PROCESS AUTOMATION WITNESS THE BENEFITS OF A DIGITAL TWIN
Oliver Bird, from Lanner, says making efficient use of resources and wise investment decisions are crucial to any successful engineering or manufacturing business
$1million-plus in internal supply chain technologies over the next two years. These businesses will need to consider two
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key aspects of such investment – pinpointing the correct type and level of expenditure to achieve the operational performance and efficiency they hope to achieve, and finding the optimum way to allocate spend to meet changing customer demand at the lowest cost per unit. Setting yourself up for success in
addressing such issues would normally involve the use of static-based modelling systems such as Excel or a professional’s gut instinct along with a fair degree of guesswork. But the Fourth Industrial Revolution’s
ongoing automation of traditional processes has heralded a shift towards digital models which are focused on connectivity and data analytics, including predictive simulation.
Interactive visualisation This software allows companies to create digital twins of their processes, modelling all stages from business functions to manufacturing, offering unprecedented insight. It generates powerful future data and helps demystify much of the analytical process by providing a rich interactive visualisation of information. By enabling businesses to test and make
assumptions and decisions in a virtual world, this smart technology provides clarity across areas such as capital investments, resource planning, process design and service policies. If you introduce a major process change or
new product into a facility, you’ll want to know what the impact will be on internal logistics. Will it result in traffic flow congestion points or have health & safety implications? Will it impact on moving raw materials, components or finished products smoothly
36 NOVEMBER 2021 | PROCESS & CONTROL
ecent figures, from a 2020 Material Handling Institute survey, suggest that 50% of companies plan to invest
between production and assembly areas? Creating a predictive digital twin allows your
business to model new processes and flows, flagging up issues and pinch points before they become a reality – in a virtual, risk-free environment.
Predictive simulation software Britvic Soft Drinks is one of the household names which has harnessed our WITNESS predictive simulation software to get to grips with how a planned new high-speed bottling line would affect internal site logistics. Initially the team looked at potential
implications outside the facility, simulating how vehicles would enter the site, flow through parking bays to loading bays, how loading and unloading would work and then how vehicles would leave the site.
your business to model new processes and flows, flagging up issues and pinch points
“ This assisted them to make a number of key
investment decisions before modelling the internal logistics movements, including forklift flows bringing raw materials to the line, taking finished products to warehousing and transporting full pallets to bays for loading onto vehicles. Until reviewing the simulation, Britvic hadn’t
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appreciated the congestion generated on certain routes to and from loading bays, creating both delays and safety issues. By using the digital twin, they were able to find a safer, optimal solution – including one-way aisles that segregate vehicles while
Creating a predictive digital twin allows
maintaining required logistics efficiency. Material handling is being impacted by
various significant, but potentially overlooked, market trends such as the move away from single-use plastics towards more sustainable materials. Members of the UK Plastics Pact have achieved a 30% reduction in 'problematic plastics' since 2018, leading to major changes in production processes. Another trend is the rise in consumer bulk
buying during the pandemic, resulting in new challenges. Clearly, the internal logistics associated with producing a 24-unit pack are very different from those required for a four- unit pack. But, in responding to such changes in
customer behaviour, you wouldn’t want to buy 30 forklifts if in fact you only need 20. Predictive digital twins can help create a watertight business case for a proposed investment in equipment, so you can design and rightsize your fleet to handle materials and products at the right pace and the lowest cost. If you don’t model future scenarios to
understand the possible repercussions, you might end up investing in the wrong equipment or processes, not to mention incurring damaging extra pain and rectification costs due to unexpected bottlenecks and delays.
Automating processes the right way Demand is growing for automated storage and retrieval systems (ASRS). The global ASRS market is expected to grow by 8% by 2025, driven by pressure from just-in-time supply chains and technical skills shortages. Using predictive digital twin technology can
help your business make more informed decisions about proposed ASRS investment and how best to incorporate it into your facility. For instance, how much should you invest
and what performance level do you need to meet your requirements without causing bottlenecks? If you can demonstrate that your
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