Food Processing Plant Rail Simulation

A study of sorting and unloading rail cars using Flexsim Simulation Software.

Overview

St. Onge Company, a supply chain engineering firm, was assisting a food processing company in the northeastern United States to expand its facility. An important component of the expansion was a rail operation.

The main rail line branched into multiple end points, called spurs, where rail cars containing raw materials (ex., sucrose, peanuts, vegetable oil) were unloaded. The cars were brought in from the main line and stored in either a spur used exclusively for storage or on an available space along an unloading spur. Each raw material type had

Bottling Line Case Study

A study of bottling lines using simulation software

Overview

Canning and bottling lines are complex processes. If a line is set up properly by using correct accumulation profiles and machine speeds, then all downtimes should be solely attributable to breakdowns, changeovers and labor issues. Conversely, if the line design is such that minor stoppages impact line performance, then overall efficiency of the facility will be degraded. The difficulty in ensuring the line is designed to maximize production and efficiency is amplified when there are different packaging formats with frequent changeovers. With packaging lines costing millions of dollars, and an increasingly competitive packaging

Manufacturing Line Case Study

A study of a manufacturing line using Flexsim Simulation Software

Overview

Operating a manufacturing line is always a challenge. Ensuring the rules for operation, staffing levels, and production capacity are all in sync with the business plan is no simple feat. Facing these challenges, a large manufacturer turned to Flexsim to develop a simulation model as a way of addressing these questions.

Issues to Solve

This manufacturer wanted to know how to best operate a new manufacturing line and answer specific questions regarding staffing, changeover times, and buffers.

The new manufacturing line required operators with different skill sets. At question was how many of each

Cream Cheese Manufacturing Case Study

A study of manufacturing cream cheese using Flexsim Simulation Software

Overview

Flexsim Software Products recently assisted a major food manufacturer with a simulation study of their cream cheese manufacturing process. The manufacturer provided Flexsim with detailed descriptions and data of the process as well as a tour of the facility. Flexsim built the simulation model and provided training on how to use, maintain and update the model it as needed. The manufacturer then performed analysis and what-if scenarios.

Issues to Solve

The model was built to achieve two goals. The first was to help the manufacturer understand the actual capacity of the plant as

Mine Smelter Process Improvement Evaluation Case Study

A study of the impacts on ore transfer via gantry cranes and AGVs during process improvement implementation at a mine smelter using Flexsim Simulation Software

Overview

A large mining company wanted to evaluate the impacts of competing process improvement plans on the productivity of their smelting process during implementation. The plant being studied initially had five reduction kilns and four smelting furnaces.

The reduction kilns were used to heat the ore to approximately 1200 degrees Fahrenheit to reduce the moisture content and ore oxide. The smelting furnaces melted the ore into slag and a metal matte that was further refined at a later

AS/RS Picking Systems Case Study

A study of an automated storage and retrieval system using Flexsim Simulation Software

Overview

Skarnes Inc., a material handling company located in Plymouth, MN, wanted to increase the throughput of one of its client’s warehousing processes. Skarnes’ client used an Automated Storage and Retrieval System (AS/RS) that interfaced with a conveyor loop that transported pallets to a picking station and then back to the AS/RS.

The AS/RS consisted of four aisles, each with a Storage and Retrieval Vehicle (S/RV). Each aisle also had an input and output conveyor that connected to the main conveyor loop. All of the conveyors in the system are

Bicycle Manufacturing Case Study

A study of the throughput of a bicycle factory using Flexsim Simulation Software

Overview

An engineering company needed to improve the throughput and lower the cost of manufacturing bicycles. The manufacturing process involved many resources, both human and machine.

Issues to Solve

A finished product in this system consists of multiple parts each manufactured by different machines. Also, many operators are required to transport parts, set up machines, inspect the process, and repair the machines.

This bicycle manufacturing company needed to solve the classic manufacturing and logistics problem of making sure enough parts arrive at the right place at the right time to produce the

Ore Transfer Case Study

A study of the impacts on ore transfer via gantry cranes and AGVs when increasing the number of ore types from one to two using Flexsim Simulation Software

Overview

In an attempt to decrease emissions, increase production by 20%, and improve the quality of the final product, a mine was evaluating the feasibility of producing two types of ore from reduction kilns. The plant being studied had five reduction kilns and four smelting furnaces. The reduction kilns were used to heat the ore to approximately 1200 degrees Fahrenheit to reduce the moisture content and reduce the ore oxide. To produce the new ore

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