Case Study: SAIC optimizes NASA manufacturing process design with SIMUL8

Optimizing manufacturing process design for NASA using SIMUL8

SAIC, working on NASA’s Ares 1-X Upper Stage Simulator program in Reston, Virginia, faced a highly complex manufacturing process with limited floor space, constrained skilled labor, multiple facilities, and the need to coordinate segment departures on schedule. To address these challenges, SAIC used SIMUL8 simulation software to optimize the design of the manufacturing process for the vehicle’s cylindrical “tuna can” segments.

SIMUL8 built an interactive simulation model of the manufacturing and mating process, using repeated sessions with process managers to refine the model and validate assumptions. The analysis led SAIC’s team to implement several changes, including mechanized welding to reduce defects and rework, a crew-based staffing approach, a schedule dashboard for better visibility, and other flow improvements. The result was a more effective manufacturing plan that helped justify process changes and support on-time delivery of the test flight article.

SAIC

George Culver

Sr. Operations Research Analyst/Engineer