Modeling & Simulation

As supply chains, logistics networks, and business processes grow and interconnect, continuous performance optimization is critical to meet customer demands and restrain costs. Increasing complexity means that disruptions due to internal or external events will grow in magnitude, posing great risks to firms that can’t afford delays, resets, or lost revenue. Bättra’s expertise in discrete event simulation enables organizations to accurately replicate complex, real-world processes, conduct predictive performance analysis on potential changes, and optimize across any performance measure with no disruption to current operations. Discrete event simulation offers many analytical benefits over static models and spreadsheet tools, especially in resource constrained environments.

Example Simulation Projects:

1. DLA J31 Whole of Government FOPL Optimization – Simulated the impact of changing DLA Planning and Order Management policies and processes to increase Material Availability (MA%) for non-CLSSA orders without decreasing MA% for U.S./CLSSA customers by changing the FMS Order Processing Levels (FOPL) and including recurring non-CLSSA orders in the item consumption rate and safety levels.

2. DLA FSG 80 HAZMAT Shelf Life Product Stocking Model – Simulated 5 years of FSG 80 product demand, order filling, quality notification processing, expired shelf life disposals, and replenishment/replacement to reasonably predict program costs and performance.

3. CAAA Ammunition Optimization Model – Simulated various strategic alternatives for receipt, storage, and issue of ammunition at Crane Army Ammunition Activity’s (CAAA).

4. AM2 Matting – Simulated the supply chain and detailed manufacturing process steps for AM2 matting (portable runway system for fixed wing aircraft) and measured the impact of buffer materials and capacity enhancements.

5. C&T Industrial Base Stabilization Model – Simulated the DLA C&T supply chain’s demand and supply management system and measured the impact of an industrial base stabilization strategy – increasing guaranteed minimum order quantities in exchange for reductions in production lead time.

6. UH-60 Blackhawk critical bearing supply chain – Simulated the complex manufacturing environment for a heavily backordered critical bearing for the UH-60 Blackhawk that included re-creating a 6-month backorder queue, order variability, variable product lot sizes for over 80 bearings, cycle times, changeover/ set-up times, and process routings across the same shared equipment/ resources multiple times. Used the simulation to measure the impact of adding buffer materials to reduce overall lead time and lean strategies aimed at reducing changeover and batch size.

7. ECWCS Layer III – Simulated the supply chain for Layer III (fleece jacket) of the Extreme Cold Weather Clothing System (ECWCS) program and measured the impact of buffer materials at various supply chain tiers.

8. MRE/ UGR Entrée Manufacturing & Assembly – Simulated Meals-Ready-to-Eat (MRE)/ Unitized Group Ration (UGR) Heat & Serve (H&S) ration production at one of the three MRE manufacturers and evaluated the impact of adding thermal processing equipment (retorts). Simulation synchronized fill line scheduling with projected retort availability and included mandatory daily FDA pathogenic bacterium reduction requirements.

9. Rotary Aircraft Critical Safety Items (CSI) Manufacturer – Simulated machine shop’s complex manufacturing environment that included product lot sizes, cycle times, changeover/ set-up times, expanding shift schedules for surge, and process routings across the same shared equipment/ resources multiple times that have caused excess queue time. Used the simulation to measure the impact of adding additional production equipment to reduce queue time, buffer materials to reduce overall lead time, and lean strategies aimed at reducing changeover time and batch size.

10. Hard Body Armor Supply Chain – Simulated the supply chain and detailed manufacturing process steps of one key manufacturer of the Enhanced Small Arms Protective Inserts (ESAPI) and measured the impact of buffer materials on surge output and lead time reduction.