Category Archives: ProModel Consulting – Case Studies

Flanagan Industries Brings New Facility Online Thanks To ProModel Solution

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Flanagan Industries is a major contract manufacturer of aerospace hardware specializing in highly engineered and high value machined components and assemblies.  Over the years their manufacturing operations had been growing steadily to the point where they absolutely needed additional capacity . The original space was not conducive to a manufacturing environment and had become an impediment to taking on more business and staying competitive in the global economy.  So Flanagan decided to expand by opening a new facility that could house bigger and better machinery, however they needed to ensure that the move to the new location would not disrupt their current operations and customer orders.

In the video below, see how Flanagan used a ProModel Simulation Solution to successfully bring their new facility online:

 

 

 

Designing Better Care For Your OR

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JCowden Profile Pic

Jennifer Cowden – Sr. Consultant

Earlier this year, my family and I took a vacation to a certain kid-friendly theme park.  As we wandered from ride to ride, we couldn’t help but note that, even at the peak times on the more popular rides, you rarely saw crowds standing outside waiting. The long lines were all contained within a succession of fairly climate-controlled rooms that obviously took some thought to plan. This particular company is big into predictive analytics, so I would hazard to say that they didn’t just guess at the maximum size of the line at peak time; they are probably not going to go live with a new attraction or other big change unless they simulate it first.  An interesting dynamic that we observed was that when a wait time for an attraction was lowered on their new mobile app, we could literally see the “flash mob” of patrons converge on that ride, causing the line to go from a 10-minute wait to a 30-minute wait in the blink of an eye.  I turned to my husband, who is also an engineer and a geek, and said “I wondered if their model predicted that.”

Theme parks obviously need to be concerned about a positive overall  visitor experience; after all, they are always competing for discretionary funds with other sources of entertainment.  Now, more and more hospitals are developing that same mindset: being cognizant of the overall patient experience to the point of modeling new spaces before they go live.  How many OR rooms should they outfit for opening day, and how many can wait?  How can they make the best use of the spare rooms?    Is there enough space in the corridors that the patients won’t feel too crowded?  Is there enough space in the waiting areas for the families of the outpatients?  How many staff members do they need for each department to minimize patient wait time?  Are there any unforeseen bottlenecks due to sudden dynamic shifts?  These are just a few of the questions that simulation can answer.

Check out Jennifer’s Ambulatory Care/OR Suite Model:

About Jennifer

Before joining ProModel in 2013, Jennifer spent 15 years in the automation industry working for a custom turnkey integrator. As an Applications Engineer she built simulation models (primarily using ProModel) to demonstrate throughput capacity of proposed equipment solutions for a variety of customers. Jennifer’s experience covers a wide range of industrial solutions – from power-and-free conveyor systems to overhead gantries and robotic storage and retrieval systems. She has also created applications in the pharmaceutical, medical device, automotive, and consumer appliance industries.

Jennifer has a BS in Mechanical Engineering and a Master of Science in Mechanical Engineering from the Georgia Institute of Technology.

Busy Season at ProModel

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Keith Vadas

Keith Vadas – ProModel President & CEO

I am pleased to report ProModel’s second quarter was very positive.  Like many businesses in the US we find ourselves on a serious upswing this Summer of 2014.  Our consultants are working on several projects in a variety of industries, including ship building, power management, retail, manufacturing, food processing, and government contracting.  In all of these projects our experienced team of consultants is working to improve efficiency, save money, and make better decisions for their clients.

ProModel’s DOD projects continue to thrive.  It is hard to believe it has been eight years since we started working with FORSCOM (US Army Forces Command)   on AST (ARFORGEN SYNCHRONIZATION TOOL).  LMI-DST (Lead Materiel Integrator – Decision Support Tool) with the LOGSA Team (US Army Logistics Support Activity) is also going strong.  Our agile team of software developers keeps improving the development process within ProModel and it shows. Just recently the NST Airframe Inventory Management Module was Granted Full Accreditation by the Commander, Naval Air Systems Command.

