How-To

Where should you allocate resources?

Simulation Modeling and Analysis

Scenario Testing
- Create multiple scenarios in the simulation model. For instance, add or remove a machine or operator at different stations and observe the outcomes.
Key Metrics
- Track lead time, throughput, and resource utilization for each scenario.

Compare scenarios to see which resource allocation yields the best performance (e.g., shortest lead time, maximum throughput).

Optimization Features
- FlexSim (and add-on modules like OptQuest) often have optimization capabilities. You can define your objective (e.g., minimize lead time) and constraints (e.g., staffing limits) and let the tool recommend optimal resource configurations.

Lean Thinking Principles

Waste Reduction (Muda)
- Identify stations with excess waiting or idle time—these might benefit most from additional resources to rebalance workload.
Leveling (Heijunka)
- Lean promotes level production, so you might allocate resources in a way that balances the workflow rather than overloading one station.
Standard Work
- Adjusting resources (people or machines) should align with standardized work instructions, ensuring that all operators follow best practices for consistency.

Building a Process Flow in FlexSim

Creating a clear, structured process flow is the foundation of any effective simulation model. Whether you’re analyzing a manufacturing line, an airport operation, or a service workflow, the goal is the same: define the activities, connect them logically, allocate the right resources, and control the flow of events. This

Which job should you schedule first? In what sequence?

Simulation Modeling and Analysis 1. Dispatching Rules * Program or set different scheduling heuristics (e.g., First-In-First-Out (FIFO), Earliest Due Date (EDD), Shortest Processing Time (SPT), etc.) in your FlexSim model. 2. Batch or Sequence Comparison * Experiment with various sequences in simulation (e.g., schedule high-priority orders first vs. regular jobs

Given the failure of a resource, how does this this affect your delivery time?

Simulation Modeling and Analysis 1. Downtime Modeling * Build probability distributions or schedules for resource downtime in your FlexSim model (e.g., Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR)). 2. Scenario Analysis * Run scenarios where a critical machine fails for a certain duration. Observe queue build-up, lead

Where Is the Bottleneck? A Practical Guide to Simulation Modeling and Analysis

Operational problems rarely announce themselves. Instead, queues silently expand, delays accumulate, and throughput declines mysteriously.