Simio Sync Digital Transformation Conference 2020

Get Inspired – Stay Forward Thinking!

Simio LLC is delighted to announce once again that the opportunity to learn more about the state of simulation and digital twin technologies is here. And yet again, this promises to be one of the biggest simulation and digital twin of the year. Simio Sync Digital Transformation Conference will focus on digital transformation technologies and how enterprises can tap into Simio to unleash the digital potential of business processes.

The event will be taking place on the 4th and 5th of May 2020 in Pittsburgh with advanced training about using Simio from the 6th to 8th of May. The first event will introduce you to Simio, the recent updates in Simio 12, and its application across industries. Keynote speeches and event programs will consist of Simio use cases and application across industries of interest. But before delving into the opportunities of the 2020 conference, here is a recap of 2019.

Simio Sync 2019 – A Recap

The 2019 Simio Sync conference was the third annual event on simulation and digital transformation built around Simio technologies and solutions. The event brought together an ensemble of experienced speakers to inspire the crowd on the role of simulation and digital transformation in the real-world. Speakers included; Chris Tonn from SPIRIT Aero systems, Ian Shillinger from Mckinsey & Company, Antonio Rodriguez from the National Institute of Health (NIH), and Dusan Sormaz from the University of OHIO among others.

Each speaker presented case studies highlighting the application of Simio within the aviation industry, manufacturing, healthcare, education, hospitality, and simulation engineering. These events proved inspiring to participants from varying industries and opened up new possibilities about applying Simio within their specific industries.

According to Jarred Thome, from USPS, his first Simio Sync event was an eye-opener in many ways. He said “This was my first year attending the conference and I was blown away by the extent to which the folks at Simio went to ensure it was a success. The content, presenters and networking opportunities were all top-notch and the Simio staff was always accessible and willing to chat. I will definitely be coming back.”

The 2019 event was one of a kind and next year’s event is expected to take things up a notch. The Simio Sync Digital Transformation Conference will consist of speakers from Fortune 500 companies willing to share their experiences with digital transformation using Simio with you. The event will also serve as a networking arena for stakeholders within the simulation and digital transformation community and participants.

All you need to know about the Simio Sync Digital Transformation Conference for 2020 will be highlighted here. In the meantime, you can sign up with Simio to receive conference updates and to register as a participant today.

Why Attend?

The fourth annual Simio Sync conference gives you the choice to learn, no matter the role you play in your company’s digitization efforts. At the end of the days, you will work away with the knowledge to help you and your company refine your digital transformation strategy to reap the rewards digitization brings.

If networking is your thing, how about coming to listen and catch up with individuals from fortune 500 companies among others. Through the years, Simio conferences have been fertile grounds for communicating and building relationships and this year’s event will be no different.

Simio Sync Digital Transformation provides an excellent opportunity to learn about simulation and its application in the real-world. Attending the event can help kick start your company’s digital transformation or refine transformation strategies to meet your defined goals. Thus, everyone is invited to attend, network, get inspired, and create fun memories while learning about digital transformation!

Code of Conduct

Simio Sync Digital Transformation conferences are safe spaces created for everyone interested in the digital twin, simulation, scheduling, and digitization. The event is open to everyone and the conference areas are safe, inviting, and supportive.

Simio representatives are also available in every location to ensure your participation is a memorable one. If you are in need of answers to Simio-related questions or event-related questions, you can reach out to a representative and your questions will be answered.

With the increasing number of participants, the golden rule of mutual understanding also applies. This will help you build better networks, and truly take advantage of the different sessions, and labs that are parts of the event.

Registration

Registration is now open. You can now take advantage of early bird tickets to become one of the first individuals or organizations to register for the Simio Sync Digital Transformation Conference for 2020. There are a plethora of excellent hotels and living areas around the event holding in Pittsburgh and the earlier you register, the quicker you will be about planning your travel and relaxation itinerary.

To register, visit the Simio Sync event page and go through the registration process. The process is quite straightforward and intuitive to accomplish. You will also have the choice of registering for the conference event and adding advanced training options to your registration form.

Session Catalog

The Simio Sync session catalog is the ultimate guide you need to navigate through the conference while bookmarking areas you are particularly interested in. The session catalog is currently live and you can browse through it while registering.

This year, there are approximately eight unique sessions divided across networking breaks to ensure you take advantage of your participation. The sessions include diverse keynote speeches from leading digital transformation experts and Simio engineers. To get a real-world feel of the application of Simio and digital transformation processes, case study sessions and presentations are also part of the event catalog.

