Simulation-based approach to analyze modular intralogistic systems in the chemical industry

Abstract Modular production systems are a response to trends towards shorter product life cycles, increasing product diversity and the resulting volatile market conditions, especially in the fine and specialty chemicals industry. The ability to flexibly adapt the production system to volatile market conditions allows different product types or production quantities to be realized quickly, flexibly and cost-efficiently. Against this background, modular intralogistic systems consisting of conceptually developed logistics equipment assemblies (LEAs) promise flexibility advantages in the case of volatile product, packaging or quantity requirements for the adjacent production-related intralogistic systems. This especially applies to the operation in small-scale, decentralized production networks. Various concepts of LEAs have already been developed for different intralogistics processes, such as the filling of liquids or granulates into small or large packages. However, the characteristics of these different modular concepts in a system integration have not yet been analyzed in the market environment of the chemical industry. Therefore, we analyze the performance of modular intralogistic systems consisting of a system integration of LEAs under disturbances and volatile market conditions in contrast to conventional intralogistic units already existing in the market. Accordingly, this paper develops a simulation-based approach as a methodological basis. With this methodology it is possible to compare different system configurations based on throughput, throughput time or utilization output parameters for different market requirements. Finally, the developed methodology represents a tool for decision support in the planning of modular intralogistic systems and provides the possibility to analyze new concepts of LEAs in a system integration.