Using simulation for more sustainable production systems – methodologies and case studies

The increased competition in the global market-place is forcing industrial manufacturers to develop their production systems by increasing flexibility, improving quality and lowering production costs. With the help of simulation techniques, the understanding of manufacturing systems can be enhanced and alternative solutions can be tested. Simulation has, therefore, played an important role in industrial development in recent years. At the same time, energy-related costs have been neglected by Swedish industry due to historically low energy costs in Sweden, in comparison with such costs in other European countries. The developments in the energy market, with uncertainty concerning future prices, have increased the need for energy efficiency. The research described in this paper focuses on methodologies developed to enhance the efficient analyses of energy systems in manufacturing plants by using discrete event simulation. The focus is on electricity use. The paper briefly presents the main features of the methodologies and describes the results from four case studies carried out in the Swedish foundry industry. The methodology improves efficiency by identifying those processes that are important, the activities that must be undertaken and the types of analyses that can be undertaken.