Other exciting events of note which you are also welcome to participate in includes the Simio Pittsburgh exploration event where you and your spouse can line up with Simio Spouses to explore the ancient city of Pittsburgh. If you are a running enthusiast, you can also choose to participate with Simio in the Pittsburgh marathon before the conference begins. These are part of the fun activities lined up for you!

Advanced Training and Hands-on Labs

The advanced training event will take place on the 6th to the 8th of May. This training focuses on the application of Simio in the real-world. Thus, you will be introduced to the different features of Simio and how they can be applied to drive digital transformations, simplify discrete event scheduling, and build digital twins of physical processes.

The advanced training program will be a boon for organizations currently using Simio and others who are interested in using it to drive digital transformation strategies. Individuals interested in digital transformation are also welcome. The hands-on lab integrates the use of case studies and the Simio interface to ensure you understand every aspect of the digital transformation process with Simio.

Networking

Tens of industry-leading organizations and individuals have already reserved their spots for the Simio Sync Digital Transformation conference. And come the 4th of May 2020, you too can pick the brains of your favorite personalities within the aviation, hospitality, education, healthcare, automotive, automation, manufacturing, and pharmaceutical industries.

Participants from Lockheed Martin, Air Canada, Boeing, BAE Systems, OHIO University, United States Postal Services, Exxon Mobil, Roche, FedEx, Honeywell, American Airlines etc. will be there. The networking dinner and entertainment sessions at 6pm create an excellent opportunity to build interpersonal relationships for the future.

Conclusion

To get the best out of the Simio Sync Digital Transformation Conference, we recommend that you participate in at least one of the following programs:

  • Participate in at least one hands-on training covering the use of Simio.
  • Bookmark and participate in a keynote session highlighting the use of Simio for your industry or related industry
  • Wear comfortable shoes and cover grounds during the networking dinner and entertainment opportunities within the conference.
  • Talk with others and explore Pittsburgh!

Top Trends in Simulation and Digital Twins Technology for 2020

Digital Twins refers to the digital representations of people, processes, and things. It is used to analyze operations and receive insight into complex processes. As 2019 comes to an end, the need to define digital twin technology still exists and hopefully by this time next year, its growth and popularity will make this need obsolete…

In 2018, digital twins were included as a top technology trend by the big names covering the tech industry. According to Orbis research, the digital twin market is expected to grow by 35% within a 5-year time frame and 2020 is right in the middle of this period. But before highlighting the trends to expect in 2020, it is only right to do a recap of the year so far. This is to note if earlier predictions have come to pass before mapping the future.

In terms of popularity, coverage of the digital twins is definitely on the right track as continuous studies by Gartner and other publications show. Today, many professionals across the technical and non-technical divide understand the digital twin concept and how it can be used to drive business processes and concepts. This is why many industries are currently integrating digital twins to bolster business insight and understand data.

The biggest adopters of digital twin technology in the geographical sense remains North America. Enterprises within the US and Canada currently leads the way in terms of adopting digital twin technology. North America accounts for approximately 59% of the digital twin market and economy while Europe and the Asian pacific comes next.

The very nature of the digital twin and simulation, as well as, the solutions they provide makes them attractive business tools for the manufacturing industry and this fact is backed up by data. The manufacturing industry’s affinity to digital twins is powered by Industry 4.0 and the varied ongoing processes that occur within shop floors. The use of smart edge devices, equipment, robots, AI, and automation also fits nicely into the digital twin concept thus making it attractive to manufacturers.

In 2019, manufacturers account for approximately 36% of the digital twin market. Other industries such as the energy and power industry, Aerospace, Automobile and Oil & Gas complete the top five industries who make use of the digital twin to enhance operations. Analyzing this trend highlights the fact that digital twins are important to simplifying complex processes where hundreds or thousands of variables and relationships are needed to successfully accomplish set tasks.

Is the Digital Twin for Only Production-based Industries?

Although the Oil & Gas industry, as well as, the energy and power sector are not tagged as manufacturing industries, a case can be made for it. Therefore, many may assume or wonder if digital twin technology is only useful within production-based industries where discrete or process manufacturing takes place. And the answer is No.

The digital twin is also being used in other industry verticals such as the hospitality industry and in restaurants. One example is the use of Simio by CKE Holdings Inc. to ease workloads in its Carl’s Jr and Hardee’s restaurants. The Digital twin is also being used to support discrete event simulations in hotels, real-estate, and tolling facilities.

