Using Simulation and Optimization in Complex Manufacturing Operations

This presentation outlines the story of a Medical Device Fortune 500 company’s experience in implementing a combined simulation and optimization solution not integrated to the primary ERP system of a critical manufacturing location. You'll learn about the pros and cons, and the challenges and lessons learned, during the implementation process using a discrete simulation model using OpStat methodology launched in two critical areas in 2015 and 2016. After a weekly simulation and optimization process was enacted, customer service rose to unprecedented levels, while plant financial performance became enterprise benchmarks. The process knowledge acquired by the team during the implementation also resulted in a major shift in the nature of the work of the planning organization, evolving from a group of schedulers to a team of holistic capacity planners. To accomplish this task in an evidence-based way, a simulation model was developed using ExtendSim. This approach helped the clinical, managerial, and facility staff to not just understand their existing department workflow but also to provide them the opportunity to test trans-disciplinary scenarios to guide the design of the new emergency department. Furthermore it provided the client with the statistics to evaluate the impact a new Chest Pain & General Observation Center and Results Waiting Lounge would have on their entire system.