Flexsim Software Research Articles

Exploring the Potential of FlexSim 3D Simulation for Robotic Workstation Analysis

Simulators play an important role in testing robotic workstations in production facilities, allowing real-world conditions to be simulated without risk to equipment and staff. They allow users to verify robot control algorithms, identify possible errors, and optimize production processes. By using simulators, companies can reduce prototyping costs and decrease downtime. In addition, it helps to improve safety in production and minimize training costs. The main aims of this research are to analyze and test the FlexSim software, which is a 3D simulator for visualizing and simulating scenarios in manufacturing workplaces. To test the program, a 3D model of a robotic workplace with conveyor belts and CNC machines was created. The simulated workplace was analysed using the analysis tools offered by the software. The results were obtained in the form of graphs, which makes it easier to visually identify downtime, weaknesses, and workstation efficiency. A comparative analysis of our chosen simulator and Tecnomatix Plant Simulation software was also carried out. These two advanced simulators are actively used at serial production plants to analyze and simulate innovative solutions at production locations. At the end of the article, the weaknesses of the two software programs are described, along with a comparative analysis in the form of a table.

Enhancing Efficiency Through Hydrogen-Powered Hyperloop Capsules: AI-Assisted Route Planning in Accordance with Circular Economy Principles

Abstract This study investigates the feasibility of integrating Hyperloop technology with hydrogen fuel systems. The primary objective was to evaluate how Hyperloop infrastructure can incorporate hydrogen refueling stations to optimize transport efficiency and sustainability. The research utilized simulation models developed with ArchiCAD and FlexSim software to analyze the integration of Hyperloop cargo and passenger transport with hydrogen refueling processes. The study included detailed simulations of Hyperloop operations and refueling logistics, focusing on safety, efficiency, and the potential for reducing carbon emissions. Key parameters such as capsule speed, refueling times, and infrastructure requirements were analyzed. Results indicated that Hyperloop technology can significantly enhance transport efficiency, particularly for high-value and time-sensitive goods, while hydrogen refueling stations offer a sustainable energy solution with considerable potential for reducing environmental impact. The findings demonstrate that integrating hydrogen refueling stations into the Hyperloop system can improve operational efficiency and sustainability. However, challenges remain in optimizing refueling processes and infrastructure development. Future research should address these challenges and explore additional AI-based optimization techniques to enhance the overall system performance. This research is especially useful for urban planners, transportation engineers, and policymakers aiming to develop efficient, sustainable transportation systems that incorporate cutting-edge technology like Hyperloop and hydrogen refueling infrastructure.

Cross-Docking Layout Optimization in FlexSim Software Based on Cold Chain 4PL Company

The paper highlights the potential of cross-docking to reduce storage time and costs. The study addresses evolving market demands that push logistics providers to adopt new technologies for operational efficiency, emphasizing the often-overlooked importance of optimizing cross-docking layouts. The research, conducted in two phases, first analyzed the current warehouse layout (Variant I) to identify inefficiencies and then designed a new layout (Variant II) that was simulated using FlexSim 2022 software. The results showed significant improvements with the new layout, including a 35% increase in deliveries and a 3.23% reduction in forklift travel distances, leading to lower operational costs. Even minor adjustments in the warehouse design proved to enhance logistics efficiency, particularly during peak demand periods like holidays. The study demonstrates how FlexSim software can be applied in cold chain logistics to optimize warehouse operations, underscoring the benefits of cross-docking for cost-effective logistics management.