The use of interconnected devices and automation within service and hospitality businesses are the driving forces behind the adoption of digital twin within a variety of industries. And the coming year is expected to witness continuous growth as more industries and professionals understand what the digital twin brings to the table.

Top 5 Trends for the Digital Twins and Simulation Technology for 2020

Interrelated Technologies will Boost Adoption Rate – The growth and maturity of interrelated technologies such as 3D printing, metal printing, and mapping will play a part in accelerating the adoption rate of digital twins in 2020. This is because of the need to monitor and consistently improve these technologies and the systems that drive them.

Using 3D printing as an example, many manufacturing outfits are currently making use of 3D printing clusters to speed up their production requirements. 3D printing clusters or farms refers to facilities where hundreds of 3D printers function simultaneously to manufacture physical items. Although these 3D printing clusters have dedicated software for managing the printing process, material delivery, scheduling, and managing the entire supply chain within these facilities are handled manually.

Digital twin solutions can eliminate the manual management and handling process in 3D printing farms to great effect. If properly executed, a digital twin of a large scale 3D printing cluster will provide a data-driven approach to optimize supply, scheduling and the manufacturing process. This will reduce expenditure including the energy expended in 3D printing cluster facilities.

Industry 4.0 will Continue to Drive Adoption – The growth in Industry 4.0 and the devices, as well as, communication channels driving the smart factory is expected to increase the adoption of digital twin solutions. In 2019, Industry 4.0 witnessed the creation of new standards from the OPC Foundation that supports the collection of data from the deepest corners of brownfield facilities. These data were collected from dumb equipment with legacy technologies using smart edge and embedded devices.

The success of this approach, means that digital twin technology can now integrate the data collected from dumb or legacy equipment when developing digital representations. This increases the accuracy levels of the representations thereby enhancing simulation results and scheduling plans. Thus, increasingly accurate digital twin ecosystems and results will create more use cases that will drive the adoption of digital twins in 2020.

IoT and IIoT to Drive Digital Twin Adoption Rate – The move to more interconnected environments across both manufacturing and service-based industries also have roles to play in 2020. As stated earlier, Industry 4.0 will enhance the adoption of digital twin technologies and this also true for the industrial internet of things (IIoT). The widespread adoption of IoT and IIoT devices or equipment have created a race to develop the best management solution to monitor interconnected activities.

This creates an avenue which digital twin service providers are currently taking advantage of and will continue to do so in 2020. The ability of the digital twin to create digital representations of IIoT devices and also integrate the data they produce creates multiple use cases enterprises will explore in the coming years. These use cases include running simulations in complex interconnected facilities to produce accurate results or to access processes that involve the use of IIoT technologies.

Digital Twin for Cybersecurity Challenges – With every passing decade, the cybersecurity challenges enterprises face keeps changing. The millennium brought Trojan horses and other viruses which were effectively stopped with anti-virus software apps and by 2010, attackers pivoted to using phishing attacks and malware. Today, ransomware, spyware, DDoS, and business email compromise attacks have become the new challenges enterprises face. Thus highlighting the ever-changing landscape of cyber threats.

To cater to these threats and attacks, digital twin solutions will be enlisted by enterprises in 2020. In this scenario, the digital twin will be used as a penetration testing tool to simulate the effects of successful data breaches or ransomware to an organizations business processes. Within the digital twin environment, attacks to core equipment can be simulated and the result will be a response pattern that ensures the crippled equipment does not lead to extended downtime.

2020 will also be expected to witness an increase in the cybersecurity threats facing cloud-based digital twin solutions. Thus, more secure communication protocols and standards regulating data use will be developed to protect enterprises making use of digital twin technology. This means developers and service providers will have an increased role to play in securing digital twin environments.

Simulation-based Scheduling – The drive to deliver real-time scheduling is expected to continue in 2020 as enterprises seek more accuracy with managing business process. The need for real-time scheduling is also driven by how enterprises intend to apply simulation and digital twin tools. An example includes the need to make business decisions in real-time, handle unforeseen occurrences such as machine downtime, and reschedule operations.

These challenges fall into the category of issues discrete event simulation (DES) software can handle. Once the required data is accessible, DES and digital twin applications can conduct simulations in real-time and provide accurate solutions to dealing with changing scenarios also in real-time. This will drastically reduce downtime and enhance performance within facilities and warehouses.

Although some DES software offers real-time simulation scheduling, many are still process-based scheduling applications and this is set to change in 2020.

