MATERIAL FLOW SIMULATION

Assembly systems

Today's assembly systems must be flexible—not only for new product variants, but also for increasing quantities. Changes in the order program often have a significant impact on the overall system. Simulation addresses the challenges before they become apparent in operations.

Typical questions that simulation can answer:

• Dimensioning buffer sizes
• Impact of disruptions and rework
• Increasing output
• Parts supply and control logic
• Investigating future developments
• Securing investments

Goods distribution centers

A goods distribution center must be able to respond as flexibly as possible to changes in the order structure. Simulation offers the opportunity to test this flexibility and highlight the limits of planning. This allows the future viability of the facility to be assessed.

Typical questions that simulation can answer:

• How many orders can be processed?
• What are the optimal strategies for order control?
• Warehouse dimensioning
• Conveyor technology performance
• Ensuring delivery reliability
• Seamless supply to order pickers

Battery production

The EDAG Group has extensive experience in the design and planning of production facilities for battery cells and the assembly of battery modules. With our powerful building blocks, we are able to simulate different planning concepts quickly and cost-effectively. This allows us to secure our customers' investments.

Typical questions that simulation can answer:

• Dimensioning of buffer sizes between areas
• Impact of disruptions and rework
• Backup of contingency plans
• Investment protection

Simulation at the airport

There is a lot of activity at the airport. Suitcases and containers are transported and distributed by automated systems. It is important that the suitcases are back on the next plane at the right time. Goods must also be sorted into new containers.

Typical questions that the simulation provides answers to:

• How does the system respond to different flight schedules?
• What sorting performance can be achieved?
• How flexibly does the system respond to disruptions?
• Can all connecting flights be reached?
• How efficient are the conveyor technology and processing stations?

Automobile factories

During production, a car passes through various manufacturing areas. Starting with the sheet metal needed for the bodywork, right through to the assembly of the vehicle logo. All manufacturing systems must function smoothly, both individually and in conjunction with each other, in order to enable fast throughput times and small buffer stocks.

Typical questions that simulation can answer:

• Output and throughput times
• Utilization of employees and equipment
• Impact of disruptions and rework
• Buffer stocks and protective circuits in the system
• Testing new manufacturing ideas

Contract logistics

Automation is not very common in contract logistics, as the ROI cannot be achieved with short contract terms. At the same time, the cost of changes to the production program is difficult to estimate.

Based on typical key figures (type of storage, space requirements, means of transport, etc.), a 3D simulation model is created that transparently displays the processes and costs.

Typical questions that the simulation provides answers to:

• Determining space requirements
• Determining resource requirements
• Analysis of cost drivers
• Investment protection

Medical technology

The medical technology and pharmaceutical industries are also facing increasing challenges—whether in production, testing processes, packaging, or logistics. Simulation can be used to effectively analyze the increasing complexity caused by product variants.

Typical questions that simulation can answer:

• Determining minimum resource requirements (equipment and personnel)
• Securing scenarios for future volume increases
• Investigations into supply security
• Investment security

Omniverse

With the help of Omniverse, the work results of different departments can be summarized on the basis of a uniform data foundation and with realistic visualization. Of course, material flow simulation is also part of this virtual factory in Omniverse.

Why connecting to Omniverse makes sense:

• Advanced visualization options for simulation results
• Communication and data transfer between different departments
• Non-expert environment for conducting simulation experiments

Painting systems

EDAG simulates painting systems for car bodies, aircraft parts, consumer goods, and much more. Ultimately, it always comes down to the interaction of the various components: dip tanks, paint booths, drying systems, cleaning systems, and the associated conveyor technology.

Typical questions that simulation can answer:

• Optimization of the number of load carriers/hangers
• Dimensioning of buffer lanes
• Minimization of throughput times
• Control strategies for sorting storage
• Investigation of different order programs
• Investment protection

Supply chain

Goods in the right place at the right time. This is essential to keep production running around the world. Transport options must be carefully selected and routes optimized. Consolidating shipments around the world to optimize transport capacity utilization is essential.

Typical questions that simulation can answer:

• Decisions about production sites and hubs
• Decisions about means of transport and routes
• Decisions about inventory management policies
• Optimization of the total costs of all transports

Virtual testing

Virtual commissioning (VC) allows the programming of the various control levels to be checked and errors to be detected and eliminated. The real control system is linked to a model that imitates the real world from the control system's perspective. This enables functional tests to be carried out even before the system is physically set up.

Advantages of VC:

• Possibility for early testing
• Quality control of the control software
• Easy testing of different scenarios
• Shorter commissioning time
• Cost savings during commissioning