Module 7: Plant Visit Simulation

Simulation is a very helpful and valuable work tool in manufacturing. It can be used in
industrial field allowing the system`s behavior to be learnt and
tested. Simulation provides a low cost, secure and fast analysis tool. It also provides
benefits, which can be reached with many different system configurations.
What is Industrial Simulation?

Industrial simulation can be defined as a computer-based model of a real production

system. Inventory, assembly, transportation and production can all be considered within
a simulation model, resulting in decisions that can maintain or improve efficiency at the
lowest possible cost. Thus, the application of simulation solutions will play a key role in
enhancing the accountability of systematic characteristics for optimization of production.

Benefits of Simulation in Manufacturing Industry

Industrial simulation has helped the industries to deal with the competition in the business
market with the growing globalization. The application of simulation solutions has enabled
the manufacturers, to decentralize the entire process of manufacturing and also gave
them access to real-time information exchange between the stages of product
manufacture life cycle.
Since Product development processes are becoming increasingly more complex, due to
versatility and variations of products, industrial simulation has emerged as the only
solution which can address this variation.
Thus, the simulation solutions have become an important phenomenon in the
manufacturing industry which connects the stages of decision making, engineering, and
operation covering the whole life span of the production system.
Some of the advantages of industrial simulation in the manufacturing industry include the
following:
1. Investment risk reduction
Simulation solutions in an industry help the manufacturer to gain a better insight, into what
their operation needs. This insight would not only help them the manufacturers to save
time but also use the right resources at the right time.
2. Waste Minimization
Simulation solutions enable manufacturers to understand the production system better. It
is due to this, that the manufacturers develop a tap over the utilization of resources within
the production facility. This in turn, not only helps in reducing the amount of waste
produced but also helps in attaining overall production efficiency.
3. Efficiency Improvement
The simulation solutions help the manufacturers to get into the minute aspects of the
production process, identify problems involved and then accordingly design solutions for
the same.
4. Reduce energy consumption and save resources
Industrial simulation felicitates the establishment of an efficient system, where all
components are perfectly tuned to each other. Each of the components within the system
contributes to the smooth functioning of the system. Energy consumption is reduced when
overdesign is avoided and valuable resources can be saved. Simulation coupled with
modelling enables one to have a quick comparison of various layouts possible, and this
helps the manufacturers to find the most suitable configuration.
5. Detects risks, thereby protecting human lives
The simulation solutions help the manufacturers to understand the functioning of the
machinery in their unit under severe conditions. This would help them to take
precautionary measures for the safety of human lives and the machinery. Virtual
system simulation allows the manufacturers to carry out tests for the most extreme
situation, without putting health and safety of human lives at risk.

Computer Simulation Helps Manufacturer Improve Safety and Health

How do manufacturing companies know the best and safest way to design workplaces
and assign tasks? Ideally, injuries and illnesses should be prevented, but historically
companies have adjusted their workplace policies, practices and procedures after an
injury or illness occurred.

Researchers tested the role of computer simulation in promoting workers’ well-being by

designing safer work. Known as digital human modeling, the simulation can help predict
behavior and hazards and evaluate work design, without putting workers at risk or
creating costly physical mock-ups.

Using a commercially available software, researchers simulated seven distinct work tasks
to identify risks for musculoskeletal diseases and develop and evaluate workstation
designs to reduce risks.