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10/13/2017 Copyright 2016 Simio LLC 1
Introduction to Simio
Simulation-based Scheduling
10/13/2017 Copyright 2016 Simio LLC 2
Agenda
�Simio Company Background
�What is Simio Risk-based Planning and Scheduling (RPS)?
�Simio Key Capabilities
�Scheduling Project Approaches
�Software Demonstration
�Simio Scheduling Workflows
�Case Studies
�Summary
10/13/2017 Copyright 2016 Simio LLC 3
1985 1996 2000 2005 2009 2010 2015 2017
C. Dennis Pegden, PhD.
Founder and Chief Executive Officer
1st
Generation
Simulation
invented
SLAM
3rd
Generation
Simulation
invented
ARENA(Market Leader)
2nd Generation
Simulation
invented
SIMAN/CINEMA
Develops
simulation-
based
scheduling
foundation for
Preactor 400
1st Scheduling
with
Simulation
invented
TEMPO
Rockwell
Automation
acquires
ARENA &
TEMPO
Dr. Pegden
founds Simio LLC
with the same
core engineering
team
4th Generation
simulation invented
(Patent for Flexible
Object Designing)
SIMIO
1st Scheduling
invented with
patented
simulation-based
risk analysis
(RPS)
Cloud-based
access for
simulation and
scheduling
execution
PORTAL EDITION
623
Universities
actively teach
simulation
worldwide
Simio Company Background
Systems Modeling Corp. Simio LLC
10/13/2017 Copyright 2016 Simio LLC 4
Simio Risk based Planning and Scheduling (RPS)
�Simulation• Visualize and understand the systems.
• Analyze system performance.
• Evaluate alternatives.
• Minimize risk of implementation.
�Planning and Scheduling• Deliver services on time and budget
in the presence of uncertainty.
• Add automated Risk Analysis to assess plan feasibility.
• Correctly allocate resources to improve daily operations.
10/13/2017 Copyright 2016 Simio LLC 5
Simio Key Capabilities
�Accurately captures Complexity
• Complex Material Handing and Secondary Resources� Cranes, robotic equipment, transporters, workers, etc.
• Specialized Operations / Resource Allocations� Changeovers, sequence dependent setups, etc.
• Experience-based Decision Logic and operating rules� Order priorities, work selection rules, buffering, etc.
1
10/13/2017 Copyright 2016 Simio LLC 6
Simio Key Capabilities
�Effectively deals with Variability
• Breakdowns and Unplanned events
• Worker and Resource schedules
• Setup, Processing and Teardown times
• Material and Order arrivals
2
10/13/2017 Copyright 2016 Simio LLC 7
Simio Key Capabilities
�Executes Concurrent planning and scheduling
• Simultaneous, in memory, solving for:
� Demand (sales order, stock orders, production orders, etc.)
� Capacity (workers, machines, transporters, cranes, etc.)
� Material (raw material, purchased material, intermediate material, etc.)
• The schedule generated through this process will fall within the
window of feasibility.
3
Demand Capacity
Material
Window of Feasibility
10/13/2017 Copyright 2016 Simio LLC 8
Simio Key Capabilities
�Provides for Interoperability between systems• Manual data entry
• Excel and CSV table binding (Excel)
• Database table binding (SQL/Oracle, etc.)
• XML transformation (ERP/SAP/Oracle, etc.)
• Connecting to Wonderware MES using the standard API.
4
MES
10/13/2017 Copyright 2016 Simio LLC 9
Simio Key Capabilities
�Facilitates Cloud based results distribution• Schedule Results
• Gantt charts
• Reports
• Dashboards
• Experimentation
5
10/13/2017 Copyright 2016 Simio LLC 10
Where does Simio RPS Fit?
�Typical Architecture
• ERP (SAP, Oracle, etc.)
• Master planning (SAP APO, etc.)
• Scheduling (Excel, Board, etc.)
• MES (Wonderware, etc.)
�Add Simio for Scheduling
ERP (SAP, Oracle, etc.)
Master Planning (APO, etc.)
Scheduling (Excel, etc.)
MES (Wonderware, etc.)
Simio RPS
Transactional
Operational
• Specified execution window
� Typical production campaign
� Multiple shifts
� Operational time fence
10/13/2017 Copyright 2016 Simio LLC 11
Scheduling Project Approaches
�A scheduling project can be approached in one of two basic ways (or hybrid) as follows:
• Model driven approach� Simulation design and/or optimization project as the initial
phase of the project
� New facility with no existing data (Greenfields project)
� Current facility but the MES that will contain the data is still in the implementation phase
� Current facility with no MES implemented and poor ERP/MRP data
• Data driven approach� Current facility with MES installed and operational (rich data)
� Current facility and Simio will integrate to the ERP/MRP system
� Current facility with all process, material and resource data in Excel data tables
� Complex systems with many process steps, parts, routings and final products
10/13/2017 Copyright 2016 Simio LLC 12
�To illustrate the process of building a simple scheduling model
using a “model driven approach” we are going to build the
process shown below in various Steps.
Simple Scheduling Model
Order
Arrivals
Cutting
Operation
Drilling
Operation
Painting
Operation
Shipping
Operation
Workers Forklift
Random
Distribution
Order Table
10/13/2017 Copyright 2016 Simio LLC 13
�To illustrate the process of building a data driven scheduling
model we are going to build the Order based process shown
below by using the Simio data add-in.
