Benefits of a systematic approach for problem analysis on manufacturing simulation modelling

In recent years, discrete simulation modelling has become a widely recognised management tool by many manufacturing firms. Many bigger companies have endorsed a policy that new investments on production resources and layout alternations must be subjected to some form of evaluation through using simulation. When building a simulation model, the process of creating the model depends very much on the simulation software that the programmer uses, his/her experience in simulation, and the way that the problem is analysed and interpreted. In the past this has sometimes resulted in an inconsistent approach to understanding the problem and therefore inaccurate simulation solutions as a consequence. This paper is the result of a collaborative project with a consultancy company which carries out simulation work for medium sized manufacturing companies. The project was to develop a consistent front-end methodology to be used in creating a new simulation model for a manufacturing firm. The paper discusses the concept of this systematic approach and its potential benefits when used in monitoring the entire process of building a discrete simulation model. The paper also explains how special forms, IDEF, and flow charts can be used effectively in such an approach.