Arena Simulation Software in Manufacturing

Model and Analyze Every Aspect of Your Manufacturing Processes

Engineers looking at virtual layout of manufacturing line.

Arena Simulation Software enables manufacturing organizations to increase throughput, identify process bottlenecks, improve logistics and evaluate potential process changes. With Arena you can model and analyze process flow, packaging systems, job routing, inventory control, warehousing, distribution and staffing requirements.

Manufacturing operations are facing pressure to become more efficient than ever. At the same time, they are becoming more specialized. Optimization of manufacturing processes requires getting it right the first time. There is no room for guesswork. Understanding system interactions, variability and resource interactions is a must when evaluating improvement options. These interactions are critical to manufacturing and are almost impossible to model in a spreadsheet, leading to decisions that can miss significant aspects of the real system.

What is Manufacturing Optimization?

Manufacturing optimization is a computer-based model of your manufacturing process that can be used to validate, test and improve the performance of your process. Simulations in the virtual world can be used to predict and improve actual performance quickly, cheaply and with lower risk than tests in the real-world. The result is enabling companies to increase throughput and reduce cost by using operational models that incorporate relevant variability and system interactions. With a functional model, all of the following can be determined:

Identification of the bottlenecks and utilization of equipment within the manufacturing operation
Achievable range of production throughput given the variability of manufacturing times and impact of product changeover and maintenance downtimes
Ideal capacity of raw material and finished goods, storage areas, tanks, conveyors, and other equipment sizing decisions

Effective optimization requires simulation, and that’s where Arena can help.

Arena is the leading global business process simulation solution, providing support to companies around the world. Arena enables manufacturers to implement production optimization solutions that will actually work in their operation.

Features and Capabilities

Easy-to-Build a Manufacturing Process Flow

Build a manufacturing process flow in a fast, intuitive and easy-to-learn manner
Drag and drop elements and structures allow you build simulations and visualize results
Engaging 2D and 3D animation capabilities that do not require programming assistance

Dashboards for Manufacturing Optimization

Built-in dynamic dashboards provide the model analysis you need to facilitate manufacturing optimization
Build customized displays of the model information to enable you to better understand what is happening in your process

Common Capabilities

Increased throughput
Reduced WIP
Eliminate bottlenecks
Optimize resource utilization
Test new design alternatives

Plant Simulation Software

Successful plant operation requires that multiple process operations are coordinated to work at maximum efficiency. If your production line is unbalanced, the result can be increased WIP, higher off-grade material and a reduction in plant throughput. Logistics inefficiencies can also increase costs when production must stop due to resource constraints or available storage capacity. Simulation can help you optimize your plant processes to reduce costs and improve throughput.

What is Plant Simulation?

Plant simulation software allows you to create digital models of your production processes to improve how each process interacts with, transitions to, and is affected by the next process. For example:

Manufacturing: model the interactions and variability between systems and resources. Determine inefficiencies and bottlenecks as well as the ways downstream operations can impact production.
Packaging: model the effects of adjustments to machine or conveyor speeds, as well as system downtime and maintenance.
Logistics: determine how scheduling or resource allocation affects efficiency with receiving, distribution, and warehousing.

Lean/Six Sigma Simulation Software

Lean manufacturing attempts to maximize value by identifying and eliminating waste, and Six Sigma attempts to improve quality by minimizing process variabilities that cause defects. One of the most significant challenges in implementing either of these methodologies is measuring how changes to a variable or a process affects that process and other processes downstream. Simulation can capture the impact of variability in ways that spreadsheets and other methods cannot.

What is Lean/Six Sigma Simulation?

Lean and Six Sigma simulation software produces digital models of your processes that allow you to see how hypothetical changes could ultimately reduce waste and defects, and improve value through cost reduction and improved throughput.

Here are some examples of ways it has been used across several different industries:

Manufacturing Rework: Automotive parts fail inspection and require rework, which is also causing gridlock in the system. Improving the pass rate will result in longer processing times, but the increase is small enough that overall throughput will be improved and chances for gridlock will be reduced.
Order Processing: Orders for heavy trucks can contain conflicting configurations or are missing key information when they are sent to manufacturing. A new order processing system will catch errors before they are submitted by the dealers, resulting in more consistent processing times.
Cancer Treatment Scheduling: when patients with the shortest jobs were scheduled first, staff and equipment resources were more available to patients with longer jobs later in the day.
Managing Hospital Blood Work: using smaller trays to carry blood work tubes improved value by reducing wasted resources and turnaround time.

1Assembly Line Simulation Software

There is a constant demand to increase production speed, product quality, and efficiency on production lines, while reducing costs. The challenge is obtaining reliable data about the ways certain variables can impact overall performance. For example:

Machine reliability: if a machine is refurbished or replaced, how much will this affect overall efficiency, downtime, and product quality?
Machine adjustment: if a machine is recalibrated to increase speed, how much will this impact product quality and the condition of the machine?
Line Balancing: what machine adjustments need to be made to balance the load across the entire line in order to maximize throughput?
Operators: do investments in additional operators, training, or automation reduce errors and performance bottlenecks?
Additional lines: does the demand for increased throughput or a new product require a new production line, or can existing lines handle the demand?

Simulation offers the actionable intelligence you need before making adjustments to your line.

What is Assembly Line Simulation?

Assembly line simulation software provides a computer-based model of your production line that can be used to validate, test and improve the performance. Simulations in the virtual world can be used to predict and improve actual performance quickly, cheaply and with lower risk than tests in the real-world. The result is enabling companies to increase throughput and reduce cost by using operational models that incorporate relevant variability and system interactions.