Production Line Digital Twin
Overview
Digital Twins can be used to simulate different production lines’ configurations, to optimise output and efficiency.
Background
Our client, a recognised leader in premium meat processing and distribution, sought to enhance the efficiency and performance of its production line, which was falling short of expectations. Despite being certified for a maximum capacity of 18,000 pieces per day, the line consistently delivered only about 14,000 pieces, leaving significant untapped potential and room for improvement.
Challenge
The challenge of the project was to identify the bottleneck and to propose a solution to increase production efficiency, raising output by 30% within a three-month timeframe. The result had to be obtained without creating disruption to the line configuration that needed to be running at capacity.
Approach
BIP proposed the adoption of a simulation tool to model and analyse the production line data and processes. The simulation leveraged input data from the SCADA system, including details on production workflows, processing times, batch identifiers, and individual units. This data was combined with insights on process bottlenecks and specific business requirements to support data-driven optimisation strategies.
Results
Results Achieved
BIP, thanks to the simulation tool, identified the bottleneck in the outbound logistics phase and, in particular, in the routing rules and loading bays configuration. Different rules and configurations were tested, and the target of 18,000 pieces per day was reached at the end of the third month of the project.