Jun 29 2004
CERAM, the internationally renowned centre for materials and technology, based in Stoke-on-Trent, has developed a procedure for manufacturers to simulate manufacturing and other processes, and optimise the efficiency of layouts, products and technologies. The results of simulation have shown huge improvements to productivity; a recent case was measured at 25% increased throughput.
CERAM’s Process Simulation involves the construction of a virtual model that can simulate a production environment. The technique uses real data to construct a map of the process and to build a virtual environment for products, which flow through the model with the same characteristics as real life processes.
When the model is validated (i.e. its behaviour is realistic), the user can try different scenarios to test production development ideas. For example, what would it be like to operate with different manning levels? Would the process be more efficient with new equipment?
The process has also been used to test out the effects of different shift working patterns and to identify process bottlenecks.
Graham Small of CERAM explained: “These and many more scenarios can be tested in a virtual environment without the risks of implementation to determine if a plan will succeed or fail. Process Simulation is an approach that can test out existing concepts or help to develop new ones. The potential for practical improvements and cost savings are significant, as well as giving manufacturers’ confidence in existing operational procedures.”
CERAM’s Process Simulation technique has been used by manufacturers of tableware, solid oxide fuel cells and refractory products in the UK and overseas, and has also been used to develop a laboratory sample processing system.
For more information on ceramics manufacturing, click here.