveries.

The report contains the following sections:

• Title page with creation details
• General information
• Model overview
• All input data
• Results from the Bottleneck analysis
• Statistical summaries

See the example report for more details.

An Experiment Report is included with all deliveries.

Since most simulations use dynamic input data, the results do not represent exact values. Instead, they are presented as statistical estimates .

The accuracy of the results depends entirely on the quality of the input data.

Example result:
Based on the given input data, the true mean throughput per hour is estimated to be between 10.1 and 10.3 , with a 95% confidence level .

To produce statistically valid results, multiple replications (or observations) must be run for each experiment.

The combined outcome of these replications is summarized in the Experiment Report.

Interactive Simulation Model

A standalone, interactive version of your simulation model. It can be run on any compatible computer without requiring special software or a license.

Editable Project File

This is an add-on for advanced users with a valid Plant Simulation software license. It provides the complete, editable project file.

With access to the editable file, you can, for example, modify your simulation project, duplicate the model, or adapt it to simulate another production line using our standard library components.

Included Library Objects

The following objects and functions from the standard library are always included in the Editable Project File :

• Stations ( onPlausibility controls included)
• Buffers ( onPlausibility controls included)
• Variants ( onPlausibility controls included)

If Bottleneck analysis are included, the following functionalities in the object from the standard library are included in the Editable Project File :

• Operation functionality
• Possible Bottleneck functionality
• Speed losses
• Quality losses
• Split of Waiting Waiting for parts / Waiting for others , has no effect unless Resources are defined

If Bottleneck analysis Level 3 are selected, the following functionalities in the object from the standard library are included in the Editable Project File :

• Internal losses: (doesn't need any extra objects)
  • Waiting for operator
  • Waiting for set-up staff
  • Waiting for maintenance
  • Waiting for ...
  • Set-up for variant
  • Set-up after a number of parts
  • Start-up loss
  • Shut-down loss
  • Failure 1, 2, 3, etc. (dynamic)
• Losses from other obejcts:
  • StoppedBy (dynamic)
  • P_ShiftCalendar , including:
    • Pauses (dynamic)
    • Weekly non-operating losses (dynamic)
    • Yearly non-operating losses (dynamic)

If any of the Worker categories are included, the following objects from the standard library are included in the Editable Project File :

• Workplace_Op
• Workplace_Se
• Workplace_Ma
• Workplace_El (optional)
• Workplace_Me (optional)
• Operator_Male
• Operator_Female
• SettingUpStaff_Male
• SettingUpStaff_Female
• Repairer_Male
• Repairer_Female
• WorkerColors (custom color definitions?)
• WorkerColorMapping (mapping of roles to colors?)