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Delivering Simulation-Based Intelligence for 35+ Years

PlantSim

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Helping manufacturing and supply chain leaders make smarter, faster decisions

Our practice is built around Siemens Plant Simulation X products to model, simulate, visualize, analyze and optimize material flow and resource utilization for all levels of your factory planning, from global facilities and local factories to specific production lines. Our team has 15+ years of PlantSim experience led by seasoned CPG industry veterans. The team has proven success in delivering over 50 models of manufacturing lines, plants, warehouses, and supply chains. 

$1B+ client savings
(single project over a decade)

35+ year history of delivering
decision intelligence

Decades of Fortune 500
manufacturing experience

Our Intelligence Spans
the Manufacturing Spectrum

50+ PlantSim projects, ExtendSim pioneers, ReliaSim innovators. Primary practice in: manufacturing lines, multi-stage plants, entire supply chains. We master whatever simulation platform your strategic priorities demand.

Deploying sensors and edge computing for digital transformation - displaying, coaching, or automating production processes. From proof-of-concept to production deployment on plant floor networks. Example: AdaptiveCoaching.ai strengthening operator decisions in real-time.

Mathematical modeling across all domains: ML, statistics, optimization. From workforce planning and long-range capacity planning to supply chain design and facility sizing. Our F# advantage makes analysts incredibly productive at model development with succinct, performant code.

Growing ideas from proof to production reality. We master your preferred technologies (Python, Knime, Power BI, Databricks), reject costly dead ends, and mature winning concepts into enterprise-grade .NET solutions using Domain Driven Design. Technology-agnostic consumption, strategic .NET production.

Model-Based Apps used by 10,000+ decision-makers daily. When ideas become "blockbusters" requiring organization-wide scaling, our Enterprise team deploys using C# for maximum integration. F# and C# interoperability ensures mathematical models seamlessly integrate into unified .NET solutions.

Our Three-Group Architecture

Innovation Group


The Crucible
Technology learning agility meets idea lifecycle management. This group vets breakthrough concepts, rejects dead ends, and nurtures promising ideas to maturity. Responsible for Edge/IoT deployment and F# model development. The crucible that created our ChiAha applications - ReliaSim , GreenfieldAnalysis.ai, and AdaptiveCoaching.ai - showcasing the wide range of capabilities this group delivers.

Modeling Group


Simulation Excellence
Deep expertise in simulation modeling using Siemens PlantSim X and our breakthrough ReliaSim tool for high-speed, high-volume reliability-focused prediction of OEE. 50+ projects across manufacturing lines, multi-stage plants, and entire supply chains.

Enterprise Group


Scaling Success
When Innovation's breakthrough ideas prove their value, Enterprise scales them organization-wide. Using C# for maximum integration and enterprise-grade deployment, this team serves 10,000+ daily users with mission-critical Model-Based Apps.
"The SDI Team were excellent simulation engineers. They were careful and thorough with understanding our issues. Their simulation was developed with alacrity and accuracy. The SDI team went above and beyond the project scope, proactively brainstorming ways to make our project better."
J Adam TrainaDirector of Operations Research,
Symbotic
“What we really found to be very powerful was the actual building of the model. It forced a certain diligence in terms of saying, if we change the system here this happens over here. We had not gone to that level of understanding the interconnections of our systems before. This definitely saves us time. It gives the ability to let the tools follow our questions and follow them rapidly, so once we have the model constructed, we can get results in as little as 15 minutes. There’s no question we will explore substantially more alternatives than we would have if this were a more laborious process like before. As a result, we end up with much more thorough and novel solutions."
Mike GeddisDirector of Engineering,
General Mills
"The Integrated Resource Planning Model was developed in partnership with Y-12. It is a decision support tool used for long-term, rough-cut resource capacity planning. IRPM evaluates the impact of rapidly changing schedules, variable budgets, and changing resource bases (i.e., personnel, equipment, and facilities and their effects on schedule performance, projected cost, and resource utilization). IRPM is used to model multiple programs and perform what-if scenarios."
Thomas M. InsalacoY-12 National Security Complex
"SDI Industry's Discrete Rate Flow represents a break-through for simulating high-volume operations. If you want to model something that is expressed in terms of rates, you need SDI Industry. Anything that can be expressed in terms of rates can be modelled more effectively than discrete event by using Discrete Rate Flow. In my years at Pritsker, we came close to this, but we never made it work like SDI has!"
Darrel StarksSimulation Consultant,
Integral Solutions
"Adaptive Coaching has been a good tool for the operators. They have been using it as a tool to reassure the oven settings. The Adaptive Coaching suggestions are within a few points of the settings the operators are using. It will be nice to see where this technology goes."
K.B.Process Technology Owner
"Instead of taking a snapshot, this is more like a video. It’s more than just a point solution. Your ability to actually see the activity in action and plot out the results allows you to understand impacts much better while the supply chain is running. We can run six months of supply chain data in a matter of minutes."
Mike GeddisDirector of Engineering,
General Mills
"We chose SDI's simulation software and consulting services to assist with business decisions regarding the restructuring of its manufacturing network. Specifically, to evaluate capital investment opportunities and asset utilization strategies in a risk-free environment.