Quantum Computing – If real-time simulation, scheduling, and process management is to be achieved, then digital twin solutions must take advantage of the speed, scalability, and high-performance quantum computing offers. Today, digital twin solutions currently leverage the cloud to provide stable and scalable services to enterprises and only a few integrate the use of high-performing computers to enhance or manage really large workloads.

In 2020, further strides will be made to speed up simulations within digital twin environments using high-performing computers. The success of this initiative will speed up real-time scheduling and complex process management for the foreseeable future.

Planning for 2020…

The benefits of the digital twin have played an important role in ensuring its adoption across diverse industries and the expected trends of 2020 will continue the increased adoption rate that came with 2019. Although digital twin solutions have become more interactive and intuitive to use, enterprises still require the assistance of experienced professionals to get the best out of their digital twin environment and this is where Simio can help.

IT managers, cybersecurity experts, and project managers can take advantage of the Simio Fundamentals Course to learn more about simulation and Digital Twin technology including its application in real-life scenarios.

Simio now has the GSA Advantage!®

We are pleased to announce that Simio has been awarded the coveted U.S. General Service Administration (GSA) IT-70 contract for Government Services.

Simio’s object-oriented Simulation and Production Scheduling software is ideally suited for all aspects of state and local government use. Now, government agencies can more easily purchase Simio products and services for design, emulation and scheduling of their complex systems.

“We’re proud and excited to offer a straightforward solution for simulation needs,” says Anthony Innamorato, a former Platoon Commander of the U.S. Navy and the current Vice President of Customer Solutions at Simio LLC. “With Simio now being awarded a GSA contract, government employees can more easily access and utilize the power of Simio.”

Simio now proudly displays the GSA Starmark Logo on our website, along with our Contract Number: 47QTCA19D008W.

The GSA’s federal procurement approval process means that Simio’s product offering has been screened and accepted as the best possible simulation software, at a fair price, within our industry. This means that state and local government buyers and their agencies can order and buy with confidence. They can implement strategic purchases more easily to expedite acquisitions. It also means that they obtain best prices, at the same time ensuring Federal Acquisition Regulation (FAR) compliance.

Already major suppliers to the Government, Military and Department of Defense, Simio’s solutions encompass a broad set of issues related to production scheduling, supply chain and logistics, as well as resource staffing. Typical application areas include fleet sizing and design, refurbishment operations planning and overall process improvement using Lean concepts.

Simio simulation can assist in any scenario where modeling is needed to determine solutions or to improve communication of ideas and promote understanding. Our software can help make important decisions that are critical for the reduction of risk.

Applications for Simio’s simulation in the federal government environment include:

  • large or complex systems with a great degree of process variability,
  • critical situations where it is too expensive or risky to do live testing, and
  • systems where data is missing or incomplete.

Take advantage of our new alignment with the GSA’s purchasing program to implement Simio’s leading edge software in your organization.

Find out more today about how you can order Simio via the GSA Advantage!®

Production Planning Software and Industry 4.0

The latest era of industrial revolution – Industry 4.0 connects and revolutionizes various aspects of the industry including manufacturing processes as well as business processes such as supply chain. The increasing demand of customized product from the customer end is a major driving theme of this transformation in the industry. The traditional processes are highly efficient for batch production and low cost scaling in bulk manufacturing but are relatively time consuming inefficient for manufacturing customized products. Similar is the case for the business processes and models that being used around this manufacturing style. There is need of new production planning style which can simulate the costs, efficiency and resource requirements in real time for any product for mass customization.Industry 4.0 uses Cyber Physical Systems (CPS) and Internet of Things (IoT) to introduce technological and human improvements, which ultimately results in enhanced productivity, product quality with reduced manufacturing time and product price. Hence, the requirement of an advanced production planning and scheduling scheme becomes paramount. In this article,we will discuss how production planning can be implemented in Industry 4.0 and the ways in which it will help manufacturers of any and every product to adapt easily to customer demands and transition smoothly into the upcoming industrial economy.

Industry 4.0 brings along the requirement of new process and production planning where most of the working environment is automatized and the data recorded is processed using fog computing, on-premise clouds or cloud computing servers. Machine to Machine communication is expected to increase more than ever. These changes raise some critical questions and concerns regarding the manufacturing and planning processes:

  • Is it possible to completely automatize production planning using CPS and IoT?
  • Can human knowledge be translated into future products?

