1. Proactive Management with Real Time Forecasting and Dynamic Simulation
Hosni Adra
CreateASoft, Inc.
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

2. Dynamic Simulation
Dynamic simulation environment differs from standard environments…
Highly interactive with fast model building capabilities.
On-the-fly changes– Modify, Analyze, Optimize the model on the fly without the need to stop and restart the simulation
Connectivity to external data systems during the simulation run
Initial state loading based on current environment state.
Dynamic model updates based on current constraints and flows.
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

3. The need for Dynamic Simulation
Reduced time for model building
Enable simulation for everyone within the organization
Improve model accuracy
Better optimization methods
Improved analysis capability
Provide “life to the model” beyond the initial simulation effort.
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

4. Management Manufacturing Side Overall Operation Efficiency
Job Scheduling
Raw Material Availability
Man Power fluctuation
Down Time and change over
Quality
Management
Overall Operation Efficiency
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

5. Management Logistics DC Side Overall Operation Efficiency
Receiving Schedules
Order Picking variation
Man Power fluctuation
Replenishment
Slotting, Racks, Layouts
Management
Overall Operation Efficiency
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

6. Issues facing Management
Staying on Schedule
Management Expectations (Employees, Management, customers)
System Variability
Accountability and data reporting
Other…
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

7. Dynamic Simulation Impact
Provide a simulation model that is accepted by the people involved.
Connect models to live data for
Current state loading
Current order/production schedules.
Provides a target schedule to work toward.
Generates a set of metrics to help identify key problems and maintenance schedules.
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

8. Solution must have...
Valid model representing the current state of the operation.
Data – Connectivity to ERP/MRP/WMS systems
Historical performance and data points
Staffing/provider constraint impact
Ability to accurately forecast.
Live model that can react to changes with minimum interaction.
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

9. Proposed Solution Historical data Other Tracking systems WMS /ERP /MRP
Known Maintenance Schedules
Dynamic Simulation
Live System – Constant Updates and monitoring
Suggested solutions
Schedule Adherence
Dashboards
Current and forecasted analysis
Proactive problem detection
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

10. Data Side Recent Maintenance and performance data
Historical Data
Forecasting effect factors
Maintenance Schedules and Rules
Recent Maintenance and performance data
ERP/WMS/MRP/SAP
Data Abstraction Layer
Tracking
data
Tracking data effect factors
Staffing, speed, efficiency
Other factors
Dynamic Simulation
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

11. Sample Simulation Model
Sample Dynamic model with connectivity
Warehouse implementation
Manufacturing implementation

12. Schedule Adherence Real time comparison of Actual vs. Planned
Indicators of delays, reason, and location.
Effect of minor delays over overall schedules.
Effect of unplanned downtime
Effect of planned downtime.
Real time overview of methods to get back on schedule.
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018

13. Real time Data Dashboards identifying current state and future state.
Controlled by station, department or area.
Displayed at individual station to
Identify current work instructions per part
Identify next part to be worked on
Generate kanban pull when needed
Alerts to notify managers of potential delays.

14. Dynamic Replay
Replaying events in the dynamic simulation environment will
Allow management to replay and study events before confronting employees.
Perform analysis and find a solution using collected data.
Present current vs proposed using real life situations.

15. Management Impact Eliminate the “Blame Game”
Eliminate “Data Manipulation” to hide problems.
Improve overall efficiency and visibility
Reduce the need to ask Why?
Be better prepared to address daily problems.

16. Proactive Management with Real Time Forecasting and Dynamic Simulation
Hosni Adra
CreateASoft, Inc
Q & A.
Process Improvement Solutions
@Copyright 2012, CreateASoft, Inc. All Rights Reserved
9/18/2018