Optimising LPG Bottling Plant With DES Using Flexsim Simulation Tool

Purpose: This study explores the application of Discrete Event Simulation (DES) using FlexSim software to enhance the operational efficiency of a Liquefied Petroleum Gas (LPG) bottling plant. The primary goal is to ensure that the LPG plant can safely and efficiently meet escalating market demands, thereby prioritising all stakeholders' safety. Design/Methodology/Approach: The research design focused on empirical research and experimental simulation modelling. The study began with collecting and analysing one month of LPG plant data, laying the foundation for developing a simulation model. Verification and validation processes ensured the model's accuracy, enabling the investigation of various operational scenarios. The key performance indicators like First Time to Failure (FTTF), Time Between Failures (TBF), and Time to Repair (TTR) were analysed. The availability rates were 77% from actual data and 76% from simulations, showing that the model is suitable for real-world use. Findings: This study's findings underscore the potential impact of proactive maintenance strategies and operational enhancements as practical and applicable approaches to optimising performance. The analysis also revealed significant improvement opportunities through what-if scenarios: increasing MTBF by 100%, reducing MTTR by 50%, and raising conveyor speed by 15%. Research Limitation: The study's dependence on a systematic literature review could restrict its ability to capture the industry's real-time dynamics. Practical Implication: Implementing proactive maintenance strategies and operational enhancements as practical approaches can reduce downtime and costs and promote productivity and safety. Social Implication: Optimising plant operations will help maintain supply chain stability with the growing demand for LPG. Originality/Value: This work contributes valuable insights and recommendations, establishing a foundation for informed decision-making in the LPG bottling sector.

A simulation-based Digital Twin for smart warehouse: Towards standardization

Cyber–physical systems are developed to meet the need to improve process flexibility, optimality, and transparency through Digital Twin (DT). Unfortunately, the application of DT is still limited in practice, and there is no standard way to achieve integration. An Asset Administration Shell (AAS) appears as a promising concept for realizing DT in a standard manner. A literature review shows that most studies only reached static DT and only considered a few specific assets, especially unmovable ones. This study contributes to DT development by proposing 3D-based computer simulation technology as dynamic DT based on the AAS Framework. The proposed concept enables DT to conduct dynamic monitoring, optimization, and direct controlling. A smart warehouse in Taiwan is used to verify the proposed concept. Assets considered include Automated Guided Vehicles (AGVs), Operator, Conveyor, Forklift, and Storage Rack. AAS structure, simulation model built in FlexSim software, and system integration architecture have been constructed. Two advantages of using simulation for DT are demonstrated: multi-objective simulation–optimization for AGV capacity planning and creating dynamic dashboards. Based on the proposed concept, industry 4.0 scenarios can be integrated comprehensively.

Simulation and Analysis of a Preemptive Transportation Model Using Flexsim Software

Simulation and Analysis of a Preemptive Transportation Model Using Flexsim Software

Gamification Approach for Interactive Learning of Lean Manufacturing Activities

The gamification approach is popular method in education as it has been widely utilized in many fields. The project focuses on designing a game for interactive learning of lean manufacturing activities to create an alternative learning method that would gain interest and efficiency in learning. Integration of gamification approach and interactive learning method was used to illustrate a virtual lean manufacturing education and training by means of users’ interaction towards provided interactive learning materials and participation in playing the designed game. Input of the project which is learning materials was developed by analysing numerous articles regarding common lean manufacturing tools and practices. Interactive elements such as animation, sound effects, lecture voice, and videos were applied in each learning material to deliver an adequate understanding of each topic. Construction of the game platform is being developed using ActivePresenter software which includes simulation videos of the production line using FlexSim software to visualize a real production floor which provides a clearer picture of the production system for users. The game should include a basic assessment of lean manufacturing practices by considering its complexity and difficulty level for users with inadequate or does not have experience in the field. The outcome of the project is expected to successfully design a basic game platform for lean manufacturing education by means of interactive learning. Users will be able to learn lean manufacturing systems using the designed interactive learning materials included in the games and self-assess themselves as the game publishes the correct and best answer option in case they answer wrongly.

Research on Irregular Warehouse Layout Based on Optimised Genetic Algorithm

Logistics is playing a significant role in supporting economic growth and material security during the epidemic period and it has been experiencing a rapid development in recent years. With the issues of personalisation and cost, the economy and society ask for higher requirements for logistics storage systems. The rational design of the functional area layout is an essential step to improve the operational efficiency of the logistics warehousing system. In reality, due to warehouse design and equipment application, there has been a gradual increase in irregular warehouses. By taking an irregular warehouse as an example, combining the operation status quo, this paper clarifies the functional area settings and constructs a 0–1 integer planning model based on the grid and systematic layout planning method with constraints, such as the unique functional attributes of the grid. We optimised the genetic algorithm based on the warehouse irregularity factor and the grids factor, and then solve it through MATLAB. Finally, by using the Flexsim software, simulation metrics were selected for evaluation, the method feasibility is verified.

