What has been considered indispensable in many industrial sectors for decades is now also becoming increasingly important in a modern precast concrete plant:
a simulation of the processes.
Everyone who operates a modern precast concrete plant knows how strong the fluctuations in the product mix, the degree of complexity, and the fluctuating workloads are in everyday life, and what a significant influence such factors have on the performance of the plant. This is where it first becomes apparent whether the existing pallet circulation system has the appropriate flexibility in terms of route guidance, whether sufficient buffer spaces are provided, whether the machines have sufficient power reserves, and whether the space for the material flow and the employees' workplaces are adequate for the tasks at hand. All in all, it is precisely these factors that determine the throughput and the labor costs consumed at the end of the day.
I recommend that anyone investing in a new precast concrete circulation plant simulate the layout of the plant with the target output, the expected variation in product mix and level of complexity, the planned storage size and duration, the intended formwork material, etc., and use the simulation to optimize the design. Of course, a simulation can also be carried out for existing precast concrete plants in order to identify optimization potential or to assess the effects of planned conversions.
- Martin Dobler Projektmanagement GmbH successfully uses the Process Simulator Professional | Edition Material Handling. -
fastplan GmbH is an engineering office for factory planning.
Our range of services covers a wide range of individual customer projects around the topic of factory. High flexibility is therefore very important to us in our software tools.
After comparing many simulation tools we decided to use the Process Simulator with Material Handling Edition, because our needs for the visualization of production processes and material supply are optimally met here in a comparatively uncomplicated and yet appealingly animated way.
The program is rounded off by outstanding support.
Johannes Hübner GmbH is a supplier of standard and customized solutions for encoders, tachometers and drives in the heavy-duty sector.
We use Process Simulator to create a digital image of our production.
This gives us the possibility to react to changing market situations with a target-oriented adjustment and balancing of our infrastructure.
The main focus is on improving productivity and the associated reduction of delivery times.
Rentschler Biopharma SE, based in Laupheim, Germany, is a leading service company
for bioprocess development and production of biopharmaceuticals, as well as
for related consulting services in project planning, implementation and regulatory affairs.
Rentschler Biopharma SE uses Process Simulator to optimize the supply of ultrapure water.
To avoid production interruptions, the simulations are used to ensure,
that ultrapure water is reliably available to the processes.
Chemie Wocklum, one of Germany's leading chemical traders, relies on Process Simulator and a close cooperation with GBU.
The traditional company with its headquarters in Balve, Sauerland (Germany), focuses with its branches and subsidiaries
on the trade with chemicals, especially acids, alkalis, solids and specialties.
In order to eliminate uncovered waste, processes must always be optimized.
With Process Simulator, we have been able to analyze more complex processes and implement the first measures.
- Ümüt Yurdaer, Process Manager at Wocklum Gruppe -
The Lucerne Cantonal Hospital (LUKS) comprises the Lucerne Centre Hospital, the two primary care hospitals Sursee
and Wolhusen and the Lucerne High Altitude Clinic Montana.
At LUKS, more than 7,000 employees care for a catchment area of around 700,000 inhabitants with 850 acute-care beds.
LUKS treats 43,000 inpatients a year and has over 680,000 outpatient contacts.
The LUKS uses the simulation software MedModel for simulation-based capacity planning in the health care sector,
especially for scenarios with high uncertainty.
In a current project, for example, the hospitalization of Covid-19 patients is predicted as a function of admissions and length of stay.
We use Process Simulator to simulate our production on our line.
For this purpose, we have created a model of the production line and simulate the effects of changes at the individual workstations
in order to be able to use a possible increase in capacity with an increase in orders.
The innovative consulting firm ProFab-L uses Process Simulator to quantify decision templates, process optimization, factory and logistics planning.
The customer base goes from toothbrush production and toy industry to classic mechanical engineering to the automotive industry - from supplier to OEM.
As a PTW education and research initiative at TU Darmstadt, CiP, a process learning factory,
forms a unique environment for learning lean methods and increasing the productivity of companies.
You experience the development of a practical production environment with real products.
We successfully use Process Simulator to evaluate logistics alternatives in value stream design.
AMR Consulting is active in operations and sales & service with a strong focus on process improvement.
In our toolbox we see Process Simulator as a powerful tool to deliver significant and resilient improvements to our customers.
The SCHLOTE GRUPPE is a global technology company.
In highly specialized plants, industrial metalworking is carried out with innovative automation concepts.
The simulation software is used here for the process analysis of the fully automated systems as well as for the simulation of inventories.
Making more efficient use of renewable energies and thus actively promoting the energy transition. That's what we stand for with our innovative technology solutions.
As Germany's market leader in the manufacture, delivery and construction of hybrid towers,
we hold the record for the world's tallest wind tower with a hub height of 178 meters.
We, Max Bögl Wind AG, are a subsidiary of Max Bögl. The company group from Sengenthal near Neumarkt i.d.Opf. is among the top 10 largest German companies in the construction industry and has been active in the wind sector since 2010.
Founded in 1929 the family-run company has around 6,500 employees with over 1.65 billion euros in annual sales worldwide.
In the field of engineering wind ProModel supports us with the planning, conception and evaluation of new production systems, as well as the entire logistical handling of our production processes.
