The Art, Science, and Craft of Simulation...​

35+ years of hands-on simulation expertise applied to real-world manufacturing challenges using discrete event simulation, discrete rate simulation, & digital twins.
Today 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. 


Testimonials


Decision Intelligence that "Just Works"

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


From Bespoke Models to Breakout Applications

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.

SDI can help your innovation efforts. Contact us at: info@simulationdynamics.com