Paweł Woźny
pawel.wozny@astor.com.pl
Simplifying the World: Intralogistics Simulations
Using FlexSim at ASTOR
Simulating processes in industry has become an indispensable tool for designing, optimizing, and verifying systems. At ASTOR, we use the FlexSim tool in intralogistics projects to support our engineering and business decisions. In this article, I will present our approach to creating simulations, emphasize the importance of simplifying models, and discuss the challenges related to the appropriate selection and processing of input data.
Types of Simulations: Focusing on Key System Elements
Our team focuses on simulating systems where we are the technology provider. These are typically elements of EtE®flow solutions and Agilox mobile robots. This means that the models we create are usually simple, with increased detail only where necessary. We prepare simulations with the goal of rapid implementation, allowing us to under- stand and verify the fundamental assumptions of the system early in the project.
Our simulations help achieve several key goals:
1. Hypothesis verification–ensuring that the system’s assumptions are correct.
2. Understanding the characteristics of system fragments – learning how individual elements affect the whole.
3. Identifying areas for optimization – seeking opportunities for improvement.
4. Identifying potential risks – minimizing the risks associated with introducing new solutions.
5. Convincing the investor – providing solid data to support investment decisions.
Simplifying the World: Focusing on Essential System Parts
One of the key aspects of our work is simplifying the systems we model. We focus on elements crucial for the simulation while generalizing the rest. This process not only saves time but also enhances the readability of simulation results. For example, if our system element is in the middle of a material flow, we simplify the elements before and after it, as well as the components of workstations it interacts with.
For some observers, this approach may seem too radical or trivializing. Nothing could be further from the truth. Simplification requires time, analysis, deliberate decisions, and a deep understanding of the processes and relationships between system elements.
Modeling Boundaries: Defining the Scope of the Simulation
The systems we simulate are usually not closed systems—they interact with the rest of the production facility, which we do not intend to model at the same level of detail. Therefore, we must consciously define the boundaries between what is modeled in detail and what is simplified. The behavior of objects outside these boundaries should also be modeled appropriately to avoid negatively impacting the simulation results.
Simplifying Input Data: A Cautious Approach
One of the key challenges in a simulation project is appropriately simplifying the input data. Production data, plant layouts, and process descriptions are fundamental source materials and should be treated as such throughout the simulation project. Simplifying this data should be done with great care and awareness. The problem is that improper simplification can lead to subtle errors that may not be visible during the simulation.
Before we start modeling, we should do two things:
1. Define boundaries for the subject and the rest of the system – clearly define which elements will be modeled in detail and which in a simplified manner.
2. Propose the characteristics of objects beyond our interest boundary – in the form of interfaces to ensure realistic and appropriate simulation results.
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