Case Study: Simulation Yields Insight

Simulation augments static data with real evidence that empowers decision makers. 
Engineering studies guide process and production updates.
One large-scale Southeastern production facility facing growing product demand was ready to invest in an update of aging equipment and operations. The existing network was complex and massive — four miles of conveyor, 13 palletizing systems, 11 new tie-in points, 33 possible inputs and 13 destinations. They turned to Haskell for an engineering feasibility study to guide the project scope and funding requirements.
Simulation reveals insight that may not appear on paper.
With the feasibility study complete, a detailed, engineered project definition plan spelled out a new layout option and variables, including maintenance and equipment selection. The report indicated that production requirements would demand a new high-speed sorter — a significant new equipment investment. The project team, however, felt more detailed simulation exercises might reveal additional insight into the line’s potential performance.
Up-front engineering helps right-size lines and equipment needs.
The full simulation mimicked the real system and provided insights on system operations, performance and verified control strategies for the entire process. The team hoped the exercise would reveal new and better design options for the large, complex system. What it revealed realized a 10-fold return, saving approximately $500,000 on equipment and systems the line didn’t need to maximize throughput. The up-front engineering effort paid significant dividends in both production volume and cost-savings. 


Reasonable Conclusions
Keith Perkey
Vice President