A systematic approach for simulation-based dimensioning of production systems during the concept phase of factory planning

Abstract Due to increasing globalization, market penetration, and technological progress, more products are becoming highly standardized and interchangeable. This has led to fierce price competition, forcing companies to compete for declining margins. To remain competitive in the long term, it is essential to consider both changeability and profitability during the early planning phases. The article proposes an approach for simulation studies using discrete-event simulation during the concept phase of factory planning. This approach aims to systematically dimension production resources while considering alternative scaling options, such as a higher degree of automation. By doing so, the approach facilitates the demand-oriented deployment of resources during the ramp-up phase, which helps to control and reduce manufacturing costs. The simulation experiments yield scaling paths that indicate the timing and quantity of resources required to meet changing demands. These paths form the basis for subsequent factory planning steps. For instance, the layout can incorporate the necessary space for a future automation solution that will be profitable, enabling faster adaptation to demand changes and securing competitive advantages. This is demonstrated in a use case where the approach was applied to the factory planning of a new production system for a sensor product family.