Dynamic simulation for the factory of the future

Ensure availability and efficiency – learn to see with the digital twin

Keeping the right products in stock in the right quantities to ensure high delivery reliability while avoiding excessive capital tie-up from unnecessary inventory – a major challenge for make-to-stock manufacturers to overcome.

Together with a large consumer goods manufacturer, Dr. Schönheit + Partner (S + P) is planning its Future Factory 2040. Following our integrated approach, expertise from our areas of factory planning, architecture and energy design is incorporated to produce an optimal result for the customer. An integral part of the future factory is the planning of the required storage areas.

To ensure high delivery reliability in the future, sufficient storage space must be available. At the same time, planned storage areas mean investments in warehouse technology that should be kept low. In order to generate an exact picture of the required storage areas, S + P developed a simulation model that depicts both the warehouse and the production. This simulation enables the optimal design of the storage areas already in the early master planning phase. The following points were taken into account:

  • Product-specific replenishment times
  • Plant capacities in production
  • Availability of machines in production
  • Sales fluctuations over several years

Compared to the widely used static approach, this dynamic simulation allows storage requirements to be better estimated and fluctuations in inventory levels across different product groups to be considered. This allowed a detailed and realistic estimation of the warehouse requirements during the planning of the Future Factory 2040. Compared to a conventional warehouse design, it was thus possible to

  • 11% of parking spaces saved,
  • a service level of over 99.9% validated and
  • a six-digit amount of inventory investment saved.

However, simulation not only enables enormous savings and optimization potentials in the dimensioning of storage areas. It can also support technology selection, layout decisions or the investigation of process changes without interrupting ongoing operations – in the warehouse, the production or beyond. In this way, simulation can also serve as a basis for cross-divisional strategy decisions for the entire fulfillment process.

Dynamic simulations are used as standard in S + P consulting and factory planning projects. The proven approach makes a significant contribution to increasing the efficiency and effectiveness of the future factory in all areas of the value chain. In addition, the simulation of processes is an important building block of the digital twin of our factories.

Are you planning a factory of the future? Would you like to know what individual added value our dynamic simulation can offer you? Feel free to contact us with your specific task.

The S + P simulation approach makes a significant contribution to increasing the efficiency and effectiveness of the future factory in all areas of the value chain.

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