The time is also ripe for opportunities in Healthcare.  Our patient flow optimization capabilities are perfect for helping hospitals and outpatient clinics improve efficiencies.  Now that the Affordable Care Act has been around for a couple of years, its impact is being felt by healthcare organizations around the country.  The expanded insured-base, and the need for improved processes and different care models is making it absolutely necessary to consider the value of modeling and simulation.  ProModel continues to work with several facilities including Presbyterian Homes and Services, and Array Architects who enhance the flow in Healthcare Facilities design by using MedModel simulation in their design processes.

To better support our base of existing customers, we just released ProModel/MedModel 2014 in July and PCS Pro 2014 at the end of Q1.  EPS 2014 (Enterprise Portfolio Simulator) was released in Q2  and includes a new easy to use, web-based rapid scenario planning tool – Portfolio Scheduler.  You can check this tool out online at – http://portfoliostud.io/#.

There continue to be lots of exciting things happening at ProModel.  We have an outstanding team of consultants and software developers-designers just looking for an opportunity to PARTNER with you to help you meet the next business challenge, or solve the next unexpected problem.

ProModel and MedModel 2014

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Kevin Field

Kevin Field – Sr. Product Manager

In regards to this release, I would like to start out by saying, in the words of Nacho Libre, “It’s pretty dang exciting, huh?”

With ProModel and MedModel 2014 we’ve tried to keep our current customers in mind as well as new customers. For current customers, the new logic windows with Intellisense and Syntax Guide should help you build models faster and easier. And being able to import graphics from third party graphic programs like Photoshop, Gimp, Paint.Net, etc. should even be more useful now that you can rotate all graphic types in the application. The improvements to the Debug window are a direct result of our work on the new logic windows.

For our new customers, the redesigned Getting Started panel (formerly known as the Control Panel) brings a lot of model building resources to the forefront. We have added new demo models and refreshed several of our previous ones. Did anyone even know we had a Quickstart video, showing you how to build a simple model and analyze results in 10-15 minutes? The most exciting part might be the How To videos our Support team has been producing for several months now. All of our customers will find these extremely helpful.

In this blog I am going to casually comment on some of the new features with the assumption that you have already reviewed What’s New in 2014 and perhaps even viewed the webinar I gave on this release. If not, you might want to consider doing so, otherwise…you can blissfully continue on with me…

New Logic Windows

It’s amazing what a few simple colors can do to help your logic be more readable. As we were developing version 9.1, I found it more and more difficult to go back to 8.6 and “drag” myself through the dreary old plain black text 🙂 It’s funny how refreshing it was to get back to 9.1! Not only the color but also line numbers really make it easy to quickly get around in the logic.

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And if you don’t like our default color scheme or want to have something a little easier on the eyes, simply customize the colors in the Logic Color Selection dialog.

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We also want to encourage good formatting in the new Logic windows by utilizing white space (spaces, line breaks, etc.) and indentation. Don’t be afraid of it! By automatically indenting and out-denting after begin and end brackets, we hope to make co-workers everywhere more willing to leap in and review your logic with you! Auto-formatting is something we are looking to improve moving forward.

Another thing we have made steps to do is deprecate certain logic elements. Begin, End, and the # comment are the main ones. Don’t worry though, they are not completely gone! They won’t show up in the Intellisense list but they will still compile if used in logic. Begin and End are easier to read and enter in logic if you use the “squiggly” brackets { and } instead. And we want to use the # character for other things like the new #region statement.

In fact, #region is one of my favorite new additions to 2014. I love the ability it gives you to section your logic and collapse it with a label describing what’s inside that hidden portion of your logic. I hope you’ll find it quite useful.

Intellisense and Syntax Guide

These new features are probably the heroes of this release. Intellisense brings every statement, function, location, entity, variable, subroutine (I’m saying every model element!) right to your fingertips. You should almost never have to remember your element names or copy them from one place in logic to another, or even leave a module to go look it up. Besides that, the days of completely typing any logic or element name are gone. This should increase your productivity by at least 10-15% 🙂 Are you with me on this?!

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Intellisense coupled with the Syntax Guide should nearly make the Logic Builder obsolete. There may be a few things we need to add in order to make that happen. Please feel free to share any suggestions you may have. We tried to make both unobtrusive to your logic creation and editing. Because of this, we didn’t add an option to hide Intellisense or the Syntax Guide.

