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Building a Proactive Analysis Environment - Visualize, Replay, Forecast.
CreateASoft, Inc.
The Process Improvement Company
 Agenda
  • Supply chain challenges
    • DC operations, distribution channels, external factors.
    • Efficiency Impact.
  • Current technologies
    • Tracking, Simulation, WMS, Voice, …
  • Dynamic analysis
    • Leveraging dynamic simulation® and tracking for improved efficiency.
  • Benefits
    • Proactive analysis and forecasting.

Challenges – DC Operations
  • DC scheduling of picking and replenishment.
  • Effect of Put-away on the DC.
  • Slotting, and DC variability.
  • Resource scheduling and allocation.
  • Capacity planning and DC limitations.
  • Material handling equipment utilization.
  • DC Inventory cost and perishable items.
 
Challenges - Distribution channels
  • Shipping routes and transportation modes.
  • Cost control and reduction.
  • Maintaining Freshness throughout the supply chain.
  • System variability and On-time delivery.
  • DC Locations and network optimization.
  • Visibility and tracking.
 
External Factors
  • Product variations and seasonality.
  • Transportation Costs.
  • Unforeseen delays due to weather/other factors.
  • Product expiration, customer requirements…
 
Simcad Pro role in the transition to Lean Manufacturing
  • The dynamic value stream provides an efficient tool to validate existing or proposed design based on different product mixes.
  • Kanban events and buffer sizes can be dynamically computed from the value stream.
  • Efficient reporting to generate best path, lean efficiencies, and OEE values.
Measuring Improvements
  • Efficiency is the key measure for Operational Quality. An efficient organization indicates that
    • Processes interact effectively.
    • Communication is well defined.
    • Customers enjoy a positive experience.
    • Picking/Receiving/Put away/Replenishment are coherent.
    • High profitability.
  • Lean Concepts applications
    • Lean Concepts normally measure process level efficiency with minimal impact on global efficiency.
    • Improving efficiency in one area should not impact negatively the overall measure, and any change effect should be analyzed throughout the process sequence.

Existing Technologies
Technology Overview
Tracking Systems RFID/Bar Code/GPS
Technology with limitations –Accuracy at a price
WMS/Voice Effective whenproperly utilized.
Featurerich environment.
SlottingTools Effectivefor static analysis
Does not include congestion and time based analysis.
Static Simulation Tools Excel/Static code heavytools
Reserved to the few who can code –“The Experts”
Scheduling Tools Effectivewhen used with a WMS.
Limited audience, lacks visualization.
Simulation Benefits
  • Simulation is an asset to any organization provided that
    • Data and models are valid.
    • Tools are easy to learn by the “Non-Expert”.
  • In the DC, Simulation is effective in
    • Improving overall DC efficiency.
    • Better understanding of material flow and process interaction.
    • Capacity Planning.
    • Resource requirements, slotting, visualization, …
Solution Requirements
  • Must be able to Visualize and Analyze the current operation.
    • Analysis is used to identify areas of maximum impact (best ROI).
    • Distribution based analysis suffers from large approximation.
      • Provides a global direction and not actual improvement.
    • Real Data provides accurate representation, with variability implemented as a distribution.
  • Human Capital –Leverage available talent, gain buy-in.
 
Dynamic Simulation®
  • Interactive On-the-Fly model changes.
    • Input/Output constraints can be modified at any time during the simulation.
  • Minimal or No coding requirements.
  • Connectivity to external systems.
    • Models update based on external factors.
 
Dynamic Simulation®
View full the presentation
 
Dynamic Simulation® Examples
  • Improved slotting.
    • Problem:
      • Capacity planning for the next 5 years.
  • Solution
    • No additional “building space” required.
      • Capacity planning for the next 5 years.
      • Requires Re-Slotting of 15 locations in the DC.
  • A 20% efficiency improvement by re-slotting the DC
  • Method
    • Optimized pick path to eliminate congestions.
    • Optimize Replenishment and Put-Away schedules.
    • Re-slot the DC based on the dynamic behavior of the DC.
 
Dynamic Simulation® Examples (2)
  • Improve DC layout
    • Problem: “The Company Standard” DC layout was implemented.
    • Solution
      • New DC Layout
      • Improved conveyor flow
  • Overall savings –$300K/Year
  • Method
    • No additional “building space” required.
      • Dynamic optimization and analysis of the interaction among DC operations.
Live Data and Dynamic Simulation®
View full the presentation
Live Tracking/Virtual Camera
  • Connectivity to WMS/Voice or other tracking systems.
  • Update rates are adjusted to system requirements.
  • Any changes on the floor are reflected on the desktop.
  • Hover or Click feedback connectivity required for maximum effectiveness.
  • Applications
    • YMS, DC, Supply Chain, …
   
Replay W/Analysis
  • By recording events, Dynamic Simulation® can replay any data point.
    • Replay is based on time.
    • Fast forward/Rewind –DVR like controls.
  • Eliminate the need to collect data for analysis
    • “Switch to Simulation” at any point during replay.
    • Data collected dynamically from the set and used in the simulation analysis.
Dynamic Forecasting
View full presentation
   
Additional benefits
  • Web enabled dashboards and animation
    • Dashboards defined per area based on live data
    • Animation based on replay or current state.
  • Alerts
    • Trucks delayed, replenishment needed, …
    • Rules determine when and who gets the alerts.
Summary
  • By Proactively managing the operation, you can
    • Reduce operation cost.
    • Increase efficiency throughout the organization.
    • Maximize utilization.
    • Provide better capacity planning.
    • Visualization/Replay/Traceability.
  • Think Ahead –Stay Ahead
    • Using enabling technology to reduce cost, improve efficiency and maximize utilization.
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