Capacity Analysis
Capacity Analysis and Optimization of Batch Processes
Our approach
The capacity of discontinuous production processes is calculated from the complex relationships between the order list, the associated recipe, the available pieces of equipment, resources and logistical elements (buffers, storage facilities). The operating sequence therefore has an inherent dynamic quality and is subject to many different capacity-relevant disruptions. Even in single product plants a realistic prediction of the true capacity that goes beyond nominal considerations is no trivial matter.
The design of batch plants on the basis of constant mean values for e.g. resources or availability remains a common practice. However, this simplified approach may result in either overdesign or unplanned bottlenecks. Our methods of analysis and design based on realistic dynamic simulation models are superior to conventional design methods. Process simulations (e.g. Batch Plus®) provide the foundation for the initial design of the recipe sequence and the component balance of the process. These models are aggregated further in material flow simulation models (e.g. VisOpt Process™) which simulate the production sequence under realistic production conditions. In this way, planned maintenance measures, stochastic disruptions, operating conduct and resource restrictions can be taken into account and demand peaks for e.g. utilities can be determined. Model-based capacity optimization is thus not only fast and flexible but also provides a new standard of planning reliability in comparison with conventional methods. We use extensive and well proven best-in-class software for simulating batch processes and material flows. In addition, we have been cooperating with software providers in development projects for many years. We also maintain interfaces between the various tools which is the key to our superior holistic approach.
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