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Debug Window

MORE THAN 3 LINES!! I think that’s all I need to say on that.

Ok, I’ll also say that debugging should almost be a joyous endeavor as you are now able to anticipate what logic may get executed next and better understand where you came from.

Routing Probability

I’m going to refer you to the webinar I gave on this new feature. In it I give a great example (if I do say so myself) of how simple it is to set up a routing probability for scenario analysis. One thing to remember, in order to use an array in the routing Probability field, the array must be initialized through an import.

Getting Started Panel

The new panel that appears when you start the program may primarily be geared toward new users, however current customers may find it just as useful. Access to the How To videos, online Help, and additional training resources (like dates of future ProModel training classes and a link to ProModel University, our online self-paced training).

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If you haven’t taken advantage of your M&S contract and utilized our Technical Support team then perhaps the Getting Started panel will help facilitate this. They are a tremendous resource to assist you in understanding different techniques for modeling aspects of your systems, troubleshooting your models and helping you get out of the paper bag you may have coded yourself into, or just a friendly person to talk to 🙂 We like to call them your “ProModel Friend”.

Speaking of the Support team, they have done a tremendous job of generating a lot of How To and Solution videos for quite some time now. The short videos range from 2-5 minutes and offer useful insight into modeling techniques and other useful software tips. Let us know if you have any suggestions for more videos!

New Graphic Libraries

A final word about our new graphic libraries. In order to create new libraries containing EMF (vector-based) files, which scale nicely when zoomed, we had to support the rotation, flipping, and sizing of these image types within ProModel. This makes it so you don’t have to generate an image for every possible rotation or flip you need to have for your animation. This reduces the size of the graphic library and thus your model footprint as well. So with this new capability, you should be using a third party graphics program like Photoshop or Gimp (which is free) to create your graphics. (Or perhaps get your coworker to do it, just don’t tell them that I suggested it.)

I can’t talk about the new graphic libraries without mentioning Laif Harwood, a member of our Support team. Laif gets credit for creating all the new graphics in the libraries. And a fine job he did! So if you want any tips on how to do it for yourself, give our Support team a call!

Well, that’s all I have steam for yammering about today. Remember…you have a ProModel Friend that’s just an email (support@promodel.com) or phone call away (888-PROMODEL).

 

Mitigating the Hawthorne Effect with Bruce Gladwin

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Bruce Gladwin, PMP - Vice President, Consulting Services

Bruce Gladwin, PMP – Vice President, Consulting Services

With over 25 years of experience in the simulation field, Bruce has worked with major corporations worldwide developing hundreds of models across a wide range of industries. In his 19-year tenure with ProModel, he has served as a Product Manager, Senior Consultant, and Simulation Trainer. Bruce was named VP of Consulting Services in 2005 and has oversight responsibility for ProModel’s Consulting and Customer Service Operations.

Bruce received a BS in Systems Engineering from the University of Arizona and an MBA from Brigham Young University. He is a certified expert in Lean production principles and received his Six Sigma Black Belt certification while employed at General Electric’s Power Systems division.

Key projects include:

  • Capacity analysis for GE Energy Products Europe – determined the maximum production capacity for gas turbine components at GE’s European manufacturing facility resulting in a savings of $9.6M  in capital avoidance.
  • Design of a green-field manufacturing site for production of GE industrial generators – resulted in a savings of $1.2M in capital avoidance and identified the need for an accelerated operator training program.
  • Design and analysis of a disassembly process for the Russian-built SS25 Intercontinental Ballistic Missile (ICBM) in support of the 1991-92 START treaties between the US and the Soviet Union

Check out Bruce’s presentation on the Hawthorne Effect from the 2013 Winter Simulation Conference and his work with a major home improvement retailer…

To Expand or Not to Expand? Medical Clinic Simulation with Jennifer Cowden

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JCowden Profile Pic

Jennifer Cowden – Sr. Consultant

Less is More

I once worked with a programmer whose motto was “Pay me by the line of code,” and, not surprisingly, his code was often lengthy, inefficient, and hard to follow.  I’ve always preferred the opposite approach;  it is an interesting challenge to try to get the same functionality into as few lines of code (or alternately, as few process records) as possible.  Also, employing reusable blocks of code cuts down on the opportunities for mistakes and overall debugging time.   When I was an applications engineer at an automation company, I often had to get assembly lines modeled in a very short turn around.

