Chemical Manufacturing Supply Chain Simulation

Chemical Manufacturing – Integrated Global Supply Chain Model

A chemical manufacturer was constructing one of the largest petro-chemical facilities of its kind, designed and built in a single phase. The production facility had limited space for on-site storage and produced goods that would be shipped via two ports to destinations worldwide. The sheer size of the system and high amounts of variation made it difficult to understand system bottlenecks with traditional static spreadsheet calculations.

The client contracted MOSIMTEC to develop an end-to-end dynamic simulation model, using Simio simulation software, to understand the holistic system, both visually and analytically.

Some of the components in the model included discrete and continuous production, production scheduling, on-site warehousing, empty container management, raw material replenishment, and truck and rail transport. The model extends past the fence of the production facility to include bulk and container port logic, ocean carriers, hub delivery and regional consumption. The holistic supply chain model utilizes a combination of push production and re-ordering logic to trigger activities within the detailed production facility model.

All user inputs can be modified through a custom Excel-based interface, providing a structured means of model analysis, along with input data validation. Input controls are extensive, including product specific packaging types, production cycles, customer demand, individual resource schedules, capacity ramp-up curves, weather impacts, and more. The user has the ability to introduce and represent randomness throughout the model inputs.

The model can be used for communication and visualization by executing at runtime speed, allowing the user to navigate through the 3D representation as needed, following predefined views of the key system areas, or following specific material handling equipment and containers as they flow through the system.

Extensive statistics are being recorded and support scenario analysis, with a detailed model, outputs available for view in raw format, pivot tables, and state of the art custom dashboards.

Stakeholders were able to visualize the entire planned system and utilize model output to understand capacity constraints before committing to final designs. The model continues to be available for operational decision-making, as the task of actual facility construction progress and site operation gets refined, including decision support regarding supplier contract negotiation.

Modelling and simulation serve as a powerful tool for chemical manufacturers, oil & gas service providers, terminal operators, and related companies, to visualize and analyze their system and make informed decisions regarding their complex integrated global supply chain.

Contact MOSIMTEC if you would like to set up a web briefing and learn more about how modelling & simulation can help make informed decisions in your business.

MOSIMTEC’s core focus is assisting clients make better decisions through application of decision support tools. Our team has extensive experience working with leading computer simulation software and solving complex issues for clients across various industries.