Case Study: Plexus improves manufacturing capacity and saves over $5,000 with SIMUL8

Plexus quickly identifies manufacturing process improvements using simulation

Plexus, a global manufacturer specializing in complex product realization, utilized SIMUL8 simulation software to identify improvements in the assembly process for a revolutionary drink dispenser at their Wisconsin facility. Their challenge was to assess and optimize production capacity for their Aftermarket Service department, which involved navigating multiple shifts, machine constraints, and travel times across the building to meet client commitments.

Using SIMUL8's discrete event simulation software, Plexus rapidly developed a model of their manufacturing process, validating assumptions with factory staff. The solution provided results within a week, enabling Plexus to guarantee a 95% production confidence interval to their client and identify optimum staffing levels. SIMUL8 also saved over $5,000 by proving the purchase of additional equipment was unnecessary. The simulation model became a live document updated regularly for ongoing process improvements.

Plexus

Ben Van Straten

Industrial Engineer