How do I know if and what value new technologies can provide for my machine, production line or factory?

January 2022

Discrete-event simulation is a data driven approach that can validate and analyze use of technologies in any machine or factory design. Based on calculations and qualified methods, we can run detailed tests through the Simulation tool and confirm the entire simulated production line before building your machine or factory. Rather than spending time and great effort on costly mechanical development, you can cut out these expenses from the early stage and quicken your time to market – all to your competitive advantage.

By doing a simulation of your set-up, we can do a fast sanity check of potential gains with new technologies and give you a proven idea on how to optimize your next machine or future production line according to your specific needs, whether you want to:

• Have a more flexible machine design (able to handle more products or be ready for it)
• Get a number of possible design layouts to choose from
• Eliminate costly mistakes and changes in pre-design
• Invest in a pre-proven state-of-the-art solution
• Reduce your average changeover time
• Increase items produced per minute
• Ensure that you are not just adding new technologies without proven added value

We offer a factory pre-design and an overview of the factory flow, as well as:

• An abstract simulation model to evaluate different layouts scenarios
• An assessment of technologies - An exploration of potential gains via simulation based on actual performance data and line settings
• Conceptual layouts
• Measurement and improvement of performance
• Expert knowledge, collaboration, and local support

In a technology study with a customer from Southern Denmark, the objective was to avoid downtime and optimize throughput. Simulation was used to compare the existing layout with alternate technology. By using the adaptive ACOPOS 6D track system, it was possible to reduce production time spent on each item by 61% going from 29,8 minutes to 11,6 minutes. When adding automated packaging to the new layout, the time spent was reduced by another 25,2%, going from 11,6 minutes to 4,1 minutes. The study showed that through simulation, we can achieve precise data that shows the most optimal number of shuttles needed to achieve the most optimal throughput, from testing different scenarios.

In another study with a customer from the pharmaceutical industry, the objective was to optimize future production lines for higher OEE (Overall Equipment Efficiency) by minimizing the BCO (Batch Change Over). Via simulation, potential gains were explored based on actual performance data and line settings. The alternative layout called “Split Line” was created for investigating whether double process stations, enabling the preparation of the next batch while running the current one, could reduce the time needed to do the BCO. The results showed that with a split line layout we could reduce the BCO with 68% and if we were adding phased BCO, additionally 12% could be gained. Additionally, 12% could also be gained on the split line by just adding Track systems in the line. All in all, providing this customer assurance that future designs should be done with dual stations and Track technology.

We invite all customers to join us at OrangePoint, our new Nordic experience room and demo area in Malmö. Here we can facilitate meetings and workshops, Automation Academy, Co-creation Lab, Demo Area, VR-experiences, and much more.

Visit the OrangePoint website and get a virtual tour around the demo area.

Experience OrangePoint

Each region in the North has its own dedicated team of Key Technology Consultants and application engineers specialized in simulation. Please contact your local KTC, they will set up a meeting.

Fredrik Patriksson (Sweden)
Business Developer
E-mail: fredrik.patriksson•@•br-automation.com
LinkedIn: www.linkedin.com/in/fredrik-patriksson

Martin Fogh Larsen (Denmark and Norway)
Head of Nordic Business Development
E-mail: martin.larsen•@•br-automation.com
LinkedIn: www.linkedin.com/in/martinlarsen 

Hannu Kantonen (Finland)
Sales Office Manager
E-mail: hannu.kantonen•@•br-automation.com
LinkedIn: www.linkedin.com/in/hannu-kantonen

Finnur Bessi Sigurdsson (Iceland)
Business Development Consultant
E-mail: finnur.sigurdsson•@•br-automation.com
LinkedIn: www.linkedin.com/in/finnur-bessi-sigurdsson