Luckily, ProModel’s macro and subroutine modules made implementing reusable code very simple.  For the medical clinic model demonstrated in this post, we took flexibility a step further by using the “ALL” option in the process edit table.  Even though this model was built to simulate eleven different clinic layouts individually, and contains over 500 patient locations, this model contains a total of only seven process records.  Adding new clinic layouts now takes a fraction of the time and can be done with minimal code adjustments.  If you have a repetitive process, or one that needs to be flexible to add workstations quickly, this methodology could save you modeling time as well.

Check out Jennifer’s work on the Medical Clinic simulation model:

 

About Jennifer

Before joining ProModel in 2013, Jennifer spent 15 years in the automation industry working for a custom turnkey integrator. As an Applications Engineer she built simulation models (primarily using ProModel) to demonstrate throughput capacity of proposed equipment solutions for a variety of customers. Jennifer’s experience covers a wide range of industrial solutions – from power-and-free conveyor systems to overhead gantries and robotic storage and retrieval systems. She has also created applications in the pharmaceutical, medical device, automotive, and consumer appliance industries.

Jennifer has a BS in Mechanical Engineering and a Master of Science in Mechanical Engineering from the Georgia Institute of Technology.

Probing LEAN Space with Dave Tucker

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Dave Tucker

Dave Tucker – Director, LSS Initiatives
Lean Six Sigma Master Black Belt

Most companies have the same basic question they are trying to answer from a model project.  How can I make more stuff quicker?  Whether it is manufacturing, government, healthcare, or most any other industry, they all want to get more items through their processes faster and often they want to do it with fewer resources.  That’s the climate we are in now.  Everyone has to do more with less.

I have observed that many problems in Manufacturing can be directly attributed to having too much WIP.  Excess WIP inventory ties up money, creates the need for storage, increases cycle time, reduces throughput, and wastes Resources time.  But Managers want to keep everyone busy so they allow more work to be introduced into their systems instead of looking for Lean ways to better manage the “pull” of work.  Companies that learn to control the amount of WIP to meet their orders always do better financially then other companies that continually flood the workplace with inventory.

So I get excited when a model shows some new information that a company has never seen or understood before.  When they can see the process waste, understand how to remove it and implement the plan – that’s a great thing.

Check out Dave’s work on the Space Shuttle Program with United Space Alliance and NASA…. 

ABOUT DAVE

Dave Tucker is ProModel’s Director of Lean Six Sigma (LSS) Initiatives and also serves as a Senior Management Consultant and Project Manager.  He assists our clients primarily by providing simulation training, model consulting services, and LSS implementation advice.  Prior to joining ProModel, Dave was the Lead Lean Six Sigma (L6S) Master Black Belt at United Space Alliance (USA), located at the Kennedy Space Center in Florida.  USA is the prime contractor to NASA responsible for the Space Shuttle Program.

Dave has over 25 years’ experience leading teams, mentoring employees, solving problems, conducting training, and improving operations. He has led more than forty Kaizen Events, completed dozens of process simulation modeling projects, conducted hundreds of training sessions, facilitated over two hundred Belts & Team Leaders, and assisted with the implementation of numerous process improvements saving millions of dollars.

Dave has an extensive background in numerous process improvement tools utilized in Lean Six Sigma DMAIC & DMEDI approaches, as well as Kaizen team methods and process simulation modeling.  He has about 14 years’ experience using ProModel process simulation modeling tools for process improvement.  In addition, he is a sought after speaker and has made many well-received presentations at Process Improvement, Simulation, Industrial Engineering, and Aerospace Conferences.  He has a BSBA in Management from the University of Central Florida.  Dave is a Certified Lean Six Sigma Black Belt and a Certified Master Black Belt.