The role of Production Planning Software in Industry 4.0 will be to address these concerns effectively and ensure that the decision making processes involved in process selection, resource allocation, operation sequence and scheduling and sufficiently automatized with knowledge importer from previous processes. This should then result in the modeling of the future product including customer based customization demands as well.

Traditional process planning being used in many industries presently is completely based only on the knowledge and experience of the individual or team working on the system. The people working on the systems are technology experts from experience rather than knowledge. The existing demand for change to the new technology solutions can be a big transition for such individuals. This might slow down the progress of these industries, especially SMEs which are slower in the adaptation process. Hence, it is important for each industry to build their own strategy to implement Industry 4.0.

All the manufacturing resources in the industry are now connected to data and information exchange enabling better quality and process control. Scheduling of the product manufacturing and supply chain are being solved by using dynamic scheduling with the help of Structure Dynamics Control (SDC). Data and knowledge is transformed to software that makes a decision based on the technical specification of the order and available material combinations. This type of process planning has been adopted completely in very few industrial processes such as welding.It is still a challenge for many manufacturers to figure out what would be the optimal technique if an industry manufactures various products with different set of technologies. Also, the scaling of this single technology-single product scheme( e.g. welding) might not be easy on multiple types of products. Visualization of the process and predetermining the resource requirements will become more important. Simulation of the complete Production Planning using real time data can be an effective solution to this problem.Let us see how a product planning software can make the manufacturing process ’smarter’.

”Smart products” enable an industry to include information about customization demands of the consumer,collect feedback which can then be used in knowledge databases used in the various phases product design, development and manufacturing process. These include process planning, operation sequencing and scheduling. The collaboration of various product parameters and consumer needs in each stage of product development cycle allows the manufacturer to continuously improve the product quality and optimize the manufacturing costs effectively in real time. This results in an overall better product from both consumer and manufacturer’s point of view. Product Planning Software enable this whole cycle managing various processes starting from material selection, shape, geometry, operation priority, time of operation, machine cost and avail- ability and many more. The Product Planning can also be linked to the ERP( Enterprise Resource Planning Software) in the cloud to include insights and data to other parts of product lifecycle resulting in a better product with every iteration.

A good production planning software that automatizes the various tasks of the product development cycle is a must for mass customization and improved efficiency in Industry 4.0. Thus, it can be easily concluded that a good Planning Production Software will form a critical building block of the industry in Industry 4.0.

The Evolution of the Industrial Ages: Industry 1.0 to 4.0

The modern industry has seen great advances since its earliest iteration at the beginning of the industrial revolution in the 18th century. For centuries, most of the goods including weapons, tools, food, clothing and housing, were manufactured by hand or by using work animals. This changed in the end of the 18th century with the introduction of manufacturing processes. The progress from Industry 1.0 was then rapid uphill climb leading up to to the upcoming industrial era – Industry 4.0. Here we discuss the overview of this evolution.

Industry 1.0 The late 18th century introduced mechanical production facilities to the world. Water and steam powered machines were developed to help workers in the mass production of goods. The first weaving loom was introduced in 1784. With the increase in production efficiency and scale, small businesses grew from serving a limited number of customers to large organizations with owners, manager and employees serving a larger number. Industry 1.0 can also be deemed as the beginning of the industry culture which focused equally on quality, efficiency and scale.

Industry 2.0 The beginning of 20th century marked the start of the second industrial revolution – Industry 2.0. The main contributor to this revolution was the development of machines running on electrical energy. Electrical energy was already being used as a primary source of power. Electrical ma- chines were more efficient to operate and maintain, both in terms of cost and effort unlike the water and steam based machines which were comparatively inefficient and resource hungry. The first assembly line was also built during this era, further streamlining the process of mass production. Mass production of goods using assembly line became a standard practice.

This era also saw the evolution of the industry culture introduced in Industry 1.0 into management program to enhance the efficiency of manufacturing facilities. Various production management techniques such as division of labor, just-in-time manufacturing and lean manufacturing principles refined the underlying processes leading to improved quality and output. American mechanical engineer Fredrick Taylor introduced the study of approached to optimize worker, workplace techniques and optimal allocation of resources.

