FlexSim_CaseStudy-New

SIMULATION FOR ANALYZING TROLLEY OPERATORUTILIZATION & AISLE CONGESTION MEASUREMENT www.steadfastglobal.com

One of the largest two wheeler manufacturers and exporters inIndia was interested in building a simulation model as part of itscontinuous improvement strategy.They wanted to simulate the Scooter assembly unit replenishmentoperation between Storage unit and assembly unit using FlexsimSoftware. This is to help them understand the current situationand help towards a larger goal to optimize operator requirementsand to ensure optimum availability of material to achieveproduction targets. Key objectives of the FlexSim simulation would beIdentify the trolley Identify theoperators utilization traffic\congestion during the parts replenishment on the assembly unit

Operators and Trucks in AisleOperators and Trucks

Project ProfileType of Project Client Engagement Size Technology/Tools Industry Users Outsourced Developed and delivered for 2 person Flexsim Manufacturing Production Simulation the Production Engineering months Engineering Department of one of the Department Model IndustrialDevelopment largest two and three Engineers wheelers manufacturer and exporter in India.Special notes  High Number of Parts Types to be Handled (168 Part Types)Other details  High Variability In Routing And Material Flow And Operator Sequence  Development of Trolleys and Trucks For Simulation  Encapsulating All Operational Aspects Of The material Movement in the plant  Comprehensive Analysis of the Traffic Congestion in Main Aisle  A development involving extensive of C++ code  Keep on Communicating with client and collect all the requirement, operational flow and information to simulate the exact floor operation. Each assumptions will be documented immediately and confirm the same with client to avoid the last minute surprise.Key Business Benefits • User can extend this model to other areas of the floor and integrate other operations • Very easy to make decisions on the floor operation either they would require more number of resources or not • Very easy to measure the Aisle congestion and Operator utilization Summary: Project was divided into different phases and implemented using the following methodology and delivered on time.

Flexsim Simulation Implementation MethodologyInitiation Data Collection Solution Design Build the simu- Analysis Delivery and lation model action planUnderstand Share the CAD Mapping the Design to Validate Drawthe simulation layout of the requirement consider and Verify conclusions,Goals and plant which with Flexsim Memory the presentobjectives needs to be Functionalities utilization Simulation results and simulated while handling Model recommen-Requirement Design to bring high number dationsAnalysis for List Compo- in the data (e.g. of parts. Addsimulation. nents\ tripsheet , path, variables to Gaining In-Collect Resources of speed etc) into Establish basic capture the formationoperation the system and the model parameters for additional and decisiondetails, collect the the simulation metrics makingprocess flow, operation Design the cod- and import based onmachine data details. ing components CAD layout Design and reports im-etc. Tour (triggers, timers, Run Experi- plementedexisting Facility List all the rules etc) Layout objects ments in theand collect info questions and on the screen, model.if required clarify with Design the connections, Analyse customer traffic rules path SimulationPrepare the (Continuous (simulation Outputsprocess flow, activity Design the surface)scope and between break times andassumption Steadfast and scheduled Implementdocs Customer until breakdowns coding logic clarity) (logic for rules)Review and Implement theconfirm reports and dashboard Customer Steadfast PROJECT MANAGEMENT (Schedule, Resource, Customer expectation Management)

PROJECT METRICSActual Vs Planned - Man HoursRequirement AnalysisModel Layout Design and Flow ConfirmationHigh Level DesignCoding & DeliveryResult Verification and Analysis With Client 0 10 20 30 40 50 60 70 80 90Actual Man Hours Planned Man Hours Actual Vs Planned - Calendar Days Requirement AnalysisModel Layout Design and Flow Confirmation High Level Design Coding & Delivery Result Verification and Analysis With Client 0 2 4 6 8 10 12 Actual Calender Days Planned Calender Days

ABOUT USboutique software Our vision is to become a 100consulting company. people company by 2020,We design and implement operating from India, with ansoftware solutions to real average revenue perworld business problems. employee of USD 100,000 P.A.Lead by a team of 3 senior technocrats and 6 mid-level project managers we have the rightmix of resources to take up projects in the range of 10 people months to 100 peoplemonths.Our current technical skills are in Salesforce, NetSuite, MEAN and Microsoft Technologies.For skills other than these, we will outsource the coding part to our vendors in India whiletaking complete responsibility for the project design and delivery.ABOUT YOUIf you are a sophisticated, market facing company with a need for designing andimplementing software solutions to solve real world business problems, or if you are aSoftware Service or Product Company in the US, looking for a reliable and committedlong-term partner, you have come to right place. We are looking for clients whose annualsoftware budget is in excess of USD 100,000.www.steadfastglobal.com [email protected] [email protected]