Plant Dimensioning

When simulating plant procedures of a continuous process, often either a strongly simplified capacitive model (Excel sheets), a discretization as event-based simulation of the material flows or a flow chart simulation is used. A simplified capacitive model often is not sufficiently accurate, because queuing effects, parameter changes and cleaning cycles cannot be considered. The event-driven approach is based on the modelling of a resource network and a stepwise simulation through the system. This simulation approach yields more accurate results than the simplified capacitive model, but dynamic and continuous parameters like concentration, density, quality etc. are only considered in a discretized manner. ORSOFT Dynamic Flow Chart Simulation transforms the model into an optimization task, which is solved with the highest accuracy possible for dynamic processes.

These methods of plant dimensioning and plant simulation are typically not applicable for production planning in a productive environment because they are held in a separate system. They have to be transferred. Later, in the operational process and with every new inquiry – e.g. new products, additional tanks, different quality requirements – model data has to be maintained and modified in the leading ERP system and in the simulation system as well.

ORSOFT provides a dynamic flow chart simulation as an add-on solution for SAP ERP / SAP S/4HANA. By using the data structure of already existing ERP systems, the additional data entries for new materials and resources only have to be maintained in the ERP system. Thus, comprehensive simulations can be conducted rather quickly. Engineers are impressed when seeing demonstration of how accurate not only material quantities but also e.g. energy demands, staff requirements or waste water loads are featured by the ERP system's bills of materials. As a result e.g. waste water profiles or energy profiles can be retrieved together with the production simulation. In matters of design and re-design usually only work plans and resource requirements have to be maintained.

The ORSOFT solution for flow chart simulation is applicable for:

  • accurate dimensioning of plant, machinery and storage tanks – covering flexibility, flow rating, margins etc.
  • generating reliable plant scheduling
  • identifying and reducing unnecessary resources, in order to define profitable plants with high flexibility and highest safety standards at the same time
  • simulating secondary resources such as energy demands, vapors, process heat, coolants, thermal loads, waste water loads etc.
  • allocating process circuits and adjusting product assortments
  • dimensioning tank volumes and hauling capacity

If the simulation, detailed scheduling and strategic planning are based on the same (ERP) data model, informed decisions on product range or capacity enhancement become possible at run time. The reusability of the model and the integration with SAP ERP / SAP S/4HANA bear potential implementation benefits if the plant and machinery are consequently planned across the entire life cycle on the basis of the same model. The assured properties become verifiable very soon, already in the planning stage, which helps to reduce later operational costs and requires less efforts for the ERP implementation in the production logistics area.