A study on model design in the simulation of manufacturing systems.

Global competition in industry demands that organisations take steps to improve or even redesign their manufacturing systems in order to remain competitive. Such improvements invariably require considerable investment and risk. The use of computer simulation allows managers to understand the underlying dynamics of complex manufacturing systems in order to identify problem areas. The models can also be used to evaluate re-design strategies and options for improvement, thereby reducing the potential risk and increasing the likelihood of a positive return on investment However, developing a valid simulation model that represents the system to a sufficient scope and level of detail to allow confident decision making is a difficult task. The research explores the application of a novel methodology consisting of a questionnaire survey, case studies with expert model builders and action research with a steel manufacturing company. Using these research techniques, this study focuses on the crucial early phases of the simulation model development process. The research demonstrates that the combination and application of the research techniques has proved to be a powerful methodology to explore the dynamic interactions of the early stages of the simulation life cycle. The findings conclude that the simulation life cycle is highly iterative process where it is difficult to identify clear steps between the different stages of a simulation project. The model builders engage in a number of cyclic activities where there is significant interaction with the client stakeholders to ensure that the model is a valid representation of the problem. The increased use of Visual Interactive Simulation Software (VISS) has had a major impact on the life cycle by allowing dynamic models to be created at a very early stage which facilitates the interaction between model builder and client.