Simulation based solution for production planning of custom cardboard transport systems

The manufacturing sector continually faces production challenges to meet client demands, specific design requirements, and production efficiency. Customising solutions adds further complexity to the manufacturing process, as each client presents a unique set of constraints and production needs. Designing and planning these customised solutions is labour-intensive, often requiring multiple iterations and the processing of complex design files across various platforms.

Van den Bos CM & Van den Bos Robotics, leading suppliers of specialised transport systems for the corrugated fibre industry in the Netherlands, are encountering significant challenges in their design and quotation workflow. The need to customise transport system solutions for each client makes this process time-consuming and creates communication hurdles, ultimately reducing the company’s operational efficiency.

To address these inefficiencies, Van den Bos CM, Van den Bos Robotics, and FIP-AM@UT have joined forces to enhance the workflow through innovative digital simulation tools. The integration of advanced technology to streamline design exchanges and boost workflow efficiency offers a valuable opportunity to overcome these challenges.

The TransFORM project aims to optimise the workflow for designing and quoting custom cardboard transport systems at Van den Bos facilities. This involves a thorough examination of current workflow challenges, an exploration of potential solutions through market-ready and custom-developed software, and a strategic plan to incorporate simulation software into Van den Bos operations. The proof-of-concept simulation solution that emerges from this project is expected to significantly reduce the time required for design iterations and the quotation process by improving communication between engineers and clients. As a result, client satisfaction will be enhanced through faster and more accurate quotations.

In summary, the TransFORM project aims to revolutionise the custom transport system design process at Van den Bos, driving greater efficiency, communication, and client satisfaction through targeted technological innovation.

Industry partner

APPROACH

These challenges were addressed using a discrete event simulation approach with the SimPy framework, creating modular components that mirrored real-world system elements like corrugators, conveyors, machines, transfer cars, and end-of-line stations. Each was configured with parameters reflecting actual operations.

A key innovation was the use of stochastic order generation via inverse transform sampling, enabling realistic production scenarios without sensitive sales data. The drag-and-drop user interface was designed for ease of use by non-technical staff. Development followed an iterative process with ongoing validation against real production data. By comparing simulation results with actual throughput, the team ensured the model accurately reflected the complex interactions between materials, machines, and processing times.

OUTCOME

The joined efforts from the TransFORM consortium resulted in an integrated simulation system that allows engineers to quickly modify and evaluate customised transport system designs. Through four main work packages, the project achieved the following results:

• Simulation of corrugated transport systems according to real world components and operational rules
• Development of production scheduler, based on simulated transport system, to evaluate system’s performance and
inform quotation process
• Insight into simulation models to support design and quotation processes
• Development and performance evaluation of simulation system according to real world constraints

The current simulation-scheduler framework provides Van den Bos the opportunity to explore and evaluate different transport system proposals to meet the unique client’s production demand and efficiency. Using innovative digital tools to inform decision-making before production, offers valuable insights for corrugated transport system manufacturers and clients.

This project was made possible through the Regio Deal supported by the Province of Overijssel and the Dutch State.

FOR MORE INFORMATION ABOUT TransFORM, PLEASE FEEL FREE TO REACH OUT TO

dr. Burak Erkayman

Guest Researcher @ University of Twente

Can Ölmezoğlu

Can Ölmezoğlu

Engineering Support, Software Development

Estefanía Morás Jiménez

Research Engineer

Martin Aretz

Research Associate, Fraunhofer Institute for Production Technology IPT

    Anna Geldmacher

    Research Associate, Fraunhofer Institute for Production Technology IPT

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