Discrete Event Simulation

Layout + Flow Optimisation

Equipment layout, material flow, and routing simulated before steel is ordered.

Where you put the new buffer determines whether throughput goes up 8% or 2%. Which corridor the AGV takes determines whether a fork-lift adds value or causes congestion. We simulate the layout alternatives in 3D before you order the steel · catching the bad layouts before they're poured in concrete.

Why this matters

Why layout decisions made on paper cost millions to undo

Layout decisions made on 2D plot plans look fine until the plant is running. The buffer is too far from the line. The AGV path crosses the operator walkway. The crane sweep clashes with the new mezzanine. Each of these decisions, once concrete is poured, costs millions to undo · if undoing is even possible. Discrete event simulation in 3D · with operator movement, AGV routing, crane interference, vehicle congestion · catches layout problems in the design phase, when they cost thousands to fix. We've done this for new automotive lines, brownfield refinery retrofits, port expansions, and pharma cleanroom buildouts.

Method

How we deliver Layout + Flow Optimisation

CEng MIE India-signed deliverables · LiDAR-powered where applicable · digital twin handover ready · routes to the Discrete Event Simulation practice lead within 24 hours.

Layout alternative encoding

2-4 layout alternatives encoded in the simulation environment · footprint, equipment placement, material flow paths, operator stations, AGV/vehicle routes.

Flow simulation

Material flow simulated with realistic cycle times. Operator movement tracked. AGV / vehicle routing simulated with congestion.

Performance comparison

Throughput, average flow time, congestion, operator walking distance, AGV utilisation tabulated per alternative.

Risk sensitivity

Each alternative stress-tested for what-if scenarios · product mix change, demand spike, breakdown of major asset.

Recommendation + 3D animation

Ranked layout recommendation + decision-grade animation for board / engineering review. CEng MIE-signed.

Standards + compliance

Built to the standards your auditors quote

Reports reference the international and national standards your regulators, F500 audit teams, and corporate process safety leads cite. Every deliverable signed by a Chartered Engineer (CEng MIE India).

ISA-95 (manufacturing reference)
USIBD LOD 350 (3D layout representation)
VDA 4.2 (auto industry layout standards)
ISO 22400 KPIs
VV&A IEEE 1730

Anonymous case anchors

What this looks like in production

Three anonymised engagements from our verified roster · quantified outcomes, no client names disclosed without written permission.

Auto plant, India · new BIW expansion

4 layout alternatives simulated. Selected layout delivered 14% higher throughput than the originally proposed layout. Saved $4M in subsequent retrofit.

Port, Singapore · terminal expansion

STS crane + RTG layout alternatives simulated. Selected layout reduced ship turnaround time by 18%.

Pharma, USA · cleanroom relayout

Cleanroom equipment layout for new packaging line. Operator walking distance reduced 32% · OEE projection improved 4 percentage points.

Frequently asked

Layout + Flow Optimisation · the practical questions

Do you work with the design house, or independently?

Either. Often the design house has 2 candidate layouts and wants independent simulation evidence to choose. Sometimes we work with the design house from concept. Both patterns work.

How early in design should this happen?

At 30% design when 2-4 alternatives are on the table. Doing it at 80% design when one layout is already locked is rescue-mode work · still valuable but less leverage.

Can you simulate operator movement?

Yes · operator path-finding, station assignment, fatigue modelling, even ergonomic analysis (with the appropriate models). Common in auto + pharma + food packaging environments.

Can you simulate AGV / vehicle congestion?

Yes · AGV routing under fleet management rules, fork-lift / crane congestion, mining haul truck spotting. AnyLogic excels at this.

How accurate does the layout encoding need to be?

At least to functional accuracy · equipment positions, flow path widths, intersections. Geometric precision is nice for animation but not required for performance prediction · simulation predicts performance from logic, not pixel-perfect rendering.

Scope your Layout + Flow Optimisation engagement.

Tell us your plant, region, and scope · a named Chartered Engineer responds within 24 hours.

4 fields. No phone interview to start.
Per-discipline routing to the Discrete Event Simulation practice lead.
Anonymous case anchors sent with first reply.
Same-day callback for deadline-driven enquiries.

Simulation / Evaluation Scoping

FlexSim · AnyLogic · Simio · decision-grade ROI evaluation.