Industry 3.0 The next industrial revolution resulting in Industry 3.0 was brought about and spurred by the advances in the electronics industry in the last few decades of the 20th century. The invention and manufacturing of a variety electronic devices including transistor and integrated circuits auto- mated the machines substantially which resulted in reduced effort ,increased speed, greater accuracy and even complete replacement of the human agent in some cases. Programmable Logic Controller (PLC), which was first built in 1960s was one of the landmark invention that signified automation using electronics. The integration of electronics hardware into the manufacturing systems also created a requirement of software systems to enable these electronic devices, consequentially fueling the software development market as well. Apart from controlling the hardware, the software systems also enabled many management processes such as enterprise resource planning, inventory management, shipping logistics, product flow scheduling and tracking throughout the factory. The entire industry was further automated using electronics and IT. The automation processes and software systems have continuously evolved with the advances in the electronics and IT industry since then. The pressure to further reduce costs forced many manufacturers to move to low-cost countries. The dispersion of geographical location of manufacturing led to the formation of the concept of Supply Chain Management.

Industry 4.0 The boom in the Internet and telecommunication industry in the 1990’s revolutionized the way we connected and exchanged information. It also resulted in paradigm changes in the manufacturing industry and traditional production operations merging the boundaries of the physical and the virtual world. Cyber Physical Systems (CPSs) have further blurred this boundary resulting in numerous rapid technological disruptions in the industry. CPSs allow the machines to communicate more intelligently with each other with almost no physical or geographical barriers.

The Industry 4.0 using Cyber Physical Systems to share, analyze and guide intelligent actions for various processes in the industry to make the machines smarter. These smart machines can continuously monitor,detect and predict faults to suggest preventive measures and remedial action. This allows better preparedness and lower downtime for industries. The same dynamic approach can be translated to other aspects in the industry such as logistics, production scheduling, optimization of throughput times, quality control, capacity utilization and efficiency boosting. CPPs also allow an industry to be completely virtually visualized, monitored and managed from a remote location and thus adding a new dimension to the manufacturing process. It puts machines,people, processes and infrastructure into a single networked loop making the overall management highly efficient.

As the technology-cost curve becomes steeper everyday, more and more rapid technology disruptions will emerge at even lower costs and revolutionize the industrial ecosystem. Industry 4.0 is still at a nascent stage and the industries are still in the transition state of adoption of the new systems.Industries must adopt the new systems as fast as possible to stay relevant and profitable. Industry 4.0 is here and it is here to stay, at least for the next decade.

Simio Partner Finalist in Franz Edelman Award

The prestigious Franz Edelman Award for Achievement in Operations Research and the Management Sciences was presented at the Edelman Gala on April 16th, 2018 in Baltimore, Maryland. The Franz Edelman competition honors distinction in the practice of Operations Research and Analytics, by both individuals and companies, with emphasis on the beneficial impact of their achievements.

To reach the finals, companies are required to demonstrate how their use of technology is transforming the approach to some of the world’s most complex problems.

Simio is proud to be the provider of the simulation that facilitated one of this year’s finalists, Europcar, through our partner, ACT Operations Research (ACTOR). Our combined technologies have been used to develop Opticar which provides forecasting, simulation and optimization of the processes relating to vehicle rental for the leading European car rental company.

Simulation for Decision Making

The vehicle rental industry is a huge, complex, constantly changing market, with cultural variations across countries. In order to meet dynamic demand, decisions are continuously made regarding fleet assets, their locations, usage and pricing. The combination of AI, statistical modeling and simulation allows all eventualities to be considered and evaluated in order to establish optimum processes and make informed decisions.

Simulation can be used to model the possibilities with respect to both capacity and revenue, helping managers of car rental companies to reduce their risks in terms of planning for optimal fleet saturation. By making quality decisions, they can constantly maximize business opportunity for the company and ensure consistent financial and service performances.

At Simio, we are constantly solving business problems of this kind through simulation. When complex system schedules and decisions are required, we deliver leading edge solutions across many industries, from manufacturing to transportation and logistics.

Simio is proud to congratulate our partner ACTOR, with Europcar, on their outstanding achievement of becoming a Franz Edelman Award finalist.

Scheduling in the Industry 4.0

Today started badly.

As soon as I hopped into my car, the GPS system was flashing red to show queues of stationary traffic on my regular route to the office. Thankfully, the alternative offered allowed me to arrive on time and keep my scheduled appointments.

In the same way as a GPS combines live traffic data with an accurate map of the city, Simio Software connects real time data sources with a modeled production situation. Just like a GPS, Simio can also impose rules, make decisions, schedule and reschedule.

The major difference is in the scale.

Simio Simulation and Scheduling Software can model entire factories, holding huge quantities of detailed data about each resource, component and material. It leverages big data analysis to run thousands of permutations of scenarios, finding the optimum outcomes for specific circumstances. Lightning fast, it can detect and respond to changes with suggestions that will keep everything flowing in the best possible way.

