Simulation optimises expansion of De Heus feed production site

A feed mill in Indonesia is being upgraded and redesigned to enable a 40% increase in production volumes. Simulations have been used to optimise the design and avoid issues or bottlenecks, protecting the long-term viability of the plant and ensuring reliable availability of animal feed to customers.

De Heus is a global animal feed supplier. Its plans for increased production at the site included a new production tower and weighbridges as well as a revised layout and truck routing and new entrance and exit. Royal HaskoningDHV was asked to evaluate potential areas for concern and to optimise bottleneck processes.

Simulation investigates base case and explores scenarios for optimisation

A simulation of the future layout and truck routing enabled the base case of the site with increased production volumes to be evaluated. The model was then used to investigate various scenarios, including the impact on site performance of changes to the supply network, processing time and arrival times, while there was no additional loading station needed as validated by the simulation model. Site performance during surge volumes that occur with the arrival of large shipments was also investigated.
“The expertise and consultancy service of Royal HaskoningDHV stood out during the project, while they were also benefiting us and the society around the facility with future safety risks’’ says Indra Kusuma Jaya, Production Manager at Royal De Heus Indonesia.

Peak queue length improved by 20%

The results of the studies indicated that queues and backlogs could arise due to future volumes of trucks at the site. This allowed De Heus to identify where improvements could be made in handling projected loads, which were then quantified in the model. By partially redistributing production to a nearby site, a 20% improvement in peak queue length could be achieved. This information made it possible to carry out a realistic cost-benefit analysis on options which will futureproof the expansion plans and help minimise air pollution and fuel consumption.
Having defined operational assumptions with De Heus, parking allocations were recommended to optimise the balance between truck volume and queue length. These investigations provided confidence that the site had adequate capacity to handle surges in traffic volume.