Simulation for the Lean Enterprise

Many companies are challenged with implementing “Lean” manufacturing principles with the overall objectives of:

• Eliminating Waste
• Improving Quality
• Reducing Lead Time
• Reducing Overall Cost

These companies are at various stages of the “Lean Journey” and may not be aware of the tools available to help accelerate the Lean process.

Are you asking…. so where do I start and what tools are available?

The fact is “Lean” implementation needs to be "customized" based on the specifics of each Company profile.

Simulation has been used for years in predictive analysis, quantifying the impact of potential changes on a process as a result of improvement initiatives like “TPS”, “JIT”, LEAN, Six Sigma and now “Lean Sigma”. Simulation is the technology to allow you to understand, quantify, and test in a low risk environment --before implementing your Lean Initiatives.

Table 1 Highlights how simulation will compliment the overall Lean Steps:

Lean Step Goal Simulation Benefits
Training Help organization see value of up coming initiatives and promote cultural change
 		 A quick visual model will help all organizational levels see the impact of change on key metrics
Choosing the right projects
 		 Prioritize Lean projects to maximize benefit
 		 Modeling is used to quickly quantify the potential impact of projects and predict resources required to support projects.
Value Stream Mapping
 		 Document the Current state and future state of a process
 		 Process Simulator allows VISIO maps to quickly be simulated and then stored electronically to support continuous improvement efforts.
Specific Initiatives
 		 Change policies, procedures and processes in anticipation of improvement
 		 Test all potential changes in a accurate, dynamic model to understand impact on the specific process and the impact on upstream and downstream activities.
 

Now with ProcessSimulator, LEAN practitioners can quickly and easily, simulate Microsoft® Visio® flowcharts, Value Stream Maps and workflow diagrams. This latest ProModel Corp’s V.A.O. technology allows users to seamlessly create and run simulation models inside Visio. It is not simple & intuitively user-friendly, this predictive & productivity improvement tool will be the indispensable boon to your LEAN Six Sigma projects!

 

 

Simulation is a Natural complement for Six Sigma Projects

 

a) Excellent Sensitivity Analysis: Sensitivity test performed through a valid simulation is an excellent methodology identifying the most appropriate CTQ impacting the process under review. This can usually be done quicker and more economically than using the high power statistical tools like Design of Experiments.

 

b) Simulation is a 6σ capable tool: Simulation is capable of delivering an answer that is highly accurate and defect free.

 

c) Evaluating Alternative Strategies: Simulation is a mainstay decision analysis process due to its ability to deliver robust answers to difficult business questions. virtually all of the Fortune 50, a majority of the Fortune 1000 and military planning units of all technologically advanced countries, use simulation rather than subjective notions to make decisions about key manufacturing and logistics process decisions.