The software simplifies decision-making processes by analyzing and evaluating measures within our concrete production and contributes to the optimization of manufacturing processes.
Hüttenwerke Krupp Mannesmann GmbH (HKM) is the second largest integrated steel mill in Germany with around 3000 employees
and an extensive product range specializing in the production of steel for the processing industry.
With the help of a modern and innovative company policy around 5 million tons of steel are produced each year.
Application areas of simulation:
- Analysis and optimization of logistics processes along the entire value chain of HKM
- Analysis of short and long-term strategies in terms of production logistics and existing steel mill capacity
to meet specific customer and quantity requirements
- Analysis of planned conversion measures to derive recommendations from the results
Lignum Consulting stands for consultancy, planning and organization for the international wood and furniture industry.
Lignum Consulting has decided to use Process Simulator in Industrial Engineering, in order to expand the activities
concerning factory and plant planning, process analysis and optimization and Lean Management.
The issue of Industry 4.0 is being discussed very intensively among those responsible for production at the moment.
The trend is towards decentralization, autonomy and networking.
In this changing environment, successfactory supports companies in terms of quality and productivity
from the analysis over the improvement concept to the implementation and success control.
Logistic and material flow simulations of the GBU based on the simulation software Process Simulator
are an important element in order to be able to experiment with virtual models without risk.
Since 1999, the Leonardo Group has been helping companies around the world to become more effective in the long term.
We generate sustainability through our own holistic approach. This is developed and implemented in teams of lean experts and psychologists together with the employees. In this way, we implement the right lean tools and get the employees appreciative.
Managers and employees develop a new understanding of leadership and personal responsibility. In this way, we create questioning, learning organizations with our customers. Further information: www.leonardo-group.com.
The Leonardo Group has been using simulation solutions from GBU mbH for many years to safeguard the line design and material supply of mixed model lines. Based on the material flow simulations of the GBU based on the logistics simulators ProModel and Process Simulator, the developed line designs are analyzed, visualized and optimized in a time-dynamic manner before realization. Typical tasks are the calculation of the placement and number of IPCs, the scaling of the throughput over the number of employees used, the determination of the necessary Kanbanmengen for material supply and the design of the routes of tugger trains.
sedak stands for large format, high quality
insulating and safety glasses up to 3.51 x 20 meters.
With the help of Process Simulator the future-oriented production system
of the glass finisher is being analyzed, visualized and optimized.
Magna Exteriors, a wholly owned subsidiary of Magna International,
is a global provider of exterior trim components and systems.
Process Simulator is used to optimize the JIT / JIS supply of OEM customers.
The challenge here is a very large number of variants and one
resulting large variance of process times in the assembly processes.
The simulation software Process Simulator has been successfully used for many years
used by master students in the course simulation in production and logistics.
After a short introduction, the students independently work on a task from their company
and present the results of the simulation study during the course.
Meiss and Partners, a consulting firm that supports the implementation of excellence,
has decided to use Process Simulator Professional.
With the help of Process Simulator, value streams and business processes in companies are made transparent.
So necessary changes succeed much better.
GE Power AG has been working successfully with GBU mbH for almost 10 years.
As a global leader in energy, GE uses ProModel simulation software
and Process Simulator for planning new, as well as optimizing existing production facilities.
Using material flow and logistics simulations, new production concepts for complete factories
or individual areas are tested for their plausibility and effectiveness.
Also in the field of plant engineering with its complex products is the use of dynamic simulation
Proven in the concept phase and is now integrated as a "standard" in the project planning.
LOBP Consulting, a consulting company for the lubricant industry,
decided to use Process Simulator Professional.
With the help of Process Simulator, design planning in grease and lubricant plants
as well as bottling and packaging systems are visualized, possible bottlenecks are visualized and optimized.
GLC Global Logistics Competence Ltd., a global logistics consultant based in Munich and London,
has decided to use Process Simulator.
Process Simulator is an important tool for GLC as part of its Logistics 4.0 initiative.
International Automotive Components (IAC) is one of the leading international automotive suppliers
for interior components and systems.
IAC uses a material flow simulation created by the GBU based on the logistics simulator ProModel.
For a new plant, machine purchase decisions are made with the help of our simulation solution
as well as the JIT/JIS supply of the OEM customer.
For 15 years, GBU has been working as a simulation service provider for Badische Stahl-Engineering GmbH (BSE).
BSE is a global consulting company for the electrical steel industry. In the long years of cooperation, we have over 35 material flow simulations in the areas of junkyard, Steel plant, finishing, storage and transport logistics for our customers.
In the last completed project at a German stainless steel manufacturer BSE was able to help Our material flow simulation of the processes in the steelworks shows considerable potential for increasing efficiency.
The consulting company emtecon GmbH, a consulting firm for transformation processes such as leadership,
Company succession and technical processes have decided to use Process Simulator.
With the help of Process Simulator, for example, the operating and logistics processes in large kitchens are visualized,
analyzed and developed solutions together with the customers.
Zahoransky AG, a full-service provider of
final packaging machines and
tamping and shearing machines for brushes and brooms
has decided to use Process Simulator.
With the help of Process Simulator, the potential benefits of new investment concepts are analyzed and communicated to the customers.