Production
Planning simulator

This Solution is actually a set of three solutions for Supply Chain needs. Manufacturing &
Logistics Strategic Simulator, Rough Cut Capacity Simulator analyzer & Detail Scheduling
Simulator and Optimizer. With these three models you will simulate, with real Data, at SKU’s
level, the production, inventories and logistics for factories and production lines according
to demand and capacity constrains in Different Scenarios.

We generally schedule production lines according to expected demand.
A lot of questions arise, to optimize our production capacity, minimize stock outs,
minimize inventory costs, and satisfy demand.

Why →

Demand is our input for our Production Plan. Demand changes and has forecast error. Inventory also
changes as actual sales are loaded. Hubs demand changes as well, and according to locations
production costs and efficiencies may vary.

This set of tools will help you decide where to produce optimizing profit, will help you, detects stock
outs, warehouse availability, shipping availability and uses Automatic Production Anticipation Features

so as to minimize stock outs, keep inventory costs at minimum, optimizing logistics. It will help you save
a lot of time and money.

Each one of the three simulators, have been designed for different goals:

Manufacturing & Logistics Strategic Simulator:
Estimates production, warehouse and logistic costs and ROA in different locations.

Rough-Cut Capacity Analyzer:
Analyze your production, compare Scenarios, Search of Free Capacities, propose optimize production plans.

Detail Scheduling Simulator and Optimizer:
Works on the optimization of weekly scheduling, according to the chosen scenario, satisfying demand and minimizing production costs.

HOW →

MANUFACTURING AND LOGISTIC STRATEGIC SIMULATOR

A company with multiple manufacturing plants needs to simulate the production demand of different
countries, by batch, of hundreds of SKU’. Each location has different costs, efficiency rates, labor
schedules, etc. It estimates the production costs, the warehouses availabilities and costs and the
logistics costs.
Once the matrix of feasible scenarios has been found by the simulator, the optimizer
will propose different production plans, according to ROA or the chosen maximize goal.

Multiple runs experiments will allow to compare the estimated key indicators for each scenario.
Sensitivity analysis with Tornados and Montecarlo can also be ran.

ROUGH CUT CAPACITY ANALYZER

Simulate
Simulate the production for the following twelve moving months of demand, open by SKUs and
production lines. The simulator will let them know production needs in units and batches, according to
demand, initial inventory, and “real production” estimated month by month
, using periodization criteria
and minimum production policies, defined by the user.

Avoid Back orders or Stock Out
Optimize the production and preproduction needed to avoid Stock-Outs for all SKUs. Within 100
automatic runs, the simulator will reproduce all the necessary production within the available capacity,
prioritizing the products shelf life and minimizing warehouse costs.

Optimize Capacity & Minimize Inventory
Optimize the use of production lines, starting with an optimized production plan, without stock-outs.
Capacity optimizer output will be used as input of this third experiment. Within this simulation, the
analytical engine will look to complete the use of monthly available capacities.

DETAIL SCHEDULING SIMULATOR AND OPTIMIZER

In a plant with different steps and constrains along its production line, it is not easy to find the detail
production plan for each step of equipment.
In the cases were final SKU is a combined formula of different intermediate subproducts, it is even
more difficult to plan the steps of the production line, in order to fulfill demand and have the availability
of components of the final formula at the packlines, in time

Our model deals with the complexity of combining the different needs of. It starts with fluid raw material and goes through each process step to build a final SKU, after a five steps process. Each step has its
own constrains, and efficiencies.

Running our model will allow you to find in seconds, the best way to plan raw material
inputs, in order to fulfill your demand and optimize your individual production capacities.