INTRODUCTION

Every manufacturing organisation sets up its operations—such as assembly, mechanical operations, supply chain, and logistics—by roughly estimating the quantity and quality of resources relative to the available budget and sales forecasts for the coming years. However, these are only best guesses based on previous experience.

To better estimate outcomes, businesses can use simulation technology to model their systems digitally. This allows them to evaluate processes and projected performance under various scenarios—considering output, time, and cost—before implementation. The flexibility to quickly make changes and test alternatives makes simulation an extremely effective and practical tool.

WHAT IS MODELLING AND SIMULATION?

Modelling and simulation (M&S) is the most powerful approach to analysing a manufacturing system or any industrial process in a risk-free environment. With M&S, you can predict how a system will perform by building a digital version of it. This virtual model allows companies to test changes, check outcomes, and make better-informed decisions—without disrupting real-world operations

The accuracy provided by these detailed predictive reports sets simulation apart from static analyses, such as spreadsheet calculations.

BENEFITS OF MODELLING AND SIMULATION

• A Total Process Audit of Your System: The building of the model automatically acts as an excellent audit of an existing system, in that one has to verify the existence and behavioural attributes (in terms of performance characteristics) of every component. Many times, this leads to insights the owner had not previously realized, identifying many parts of the process where data is absent or incorrect.
• Testing New Strategies and Changes: If the model is tested for an already performed scenario and the results are correct, one can believe in future results from the software models, as one tries out new strategies and changes.
• Visibility: The owner gets to see the whole system at one go. This is priceless, as systems, processes and their interconnectivity get monstrously complicated as companies grow and evolve
• Communication ability from a visualization perspective: Communication becomes faster, easier and better between management, process owners and customers. Also, queries and ideas can be almost instantly tested at the meetings, leading to quicker and more rational decision-making. How many hours and meetings have we spent trying to get a team to read, understand and decide upon complex 60-page proposal documents? Imagine being able to reach conclusive decisions in 1 or 2 meetings!
• Risk Management for What-If Scenarios: A model can be used as a R & D tool to prepare for critical scenarios which may never happen, such as unusual and sudden large orders, fire and other disaster response systems etc.
• A Powerful Internal and External Sales Tool: In many cases, the model can be used as a sales tool by an organization to win business, by impressing a customer with the fact that not only is one organized, but can also, prove the ability to deliver on time and the validity of the proposed solution via simulated results. Internally too, when one needs to sell to Upper Management the necessity to invest in new machines, men or material, simulation is a very powerful asset
• E-Learning and Internal and External Training Tool: Any person newly inducted into owning, managing or executing a process can be up and running very fast, using Witness as an E-learning tool. In fact, solution vendors and buyers can use the model for training customers and end-users on the process design and operating procedures.
• Brainstorming tool for Multiple Process Stakeholders: A visual simulation model can be used for brainstorming on new ideas of performance improvement with, for e.g., managers of Mfg., Sales, Maintenance, Purchase and the CFO together bringing their thoughts and analysis to explore and test possible solutions and their repercussions.
• Insurance: Simulation results can be viewed as insuring the worth of spending of time and money, before you commit to a plan.

WHY DO THIS COURSE?

Even in state-of-the-art practices such as Industry 4.0 and 5.0 supported by the World Economic Forum, Simulation is recognised as one of the nine critical components. It improves productivity, flexibility, and competitiveness. Interestingly, it is the only one that focuses on the future and ultimately that’s what matters to decision makers. The developed world is fully committed to using simulation, as a mandatory decision support tool and this practice will soon become de facto even in developing countries. To learn how to make rational, informed and data driven decisions, the modern manager has to be able to evaluate all his possible courses of action and decide wisely. He/she can simulate entire business processes, understand systems thinking, and evaluate alternative decision paths. They learn to run and analyse “what-if” scenarios for maximum efficiency, cost reduction, and profit optimisation.

Ultimately, simulation helps decision-makers take action backed by data—not just intuition.

AN OVERVIEW OF THE COURSE CONTENT

• Methodology for simulation project management
• Understanding WITNESS simulation fundamentals
• Building and running basic WITNESS models
• Adding complex logic and using external data sources
• Configuring experiments and interpreting results
• Exploring & modeling Business case study exercises, demonstrating the application of WITNESS to real world scenarios