Crop Science: Simulation supports site planning at Bayer
Software: INOSIM
Bayer AG manufactures crop protection products and seeds and has been using simulation for several years in its Crop Science division to support decision-making on planning issues. Since 2019, SimPlan has been supporting the company in its Virtual Factory project.
Initial situation: Bayer introduces simulation for site planning
Bayer has established simulation as an integral part of planning within its Crop Science division, as decisions regarding production lines at multiple sites need to be thoroughly substantiated. Given the complexity of processes in crop protection product and seed production, planning based purely on experience is no longer sufficient. Bayer therefore brought SimPlan on board as a partner for the Virtual Factory project to handle the modelling of the production lines and has been working with the company on this since 2019.
Objective: To analyse material flows across multiple sites
The simulation aims to visualise the material flows of the production lines at various sites and identify potential for optimisation. Specifically, the simulation was designed to answer the following questions:
- Where do bottlenecks occur in the production process
- What potential for improvement can be identified
- How do different shift patterns and staff scheduling affect the process
- How can production orders and campaigns be planned effectively
Solution: SimPlan models the production lines using INOSIM
SimPlan used INOSIM for the modelling – a simulation tool developed specifically for the process industry. First, SimPlan analysed the processes at each site in detail, as this is the only way to build a model that accurately reflects the real-world processes. SimPlan then mapped out the line structures using layouts featuring the respective containers and described the recipes for all manufacturing processes within the model.
To evaluate the simulation runs, SimPlan used Gantt charts, which enable the analysis of line capacities. To ensure the models remain usable beyond the scope of the project, SimPlan worked with Bayer and INOSIM to develop templates and standards for future modelling. SimPlan also produced training materials to enable the on-site teams to use the models independently.
Results: Standardised models for multiple sites
The Virtual Factory project has now produced models for several sites. Because SimPlan structured the models in such a way that even staff without simulation experience can work with them, the site teams themselves are now responsible for using the models.
- Models for multiple sites have been completed
- Use of the models has been handed over to non-simulation experts on site
- Various shift scenarios were compared to determine their impact on throughput
- A standardised template solution for future modelling is available
- Training materials for the site teams have been developed
Why standardisation makes all the difference
The project demonstrates how simulation can be made permanently effective within a group with multiple production sites. Whilst individual simulation models do provide insights, it is only through shared templates and standards that modelling becomes comparable and repeatable across sites.
Because SimPlan has also developed training materials, knowledge is not confined to individual experts but is transferred to the site teams themselves. In this way, a single simulation project becomes a method that Bayer can apply independently to other sites and issues in the future.
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