- Neenah, WI, U.S.
- Project goals
- Identify manufacturing efficiency improvements
Achievements with Simul8
A 95% production confidence interval on the volume of units which could be assembled for their client
Identified staffing levels required to meet this client commitment and customer demand
$5,000 in equipment savings that would have been purchased without simulation insight
About the project
Plexus is the industry leader in servicing mid-to-low volume, higher complexity customer programs characterized by unique flexibility, technology, quality and regulatory requirements. Award-winning customer service is provided to over 140 branded product companies in the Communications, Healthcare/Life Sciences, Industrial/Commercial and Defense/Security/Aerospace market sectors.
Continually looking at ways to utilize innovative technology in the solutions they provide to clients, Plexus recently utilized SIMUL8's discrete event simulation software to identify manufacturing process improvements at their facility in Wisconsin, where they assemble a revolutionary drink dispenser for a major global beverage client.
"I would recommend Simul8 because it is quick to learn and powerful to use.
It can save you from making costly assumptions in commitments to customers, as well as reducing the risk of buying new equipment without knowing the outcome of that purchase."
Industrial Engineer, Plexus Corp.
A powerful tool for manufacturing decision making
Plexus' results with simulation provided valuable insight in just a few days and enabled several key manufacturing decisions to be made:
- The simulation results enabled Plexus to provide their client with a 95% confidence interval on the number of units that could be assembled based on current infrastructure constraints.
- As well as showing how many units could realistically be produced, the simulation also provided Ben and his team with valuable recommendations for the optimum level of staffing that would be required to meet this manufacturing commitment.
- Simul8 also quickly saved Plexus over $5,000 by proving that the purchase of additional machinery to add capacity to parts of the assembly process was not necessary.
With the ability to run different production scenarios within the simulation model, Plexus could also quickly identify areas where production output could be increased if required, and importantly, what the impact of this would be on manufacturing KPIs and costs.
The simulation of the manufacturing floor has been so successful that it is now utilized as a live document which is updated on a weekly to monthly basis for ongoing production capacity information and process improvements.