PacSi for the simulation of processing and packaging systems
PacSi was developed specifically for the simulation and optimisation of processing and packaging systems. The software not only models individual machines, but also takes into account the interaction between machines, interlinking elements, operating personnel and other influencing factors within a production line.
This enables you to investigate, even during the planning stage, how different plant concepts perform under realistic conditions. Existing plants can also be analysed to identify bottlenecks, uncover potential for improvement and compare different optimisation measures.
Realistically analyse line structure and efficiency
The performance of a processing or packaging plant does not depend solely on the performance data of the individual machines. What is crucial is the interaction of the entire line.
PacSi therefore takes into account both the machines and the interlinking elements between the individual process steps. This allows you to examine how different line structures affect throughput, utilisation and plant performance.
Manual activities can also be taken into account. These include the number of operators and manual packaging processes. This results in a model that takes into account not only the technical structure of the plant but also the impact of manual work steps.
On this basis, it is possible, for example, to compare different plant concepts and identify potential bottlenecks even before making an investment or carrying out a refurbishment.
Incorporating operating staff in detail into the simulation
In packaging plants in particular, operating staff often have a direct influence on the performance of the entire line. PacSi therefore enables a detailed representation of the operator strategy.
Factors taken into account include the position of operators, travel times and the priorities of individual tasks. A distinction can be made between regular operator tasks and the resolution of faults.
This allows different staffing concepts to be examined within the simulation model. For example, it is possible to analyse whether the current number of operators is sufficient, how longer walking distances affect operations, or what consequences different priorities have when tasks occur simultaneously.
In this way, PacSi supports not only technical plant planning but also the assessment of the required staffing levels.
Optimising production and plant operation
With PacSi, different variants and planning scenarios can first be examined in the simulation model. This allows changes to be evaluated before they are implemented on the actual plant.
The factors taken into account include, amongst others:
- Layout variants
- Line throughput
- Fault behaviour
- Set-up time matrix
- Order size
- Planning scenarios
- Delivery date
The failure behaviour in particular plays an important role in interlinked systems. A single failure can have repercussions on upstream and downstream areas. Buffers can partially mitigate these effects; however, their effectiveness depends on their size and position within the line.
Simulation enables such dynamic interrelationships to be investigated and different variants to be evaluated under comparable conditions.
Typical questions for simulation with PacSi
PacSi provides support for specific questions arising from the planning and optimisation of processing and packaging lines. Rather than making decisions based solely on average values, theoretical machine capacities or empirical data, various scenarios can be examined within the model.
Typical questions include, for example:
- What throughput does the entire line achieve under realistic conditions?
- Where do bottlenecks occur within the plant?
- How do machine malfunctions affect line performance?
- How should buffers be sized and positioned?
- What are the effects of different layout variants?
- How many operators are required?
- How do travel times and task priorities influence plant performance?
- What impact do different order sizes and set-up operations have?
In this way, different approaches can be compared, and planning or investment decisions can be supported by simulation.
From the initial plant concept to detailed simulation
Not every question requires a comprehensive simulation model right from the start. SimPacSi is therefore also available to provide a simple starting point.
This browser-based application allows processing and packaging systems to be modelled and simulated. This makes SimPacSi particularly suitable for initial investigations and questions arising in the early planning and optimisation phases.
For more complex requirements and detailed models, PacSi provides the complete simulation solution.
Get to know PacSi
Would you like to know how PacSi can be used to analyse your processing or packaging plant? Talk to us about your specific enquiry or gain an initial insight into the application in our free PacSi / SimPacSi webinar.