Approach
To address these challenges, Möbius executed the following steps:
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Process mapping
The entire packing process was mapped in detail, capturing all interactions between packing lines, warehouse operations, and material flow constraints. -
Data collection & validation
Existing data was gathered from the company’s SAP system and machine logs. Missing data was supplemented through targeted sampling and observational studies. -
Bottleneck identification & simulation
A stochastic time-based model was developed to simulate the production line under various scenarios. The model allowed dynamic parameter adjustments (e.g. line speed, input distribution, bag sizes). The output of the model was visualized in a clear dashboard to pinpoint possible bottlenecks. -
Scenario analysis
More than 20 different operating scenarios were tested, each analyzing the impact of varying input and output parameters. Key focus areas included warehouse movements, conveyor usage rates, and packing line efficiency. The analysis also provided insights into the realistic capacity of the current setup, offering a clear understanding of operational constraints.
Results
Through the application of advanced simulation techniques and data-driven analysis, our client acquired valuable insights into its packing operations. The project identified critical bottlenecks and their interdependencies while providing actionable recommendations for both short-term improvements and long-term strategic planning.
Key areas of focus included enhancing monitoring capabilities, optimizing production planning, and exploring future investment opportunities. With improved monitoring and optimized workflows, the company is now well-positioned to increase packing line efficiency, minimize downtime, and improve overall supply chain performance.
