Highly accurate simulations optimise food company productions’ site at Malaysia site

The company’s masterplan included multiple upgrades to existing packaging line assets to increase production volumes, to streamline production processes as well as automation of the end of line packaging process. The challenge facing the engineering and site team is that increased throughput in one area can result in unexpected bottlenecks in another downstream part of the process. This is particularly true when considering the real-world variability and complexity inherent in production lines. This in turn can affect return on investment if anticipated line speeds and production capacities are not realised.

Royal HaskoningDHV was contracted to undertake a simulation study to dynamically validate the plans and verify the benefits expected from the investment. To achieve this goal, we developed simulation models using WITNESS software to represent the packaging line assets from process input into primary packaging through to end of line palletisation. The modelling provided valuable insight by highlighting how process bottlenecks changed across various SKU sizes and future state process increase scenarios. For example, certain infeed conveyors which bring packaging to the filling machine had not yet been identified for speed upgrade to keep pace with process throughput increases.

Simulations closely replicate variability of real-life operations

“In the past, this work would have been done using Excel-based spreadsheets,” explained our client’s engineering director. “While these make an accessible approximation tool that can be easily shared, the downside is that as soon as you try to reflect what is happening on the line, you cannot model the interdependency.”

Simulation and Process Improvement Consultant at Royal HaskoningDHV Digital, Kim Wee Koh, added: “By incorporating realities such as throughput variability, machine breakdowns and sensor logic in conveyors, our data-driven simulations are as close as possible to representing actual future-state performance. It is more accurate than using static Excel calculations because it represents all ranges of possible data and replicates actual system behaviour, incorporating the natural variability that occurs in real operations.”

The simulations identified some surprising interdependencies on the conveyors which had not been seen in Excel or any other modelling. In previous explorations, our client had focused on major components, but our model showed interdependencies that had not been anticipated. This provided insight for conveyor speed and design.
During the project, we conducted live workshops with our client’s team – virtual and in person – where future scenarios such as machine speeds and asset combinations were brainstormed. By changing model inputs, results of the scenarios were seen in real time. The benefits of such workshops for bringing project teams and stakeholders together are recognised by our client which believes it was the right approach not only for this project but for others too.

Project identifies where bottlenecks need to be avoided

The simulation project enabled teams to identify the bottlenecks in other key process steps that needed to be upgraded to match the capacity of the new machines in the masterplan. To achieve an efficient manufacturing process we then mapped the investment priorities that would increase throughput results at various stages of the masterplan, leading to the packaging area supporting the projected increase in process throughput.

Automation projects also involve equipment vendors, evaluating the fit of their technologies in the process. By experimenting with various automated packaging set ups, we provided the information our client needed to make a key decision for the masterplan. The results of our simulation study enabled cost-benefit comparisons between the supplier technologies or solutions under consideration. This exercise helped our client confirm assumptions around speeds and other variables. In relation to the interdependencies on conveyors, it led to the revision of specifications and certain interfaces.

“The benefit of the exercise was that we were able to confirm some assumptions and were given new insights on some of the specifications we need to adjust. It helped us reach decisions in areas where we faced multiple options,” our client’s engineering director concluded.