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3D Simulation for Food Plants
Visualize. Analyze. Optimize.
SIM4food
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See the Future (Really)
But… What if we could…
• See bottlenecks before they happen?
• Anticipate just about every real-world condition in truck yards, at receiving bays or on plant floors?
• Time and measure every process, every footstep?
• Move pieces around, add or subtract structures, try different approaches in just a few mouse clicks?
What if we could… see into the future before ever turning a shovel or pouring a yard of concrete?
SIM4food does all of that.
It uses sophisticated 3D modeling and robust data to help plants see into the future, adjust setups and optimize performance. It helps plants avoid mistakes that cost time in lost efficiency, money in redesign/reconstruction or both.
When it comes to food plant design and operations, “We did not see that coming…” or “That was not supposed to happen…” are expensive phrases.
Like, millions and millions of dollars expensive.
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3D Insights
Customers initially used SIM4food to look at dairy plants from the front door, with Blimling modeling capabilities and knowledge delivering actionable insights around milk intake. Armed with understanding, processors intelligently examine expanding capacity, optimizing infrastructure investment, streamlining layout and maximizing labor.
Decisions about those variables translate to millions of dollars in upfront and ongoing costs.
But SIM4food does not stop at milk plants or the receiving bay. The software and the Blimling team can simulate other areas, both inside and outside plant walls for just about any type of food operation.
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SIM4food creates realistic renderings of every key aspect of plant infrastructure, processes and people. It accurately measures design performance from throughput, resource utilization and cost perspectives.
Key Questions that SIM4food Helps Answer:
• Do we need more receiving bays?
• What is the optimal number of bays?
• What staffing changes impact truck turnaround time?
• Will a drop hook setup reduce driver wait times?
• Where should testing take place?
• What physical changes would speed throughput?
• Can a “slip seat” setup work?
Number of trucks processed per day
Utilization levels for people and assets
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Powerful DashboardsGO BEYOND SKETCHES, GUESSES AND PIECEMEAL PLANNING
Your model comes to life with SIM4food. Dashboards track performance, for example:
Truck and driver turnaround time
Location and severity of bottlenecks
Scenarios may be assessed based on capacity, speed and cost.
Design Flaws Can Cost Millions
• Bottlenecks: A constraint in any area (receiving bays, wash stations, truck yards, holding areas, etc.) can result in chronic, major wait time issues. One hour of wait time costs a hauler $40-$50 in idle truck and driver cost. For a 50-load per day plant, an average of one hour of wait time costs $700,000-$900,000 annually.
• Overbuilding: Every unneeded receiving or shipping bay, storage area, wash station or other assets along a process increases plant building costs by more than a million dollars.
• Penny Wise, Pound Foolish: Efforts to minimize cost in one part of the supply chain such as plant intake can create far higher costs in other areas (more wait time, more trailers, more labor). That can drive up total cost by millions of dollars per year.
Best practice performance requires the right the right layout, optimized physical assets, appropriate labor roles and staffing, receiving SOPs, scheduling approach, equipment maintenance, and end-to-end capacity balance. Good plants make it look easy.
But, for others, problems can snowball quickly, creating recurring issues that impact both plant and supplier in terms of speed, capacity and cost. The key—doing several little things and a few big things right.
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DESIGN: WHERE THINGS CAN GO WRONG
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Frequently Asked Questions
WHY SIMULATION? CAN’T THIS BE DONE WITH SPREADSHEETS?
Spreadsheets lack dimension. They cannot reflect or capture real-world complexities associated with truck receiving. Turnaround time depends on random, intertwined factors such as: Is the bay full? How many trucks are in front of me? Do I need to wash? Are the silos or othre storage areas full? Simulation supports load-arrival variability and individual resource modeling. That allows our team to determine the most cost-effective way to meet or surpass speed and capacity objectives.
CAN SIM4FOOD HANDLE PROCESSING, PACKAGING OR OTHER PARTS OF THE PLANT?
SIM4food can be adapted to examine a variety of processing, manufacturing and distribution environments. We have available resources with plant simulation experience — inside and outside the four walls. Let us know where your area of interest lies. We will put together the right team to deliver actionable intelligence.
HOW LONG DOES IT TAKE, AND WHAT DOES IT COST?
After an initial demonstration and discussion, Blimling provides a project cost estimate and timeline based on scope and complexity. A typical project may take 6-12 weeks. During this time, we collect, build models, conduct live working sessions and finalize design — all in ways that address your specific needs.
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Project Path
Demo/Discuss Need and Scope
Proposal Fees/Timeline
Define/Collect Data
Build Model/Score Design
Live Work Sessions
Finalize Design/Business Case6-12 Weeks
SIM4FOOD PROVIDES ACTIONABLE INSIGHTS THROUGH A SIMPLE, COLLABORATIVE ENGAGEMENT.
We’re ready to help you design and analyze receiving operations and investments:
• Facility layout• Appropriate physical assets - bays, wash
facilities, storage, etc. • Staff levels• Processes and roles• Robust data output
Visualize. Analyze. Optimize.
Learn more800.323.7662