The modeling was extremely successful. We have uncovered additional options for low capital cost business growth, some of which were not readily apparent beforehand.”

Rick DoughertySenior Manufacturing Analyst,
DOW
"The Tactical Logistics Distribution System (TLoaDS) is a powerful and flexible simulation application for assessing current or future tactical distribution systems. It is a discrete event analytical model for assessing the pros and cons of new doctrine, distribution techniques, organizational structures, and equipment concepts. It can also be used for mission planning allocating available resources to sustain a military force in a wide variety of scenarios. TLoaDS models the order assigning and filling process. While order assigning is simple, the order filling process dynamically selects the combination of container, handler, and transporter appropriate for the current order, conditions and rule set. A scoring system with user adjustable weighting factors allows biasing the shipment plan towards more efficient use of transporters, or more responsive filling of orders."
Bob Hamber Defense Modeling and Simulation Office

The Coffee Production Revolution: When Process Changes Create Chaos

The challenge:

Quality improvements required inserting a new production stage between roasting and grinding, creating “shifty bottleneck” problems that Advanced Planning Systems couldn’t handle.

Why traditional analysis failed:

Moving bottlenecks as a result of packaging size changes couldn’t be analyzed with static methods.

The modeling breakthrough:

Our Discrete Rate Simulation technology – originally developed for exactly this type of bulk flow, rate-based problem – enabled conception, testing, and verification of an entirely new scheduling algorithm.

Result:

Successfully adapted plant operations to new production constraints with robust scheduling across various demand scenarios.

Food Processing:
When Simulation Reveals Hidden Opportunities

The challenge:

Olive processing company needed to understand true production capacity and scheduling constraints.

The modeling solution:

Detailed simulation revealed bottleneck dynamics, tested scheduling approaches, and quantified variability effects.

Results:

15% throughput improvement through Theory of Constraints-based scheduling optimization.

“The model confirmed bottlenecks at certain operations in the plant… an effective tool to evaluate proposed capital expenditures and scheduling changes over short and long-term periods. The simulation offered Lindsay personnel an understandable representation of their large, complex plant. The simulation is a tool that has allowed [us] to evaluate critical factors about the facility while discarding irrelevant detail.”

— Robert Rugeroni
IT Director, Bell Carter Foods

VINLogic:
From Technical Model to Business Application

The transformation:

From 6-hour technical model requiring simulation expertise to 20-minute business application accessible to CFOs and analysts.

“VinLogic is at the heart of what we do. Our analysts run it every week. I run the model to more accurately predict our annual budget! The reason we never call you is because the model just works.”

— Linda Suddeth
CFO, Insight Network Logistics

Results:

$1+ billion annual savings through 10+ years of continuous operation as a core business asset.

“We leveraged VINLogic to recommend solutions that saved $21.7M in inventory carrying costs and reduced transit time by 19%.”

— Mike Keller
Network Analyst and Engineer, Union Pacific Railroad

ChiAha.ai is a reliability-focused, performance-based, production simulator built to predict OEE +/- 1%.
Plant Manager-friendly – up to 1,200x faster than legacy sim tools.
GreenfieldAnalysis.ai is an AI-powered network design tool that models both Greenfield and Brownfield Supply Chains to determine optimal facility locations.
AdaptiveCoaching.ai is a production edge/iiot system that builds on your operator’s expertise through real-time coaching with expert suggestions.

Partner with America's
Manufacturing Intelligence Leaders

  • 15+ years under Master Services Agreements
  • Embedded in major companies’ innovation ecosystems
  • 100% American owned and operated
  • The best-kept secret behind industry breakthroughs
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