Evaluating production improvement opportunities in a chemical plant: a case study using discrete event simulation

This paper presents a case study on using a discrete event simulation-based approach to evaluate the proposed capacity expansion and reliability improvement opportunities at a chemical plant of The Dow Chemical Company. The simulation model was successfully used to evaluate the effect of batch size increase and automation of raw material loading on the plant productivity. In addition, the modelling work identified critical failures that were significant contributors towards production loss. Despite the strong capabilities of simulation for modelling complex system dynamics and uncertainties, there are challenges associated with use of simulation. Simulation projects for such complex systems are typically long term, and require effective stakeholder management techniques for successful execution. We discuss some Six Sigma-based best practices that aid in successful execution of such projects and for ensuring the sustainability of simulation models for evaluating future improvement efforts. Journal of Simulation (2012) 6, 81-91. doi:10.1057/jos.2011.20; published online 16 September 2011