Perancangan Tata Letak Proses Produksi Kursi Furnitur Menggunakan Metode Activity Relationship Chart (ARC) di PT. Rama Teknik

Rama Teknik Company, a manufacturing company in Indonesia founded in 2015, offers innovative business solutions based on research and development. The production process faces layout irregularities which result in disruptions in the production flow. The impact is that the material handling frequency becomes longer and causes material handling costs to become high. Apart from that, the company also experienced failure to achieve production targets. Decision making regarding layout and location is very important in determining a company's long-term operational efficiency. The aim of the research is to redesign the optimal factory layout. To improve the layout of workstations, the research department uses the Activity Relationship Chart (ARC) method which is implemented through FlexSim simulation software. The initial and proposed layouts were simulated using FlexSim software. The stages start from designing the initial layout, then looking for problem gaps. After that, redesign the new layout. The results of the initial layout show 309 finished products, representing a 100% output rate for Queue4 semi-finished goods, 5 warehouses, and 0 finished products in PL. After retesting with the proposed layout, the initial raw materials were 334.49, Queue1 had 285 items, and there was a 38% increase in finished products, a total of 427 seats.

An Assortment–Quantity Optimization Problem in Printing Industry Using Simulation Modelling

This paper presents a method for assortment–quantity production scheduling in a printing company. The company uses specialized machinery to make prints on clothing. The method is based on a study of the company’s practical operations and the production technologies used. It involves the construction of simulation and optimization models of the process. The simulation models reflect the technical aspects of the production process and the business requirements. Optimization models provide solutions that balance product sales revenue with appropriate production schedules. On this basis, managers can make resource-balanced decisions on the implementation of selected production plans, taking into account the current economic conditions of the company. The experiments used the FlexSim simulation program (by FlexSim Software Products, Inc., Orem, UT 84097 USA; v. 20.1.3.1) and the OptQuest optimization package (embedded in FlexSim), resulting in a cost-effective solution in a short time. The proposed method, thanks to the optimization of the production program, provides savings in the use of materials for production, as well as water and energy savings in the production process. Thanks to the possibility of analyzing the process without interfering with it, provided by simulation modelling, the method practically eliminates the costs and time needed to prepare the execution of new production orders. This contributes to the sustainable development of the company and provides an opportunity to assess the impact of potential business decisions in the company prior to their implementation. The method has been directly applied in a company to improve its performance. The method is scalable and can be applied to problems of varying complexity and production systems of different types and sizes. This is especially true for small- and medium-sized companies that use discrete manufacturing in the textile, metal, and furniture industries.

Multi-AGV Scheduling under Limited Buffer Capacity and Battery Charging Using Simulation Techniques

In recent years, automated guided vehicles (AGVs) have been widely adopted to automate material handling procedures in manufacturing shopfloors and distribution centers. AGV scheduling is the procedure of allocating a transportation task to an AGV, which has large impacts on the efficiency of an AGV system with multiple AGVs. In order to optimize the operations of multi-AGV systems, AGV scheduling decisions should be made with consideration of practical issues such as buffer space limitations and battery charging. However, previous studies have often overlooked those issues. To fill this gap, this paper proposes a simulation-based multi-AGV scheduling procedure for practical shopfloors with limited buffer capacity and battery charging. Furthermore, we propose three kinds of rules: job selection rules, AGV selection rules, and charging station selection rules, for AGV scheduling in practical shopfloors. The performance of the rules is evaluated through multi-scenario simulation experiments. The FlexSim software v.2022 is used to develop a simulation model for the experiments, and the experimental findings indicate that the job selection rules have larger impacts on the average waiting time than the other kinds of rules.