Thank goodness for Simio, because Industry 4.0 is here.

Smart Factories employ fully integrated and connected equipment and people, each providing real time feedback about their state. Data is constantly collected on each product component, for process monitoring and control. Every aspect of the entire operation is managed through its associated specifications and status data. This large, constant stream of information coming from a known factory configuration can be received, stored, processed and reported upon by the powerful Simio software.

With Industry 4.0, nothing is left to chance. Everything is monitored and optimized, and performance is predicted, measured, improved and adapted on an ongoing basis. Management of so many interconnected components requires a scheduling system that is specifically designed to operate in this dynamic data environment. Simio Production Scheduling Software can be relied upon to provide the integrated solution for enabling technology in the Smart Factories of the future.

We are already seeing a rise in robotics and the increasing digitalization of the manufacturing industry under the effects of Industry 4.0. Soon all components of the factory model will be interconnected, just like my future driverless car that will communicate directly with my GPS to take the best route using current traffic information.

All I will have to do is sit back and enjoy the ride.

How Much Data Do I Need?

I have discussed data issues in several previous articles. People are often confused about how much data they really need. In particular, I frequently hear the refrain “Simulation requires so much data, but I don’t have enough data to feed it.” So let’s examine a situation where you have, say 40% of the data you would like to have in order to make a sound decision and let’s examine the choices.

1) You can possibly defer the decision. In many cases no decision is a decision in itself because the decision will get made by the situation or by others involved. But if you truly do have the opportunity to wait and collect more data before making the decision, then you must measure the cost of waiting against the potential better decision that you might make with better data. But either way, after waiting you still have all of the following options available.

2) Use “seat of the pants” judgment and just decide based on what you know. This approach compounds the lack of data by also ignoring problem complexity and ignoring any analytic approach. (Ironically enough this approach often ignores the data you do have.) You make a totally subjective call, often heavily biased by politics. There is no doubt that some highly experienced people can make judgment calls that are fairly good. But it is also true that many judgment calls turn out to be poor and could have benefited greatly from a more analytical and objective approach.

3) Use a spreadsheet or other analytical approach that doesn’t require so much data. On the surface this sounds like a good idea and in fact, there is a set of problems for which spreadsheets are certainly the best (or at least an appropriate) choice. But for the modeling problems we typically come across, spreadsheets have two very significant limitations: they cannot deal with system complexity and they cannot adequately deal with system variability. With this approach you are simply “wishing away” the need for the missing data. You are not only making the decision without that data, but you are pretending that the missing data is not important to your decision. An oversimplified model that doesn’t consider variability or system complexity and ignores the missing data … doesn’t sound like the makings of a good decision.

3) Simulate with the data you have. No model is ever perfect. Your intent is generally to build a model to meet your project objectives to the best of your ability given the time, resources, and data available. We can probably all agree that better and more complete data results in a more accurate, complete, and robust model. But model value is not true false (valuable or worthless) but rather it is a graduated scale of increasing value. Referencing back to that variability problem, it is much better to model with estimates of variability than to just use a constant. Likewise a model based on 40% data won’t provide near the results of one with all of the desired data, but it will still outperform the analytical techniques that are not only missing that same data, but are also missing the system complexity and variability.

And unlike the other approaches, simulation does not ignore the missing data, but can also help you identify the impact and prioritize the opportunities to collect more data. For example some products have features that will help you assess the impact of guesses on your key outputs (KPIs). They also have features that can help assess where you should put your data collection efforts to expand sample or small data sets to most improve your model accuracy. And all simulations provide what-if capability you can use to evaluate best and worst case possibilities.

Perfection is the enemy of success. You can’t stop making decisions while you wait for perfect data. But you can use tools that are resilient enough to provide value with limited data. Especially if those same tools will help you better understand the value of both the existing and the missing data.

Happy modeling!

Dave Sturrock
VP Operations – Simio LLC

Simulation Stakeholder Bill of Rights

The people who request, pay for, consume, or are affected by a simulation project and its results are often referred to as its stakeholders. For any simulation project the stakeholders should have reasonable expectations from the people actually doing the work.

Here I propose some basic stakeholder rights that should be assured.

