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Discrete Event Simulation (DES) and FlexSim Overview
π Discrete Event Simulation (DES) models processes that happen over time based on specific, distinct events (e.g., a person taking 4 seconds to move).
π₯οΈ FlexSim, established in 1979 and acquired by Autodesk in 2023, specializes in building detailed simulation models, offering expertise in throughput and bottleneck analysis.
π A key differentiator in FlexSim is its Process Flow system, which uses a flowchart structure making complex models easier to understand, even for non-modelers.
π’ FlexSim is utilized by major Fortune 500 companies, including Amazon, Toyota, and FedEx, to create digital twins and verify theoretical scenarios.
Theoretical Use Case: Optimizing an AGV Loop
π― The goal of the AGV loop scenario was to determine the exact number of Automated Guided Vehicles (AGVs) needed to meet a target throughput of 45 jobs per hour, thereby avoiding unnecessary capital expenditure.
πΊοΈ Model inputs required specifications such as facility layouts (like AutoCAD DWG files), AGV performance (acceleration, speed), station cycle times, and downtime information (MTBF/MTTR).
βοΈ FlexSim models accurately reflect 3D space, calculating travel time based on distance and speed (e.g., 2 feet apart at 1 ft/second takes 2 seconds).
π The model allows for detailed AGV pathing control, including stopping distances, traffic control, speeds, accelerations, and battery usage.
Experimentation and Results Analysis
π§ͺ Experimentation in FlexSim involves defining scenarios (different parameter sets, like varying AGV counts) and replications (running the scenario multiple times with different random seeds) to ensure statistically significant results.
π Key Performance Indicators (KPIs) generated automatically include mean values, confidence ratings (e.g., 95% or 99%), and box plots to identify outliers.
π‘ In the AGV case, the analysis revealed that 11 AGVs achieved the target of 45 jobs/hour; using 12 or more slightly *decreased* throughput due to traffic issues.
π The simulation process is iterative, allowing for further testing of variables like buffer space, station relocation, or changes in cycle time tolerances.
FlexSim Capabilities and Interfacing
π« FlexSim does not automatically detect bottlenecks; instead, utilization percentages (e.g., one station at 100%) or detailed interaction analysis must point to restrictions.
π FlexSim supports numerous modules beyond AGVs, including robotics, ASRS systems, conveyors, GIS trucking navigation (for inter-facility transfers), and even fluid modeling in pipes.
π The software supports emulation via a specific module to interface with real systems like PLCs (Programmable Logic Controllers), enabling the simulation to act as a true digital twin for testing control logic.
Key Points & Insights
β‘οΈ DES is ideal for "if-then-else" modeling of discrete events over time, creating a functional digital twin of a facility or process.
β‘οΈ The primary benefit of simulation modeling is cost avoidance by precisely determining the required number of assets (like AGVs) needed for operational targets.
β‘οΈ When building models, clearly define the core question upfront (e.g., "How many AGVs are needed?") before collecting detailed specifications.
β‘οΈ FlexSim's Process Flow functionality allows non-modelers familiar with flowcharts to effectively read and understand the logic within complex simulations.
πΈ Video summarized with SummaryTube.com on Nov 14, 2025, 08:47 UTC
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Full video URL: youtube.com/watch?v=P6wdK10AIu4
Duration: 29:04
Get instant insights and key takeaways from this YouTube video by PMC Videos.
Discrete Event Simulation (DES) and FlexSim Overview
π Discrete Event Simulation (DES) models processes that happen over time based on specific, distinct events (e.g., a person taking 4 seconds to move).
π₯οΈ FlexSim, established in 1979 and acquired by Autodesk in 2023, specializes in building detailed simulation models, offering expertise in throughput and bottleneck analysis.
π A key differentiator in FlexSim is its Process Flow system, which uses a flowchart structure making complex models easier to understand, even for non-modelers.
π’ FlexSim is utilized by major Fortune 500 companies, including Amazon, Toyota, and FedEx, to create digital twins and verify theoretical scenarios.
Theoretical Use Case: Optimizing an AGV Loop
π― The goal of the AGV loop scenario was to determine the exact number of Automated Guided Vehicles (AGVs) needed to meet a target throughput of 45 jobs per hour, thereby avoiding unnecessary capital expenditure.
πΊοΈ Model inputs required specifications such as facility layouts (like AutoCAD DWG files), AGV performance (acceleration, speed), station cycle times, and downtime information (MTBF/MTTR).
βοΈ FlexSim models accurately reflect 3D space, calculating travel time based on distance and speed (e.g., 2 feet apart at 1 ft/second takes 2 seconds).
π The model allows for detailed AGV pathing control, including stopping distances, traffic control, speeds, accelerations, and battery usage.
Experimentation and Results Analysis
π§ͺ Experimentation in FlexSim involves defining scenarios (different parameter sets, like varying AGV counts) and replications (running the scenario multiple times with different random seeds) to ensure statistically significant results.
π Key Performance Indicators (KPIs) generated automatically include mean values, confidence ratings (e.g., 95% or 99%), and box plots to identify outliers.
π‘ In the AGV case, the analysis revealed that 11 AGVs achieved the target of 45 jobs/hour; using 12 or more slightly *decreased* throughput due to traffic issues.
π The simulation process is iterative, allowing for further testing of variables like buffer space, station relocation, or changes in cycle time tolerances.
FlexSim Capabilities and Interfacing
π« FlexSim does not automatically detect bottlenecks; instead, utilization percentages (e.g., one station at 100%) or detailed interaction analysis must point to restrictions.
π FlexSim supports numerous modules beyond AGVs, including robotics, ASRS systems, conveyors, GIS trucking navigation (for inter-facility transfers), and even fluid modeling in pipes.
π The software supports emulation via a specific module to interface with real systems like PLCs (Programmable Logic Controllers), enabling the simulation to act as a true digital twin for testing control logic.
Key Points & Insights
β‘οΈ DES is ideal for "if-then-else" modeling of discrete events over time, creating a functional digital twin of a facility or process.
β‘οΈ The primary benefit of simulation modeling is cost avoidance by precisely determining the required number of assets (like AGVs) needed for operational targets.
β‘οΈ When building models, clearly define the core question upfront (e.g., "How many AGVs are needed?") before collecting detailed specifications.
β‘οΈ FlexSim's Process Flow functionality allows non-modelers familiar with flowcharts to effectively read and understand the logic within complex simulations.
πΈ Video summarized with SummaryTube.com on Nov 14, 2025, 08:47 UTC
Find relevant products on Amazon related to this video
As an Amazon Associate, we earn from qualifying purchases

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