Simulasi Proses Picking Order dengan Metode Dedicated Storage Menggunakan Software Fleksim (Studi Kasus PT XYZ)

PT XYZ is a manufacturing company that produces food and drinks by providing quality products that are halal, high quality and safe for consumption by the public. In producing products, companies must provide several adequate facilities to support production activities, one of which is warehouse facilities. Currently, warehouses where finished food products are stored are stored randomly or placed in empty areas without paying attention to product entry and exit activities. This condition causes picking activities to take a long time and makes stock monitoring difficult. The aim of this research is to produce an appropriate goods storage design so that it can increase warehouse effectiveness. This research uses a special storage method. Where a special storage policy or method is permanently placed on each item. The number of product storage locations must meet the maximum storage space requirements and a simulation is carried out using FlexSim software. The research results show that designing goods storage using the dedicated storage method results in a reduction in the distance traveled for the collection process reaching 52%.

Modeling and Simulation of Community Group Buying Warehousing and Distribution Center Based on Flexsim

With the continuous increase in the demand for small quantities, diverse varieties, and high-efficiency goods distribution, there is a growing customer need for short-cycle products. In this context, leveraging Flexsim software platform, this paper models the warehousing and distribution center for community group-buying goods. The modeling encompasses key operational aspects such as product supply, storage, picking and grouping, as well as loading and unloading, and distribution. Through simulation, the results are analyzed and optimized, yielding the optimal layout scheme for the community group-buying warehousing and distribution center model.

Workshop layout optimization method based on sparrow search algorithm: a new approach

ABSTRACT Reasonable workshop layout can reduce the transportation distance, reduce the production cost and improve the production efficiency. Aiming at the problem of unreasonable workshop layout, this paper takes an actual case as the research object and studies its workshop layout. Firstly, the mathematical model with the objectives of minimizing logistics transportation cost and maximizing non-logistics relationship is established. Then, the sparrow search algorithm (SSA) is used to find the optimal layout that satisfies the objective function. Finally, Flexsim software is used to simulate the layout scheme. The results show that compared with the genetic algorithm and the original layout scheme, the layout scheme obtained by the SSA algorithm reduces the total transportation distance by 26 m and 325 m, and improves the non-logistic relationship by 1.6% and 24.84%, respectively. Optimizing the layout using SSA algorithms increases product productivity, which is a good improvement over the original workshop layout.

Research on Simulation and Optimization of Regional Express Cabinet Modeling based on Flexsim

In order to solve the problems of intelligent express cabinet quantity distribution and unreasonable grid configuration at the end of express delivery, improve customer satisfaction, and coordinate the investment cost and profitability of enterprises. Using the Flexsim software to simulate the distribution mode of regional express cabinets, set relevant parameters, analyze the utilization rate of intelligent express cabinets and the utilization rate of express cabinets, optimize the number of intelligent express cabinets and the configuration of the number of lattices, and enhance the corporate brand image.

Optimization Solutions of a Multistage Balanced Transport Problem with using of the Potential Method

Route optimization is an important issue because it allows improving the economic component in production. Its generalization to optimization problems on networks is shown. The transport task is formulated in the network setting: to make a plan of cargo trans-portation on the transport network so that the cargo stocks were taken out of the points of depar-ture, the needs of consumers at the destinations were met, and the total cost of transportation was minimal. The algorithm of its solution is given, revealed on a concrete example of delivery of products to customers who sell these products on a daily basis. Tables of the basic and optimal plan, a transport network of the optimal plan of transportations are made. The process of solving such a problem by modeling in the environment is proposed. The simulation model of this process was created with using the FlexSim software. The process of creating the simulation model is demonstrated