1. Partnership – The modeler will do more than provide information on request. The modeler will assume some ownership of helping stakeholders determine the right problems and identify and evaluate proposed solutions.
2. Functional Specification – A specification will be created at the beginning of the project to help define clear project objectives, deadlines, data, responsibilities, reporting needs, and other project aspects. This specification will be used as a guide throughout the project, especially when tradeoffs must be considered.
3. Prototype – All but the simplest projects will have a prototype to help stakeholders and the modeler communicate and visualize the project scope, approach, and outcomes. The prototype is often done as part of the functional specification.
4. Level of Detail – The model will be created at an appropriate level of detail to address the stated objectives. Too much or too little detail could lead to an incomplete, misunderstood, or even useless model.
5. Phased Approach – The project will be divided into phases and the interim results should be shared with stakeholders. This allows problems in approach, detail, data, timeliness, or other areas to be discovered and addressed early and reduces the chance of an unfortunate surprise at the end of a project.
6. Timeliness – If a decision-making date has been clearly identified, usable results will be provided by that date. If project completion has been delayed, regardless of reason or fault, the model will be re-scoped so that the existing work can provide value and contribute to effective decision-making.
7. Agility – Modeling is a discovery process and often new directions will evolve over the course of the project. While observing the limitations of level of detail, timeliness, and other aspects of the functional specification, a modeler will attempt to adjust project direction appropriately to meet evolving needs.
8. Validated and Verified – The modeler will certify that the model conforms to the design in the functional specification and that the model appropriately represents the actual operation. If there is inadequate time for accuracy, there is inadequate time for the modeling effort.
9. Animation – Every model deserves at least simple animation to aid in verification and communication with stakeholders.
10. Clear Accurate Results – The project results will be summarized and expressed in a form and terminology useful to stakeholders. Since simulation results are an estimate, proper analysis will be done so that the stakeholders are informed of the accuracy of the results.
11. Documentation – The model will be adequately documented both internally and externally to support both immediate objectives and long term model viability.
12. Integrity – The results and recommendations are based only on facts and analysis and are not influenced by politics, effort, or other inappropriate factors.

Note that every set of rights comes with responsibilities. The associated stakeholder responsibilities are discussed as part of the Simulationist Bill of Rights.

Give these expectations careful consideration to improve the effectiveness and success of your next project.

Dave Sturrock
VP Products – Simio LLC

Why Simulation is Important in a Tough Economy

Everyone wants to cut costs. No one wants to spend unnecessarily. When budgets are tight, software and software projects are an easy place to cut. Staff positions like Industrial Engineers are sometimes easier to cut or redeploy than production jobs. I suggest that following this reasoning to eliminate simulation projects is often short-sighted and may end up costing much more than it saves. Here are a few reasons why it may make sense to increase your simulation work now.

1) Minimize your spending. Cash is tight. You cannot afford to waste a single dollar. But how do you really know what is a good investment? Simulate to ensure that you really need what you are purchasing. A frequent result of simulations intended to justify purchases is to find that the purchases are NOT justified and in fact the objectives can be met using existing equipment better. A simulation may save hundreds of times its cost with immediate payback.

2) Optimize use of what you have. Could you use a reduction in cost? Would it be useful to improve customer satisfaction? I assume that your answer would always be yes, but even more so in difficult times. But how can you get better, particularly with minimal investment? Simulation is a proven way to find bottlenecks and identify often low-cost opportunities to improve your operation.

3) Control change. In a down economy you are often using your facilities in new and creative ways – perhaps running lean or producing products in new ways or in new places. But how do you know these new and creative endeavors will actually work? How do you know they will not cost you even more than you save? Simulation helps you discover hidden interactions that can cause big problems. Different is not always better. Simulate first to avoid costly mistakes.

4) Retain/improve your talent pool. Some people who might otherwise be laid off may have the skills to be part of a simulation SWAT team. By letting them participate in simulation projects, they will likely achieve enough cost reduction and productivity improvements that they more than pay for themselves. As an added bonus, the team will learn much about your systems, the people, and communication – knowledge which will improve their value and contributions long after the project is complete.

5) Reduce risk. You are often forced to make changes. How do you know they are the right changes? Will a little more, a little less, or a different approach yield better results? How do you measure? A strength of simulation is its ability to objectively assess various approaches and configurations. Substitute objective criteria for a “best guess”, and, in turn, reduce the risk associated with those changes. In a down economy it is more important than ever that you don’t make mistakes.

In summary, rather than thinking of the cost of simulation, you should think of what the investment in simulation today will save you today, tomorrow and every day following. Simulation is not a cost, it is an investment that may return one of the best ROIs available in a tough economy.

Dave Sturrock
VP Products – Simio LLC