Data Driven Model
Filler 1
Tankfill 1
Packer 2
Mixing 2Order
Entry
Store Blue
Products
Workers
Mixing 1
Packer 1
Mixing 3
Store Red
Store Green
Filler 2Tankfill 2
Intermediate
Storage
10/13/2017 Copyright 2016 Simio LLC 14
Demonstration
�Let’s look at a more detail demonstration:
10/13/2017 Copyright 2016 Simio LLC 15
Simio Scheduling Workflow
�Manual Scheduling with MES integration
New Order DataProduction Schedule
Pro
du
ction
Master planning Operator View
MES
Operator
Screen
Ord
ers, W
IP, e
tc.
Sch
ed
ule
Pro
du
ctio
n D
ata
Order/Shop floor StatusActual Production Data
Production Floor
MES
Manual
Planning
Master Scheduler
10/13/2017 Copyright 2016 Simio LLC 16
Simio Scheduling Workflow
�Automated Scheduling with MES integration (Solver mode)
New Order DataProduction Schedule
Pro
du
ction
Master planning Operator View
MES
Operator
Screen
Ord
ers, W
IP, e
tc.
Sch
ed
ule
Pro
du
ctio
n D
ata
Order/Shop floor StatusActual Production Data
Production Floor
Simio
Portal
View
Production Schedule
MES
Au
tom
ate
d
10/13/2017 Copyright 2016 Simio LLC 17
Simio Scheduling Workflow
�Automated Scheduling with MES & Manual Intervention
New Order DataProduction Schedule
Pro
du
ction
Master planning Operator View
MES
Operator
Screen
Ord
ers, W
IP, e
tc.
Sch
ed
ule
Pro
du
ctio
n D
ata
Order/Shop floor StatusActual Production Data
Production Floor
MES
Manual Intervention
Au
tom
ate
d
10/13/2017 Copyright 2016 Simio LLC 18
�Global Manufacturer – saves $300 million per annum with vessel reduction
�Agricultural Equipment - $240,000 per annum less labor while trailer-to-door processing time drops 50%. Number of dock doors reduced with growth without more dock doors.
�Air Force – increased process output 30% that increased revenue $10.35 million
�John Deere - production scheduling tool was used to create a feasible schedule that stabilizes production operations from increased throughput
�Vancouver Airport – saved $100 million by avoiding unnecessary terminal expansion
�BAE Systems – helped meet production deadlines and decrease overtime
�Retirement Clearinghouse – shows Americans can add $115 billion to their savings with auto portability
�Cosan - predicted unnecessary sugar cane transport purchases that saved $500,000
�Virgin Airlines - showed that a new gate plan would decrease OTP by 50 points and drop them from 1st place market leader to 2nd
User Financial Impact Examples
10/13/2017 Copyright 2016 Simio LLC 19
Denmark Capitol Region
Challenges
Size of scope and complexity of the environment.
No compromise environment.
Sterile equipment availability.
Delivery performance to other hospitals.
Solution
Sequences that respect all process constraints.
Quick and efficient re-planning and scheduling.
Fully automated solution.
Awareness of all variability in the process.
Value
Meet committed performance targets.
Real-time integration to the execution systems.
Optimized resource schedules.
Forward visibility based on expected demand
10/13/2017 Copyright 2016 Simio LLC 20
Challenges
Ineffective planning in Excel.
Infeasible production schedules.
Schedules are disconnected from the MES and ERP.
Poor production performance and throughput.
Solution
Integrated scheduling and MES solution.
Sequences that respect all process constraints.
Quick and efficient re-planning and scheduling.
Schedule presented on the MES operator screens.
Value
Greater production stability.
Improved production throughput and efficiency .
Data integration and integrity.
Time feedback and re-planning.
John Deere
20
10/13/2017 Copyright 2016 Simio LLC 21
Shell Vessel Scheduling
21
Challenges
Size of scope and complexity of the environment.
Weather and delivery constraints.
Equipment availability.
Delivery performance to offshore facilities.
Solution
Sequences that respect all process constraints.
Quick and efficient re-planning and scheduling.
Discrete event simulation.
Awareness of all variability in the process.
Value
Measure the quality of the schedule.
Allow users to react to changes in the system.
Schedule visibility to all parties in the supply chain.
Visibility allows running tighter operation.
One tool for LT planning and ST scheduling
10/13/2017 Copyright 2016 Simio LLC 22
Steel Corp.
The Company: Produces build-to-specification rolled-
steel. Most important metrics: quality & on-time
delivery.
The Challenges: Current tools do not capture key
scheduling considerations.
� Worker schedules and qualifications
� Equipment availability
� Material allocation complexity
� Random aspects of the process
The Solution: A simulation model takes into account
all of the factory process complexity, production
order/material matching algorithms, and due date
considerations.
The Results: Additional market share expected with
existing capacity.
10/13/2017 Copyright 2016 Simio LLC 23
Problem Statement
� Ramping up production of the F-35 Joint Strike
Fighter from 1 aircraft per month to 1 per day.
� Response time and accuracy of decision support
techniques is insufficient to evaluate the outcomes
of complex and highly interconnected operations
environments.
Business Rationale
� Mitigates risk to production cost and schedule by
providing increased visibility of potential production
problems and the ability to judge the effectiveness
of possible solutions.
Expected Results
� Reduce lost days 50%
� Less workstation delays $3.67M/yr.
� Less rescheduling review $173K/yr.
� 5-Year NPV ROI 18.6 : 1
F35-Joint Strike Fighter
F-35 Joint Strike Fighter
10/13/2017 Copyright 2016 Simio LLC 24
Summary
�Provide both simulation and scheduling
�Unique capabilities• Captures and represents complex processes
• Manages process variability
• Concurrent planning creating feasible schedules
• Provides for an Integrated solution (WW MES)
�Creates unprecedented value
�Enables repeatability and corporate wide rollout
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