BALANCING EFFICIENCY AND FLEXIBILITY – A SIMULATION OF LINE CONFIGURATIONS

Purpose: The purpose of the study is to examine the impact of production line configurations on operational efficiency using simulation tools. Analyzing various scenarios with a variable number of production lines allows for an assessment of how infrastructure modifications affect system performance, resource management, and operational flexibility. Design/methodology/approach: The study was conducted using FlexSim software, which enables the modeling and analysis of production processes. Key steps included: collecting operational data, developing a simulation model, validating the model, and analyzing the results for three configurations: one, two, and three production lines. Model validation was performed by comparing simulation results with real-world operational data. Findings: The findings indicate that a single production line ensures high operational efficiency (around 98%), but its rigidity limits adaptability under changing conditions. Adding a second production line results in a moderate decrease in efficiency (approximately 1.2%), while significantly enhancing flexibility and resource management capabilities. Three production lines offer the highest flexibility; however, efficiency drops to approximately 80%, which may cause challenges related to underutilized resources and increased operational costs. The optimal solution, balancing flexibility and efficiency, is the addition of a second production line. Adding a third line may only be justified under conditions of significant demand growth. Research limitations/implications: The study's limitations stem from the simplifications in the model, such as the assumption of constant production parameters and the exclusion of market variability. Future research should consider dynamic market conditions and a more comprehensive cost analysis. Originality/value: The study introduces an innovative approach by applying computer simulation to evaluate the efficiency of different production line configurations. The insights provided in the article are valuable for production engineers and managers, assisting them in making informed decisions about optimizing production systems.

Desain Optimal Tata Letak Fasilitas Dengan Menggunakan Metode CORELAP dan Algoritma CRAFT

UD. Doa Emak is an appropriate technology business engaged in the manufacture of tools or machines of various models and sizes. UD Doa Emak accepts production requests that vary according to customer requests. There is increasing customer demand and product variations, UD owners. Doa Emak expands the production area so that currently there is empty land that has not been utilized. The land area owned by UD. Doa Emak is 623 m2 with a percentage of vacant land of 48%. By utilizing vacant land, it is possible to increase utilities and optimize machine arrangement so that the transfer distance becomes more efficient and production capacity will increase. This research will solve the problem of production facility layout by redesigning the layout using the CORELAP (Computerized Relationship Layout Program) method, the CRAFT Algorithm (Computerized Relative Allocation of Facilities Techniques) and will be simulated with Flexsim Simulation to provide alternative decisions on the proposed layout. From this study, the results of the CRAFT method were more optimal than the initial layout with a large OMH depreciation of Rp. 49662,6 and efficiency percentage of 3,29%. Simulations using flexsim software produced a total traveled of 115843 m/month.

Optimization of Teller Services Using Queuing Theory at XYZ Bank

Bank XYZ is one of the largest state-owned banks in Indonesia that provides various financial services. Currently Bank XYZ has 3 teller services only. This study aims to determine the use of customer queuing schemes currently used in XYZ bank teller services. The data processed is the arrival of customers who transact at the teller area of Bank XYZ. This study uses the Queuing Theory method with the M / M / S (Multiple Channel Single Phase) model and also uses FlexSim software. Then analyze with the addition of the number of tellers (services). Finally, a comparison is made between manual and software calculation methods. Based on the results of the data analysis, the optimal improvement in the application of the queuing system is to add 1 teller service to 4 teller services. The improvement in the performance of the queuing system is characterized by a reduction in the number of customers in line at peak hours 10.00 - 11.00 which initially amounted to 11 people reduced to 3 people and the average waiting time of customers in the queue from 10.08 minutes to 4.02 minutes. Therefore, optimal queuing system performance can be ensured by increasing the number of tellers to four.

Pemodelan Simulasi untuk Mengurangi Antrian pada Fasilitas Layanan Kesehatan

Service is the main indicator of the sustainability of a service. The quality of services is the main factor that must be considered in maintaining the existence and competition of services, including health facility services. This research was conducted at one of the health service providers in the city of Batam. One aspect of health service quality is queuing service. Therefore, the quality of service in the queuing system in health facilities is an interesting thing to research. This research measures the level of optimality of the queuing system currently in effect at the Saffira Mitra Medika clinic. The measurement focuses on service time, the number of patients served, and the waiting time for patients to be served in the queue system. The results of measuring the current queuing system are compared with other proposed queuing system scenarios, so that the level of patient satisfaction as customers is met. The proposed queuing system was obtained through a simulation approach, with the help of Flexsim software. A simulation approach was chosen to facilitate modeling in the proposed queuing system