Case Study: Plexus achieves manufacturing efficiency improvements with Simul8

Plexus saves $5,000 and boosts production confidence with SIMUL8

Plexus, a manufacturing company servicing branded product companies, needed to identify efficiency improvements for assembling a revolutionary drink dispenser for a major global beverage client at their Wisconsin facility. The challenge was to assess and optimize production capacity for their Aftermarket Service department, a complex process with multiple shifts, machine constraints, and travel time. Plexus utilized SIMUL8's discrete event simulation software to address this.

Using SIMUL8, an industrial engineering team rapidly developed a simulation model that mapped the facility's processes and constraints. The solution provided Plexus with a 95% confidence interval on production volume and identified the optimum staffing levels required to meet customer demand. SIMUL8 also delivered immediate cost savings by proving that a planned $5,000 equipment purchase was unnecessary. The simulation model became a live document used for ongoing process improvement and capacity planning.

Plexus