What’s the impact of a major process change on WIP, traffic flows and routing?
If you introduce a new product or line into a facility, what’s the impact on internal logistics? Will new congestion points be introduced? What are the health and safety implications? Can we smoothly transport raw materials, components or finished products to or from assembly areas?
By creating a predictive digital twin, you can model new processes and flows, and identify pinch points before they emerge in reality – all in a risk-free, digital environment.
First, the team looked at the potential implications outside of the site. The predictive digital twin of the future facility simulated how vehicles would enter the site, flow through parking bays to loading bays, how loading and unloading would work, and how the vehicles would then leave the site.
Having made a number of key investment decisions using this simulation, they then modelled the internal logistics movements, including forklift flows bringing raw materials to the line, taking finished products to warehousing and transporting full pallets to loading bays for loading onto vehicles.
Until reviewing the simulation, Britvic hadn’t realised how much congestion would occur to and from the loading bays, creating both delays and safety issues. Using the digital twin, the team identified a safer, more efficient solution that included one-way traffic flows to segregate vehicles while maintaining the required logistics efficiency.