Production simulations – Ensuring return on investment

Developing production and making investments may seem like straightforward decisions – add machines, increase capacity and expect production to grow in proportion. But is it really that simple?

Why don’t 10 machines always produce twice as many?

If 5 machines produce 5 products per minute, why wouldn’t 10 machines produce 10 products in the same time? The answer lies in the overall production process: material stocks, intermediate stocks, material flows and labour load can limit capacity growth. Simply adding more machines does not automatically mean more efficient production if other critical resources are not kept up.

The problem has also been that simulation software costs a lot of money and there is a shortage of simulation experts. In many cases, it has been cheaper to buy an extra machine than to do the necessary simulations. But not anymore.

A cost-effective solution for optimising production

Now we finally have a cost-effective solution for this market that allows production capacity to be accurately optimised – without the need for rigid simulation models and high costs. The simulation model can be easily built, even for an entire factory and thousands of different product variants.

At Hefmec, we have already helped many of our customers to use these simulations to assess the return on investment and optimise the number of production machines and the necessary intermediate stocks when increasing production capacity. These analyses help us to identify which investments really add value – and not just more machines waiting on the production line.

How do production simulations help decision-making?

  1. Identifying bottlenecks – Simulations can be used to identify where production slows down and what factors are limiting capacity.
  2. Optimising resources – Matching machinery, labour and material flows improves efficiency and reduces waste.
  3. Cost management – By simulating different investment options, it is possible to predict which solutions will deliver the best return.
  4. Real-time validation – Our simulations are not just based on theoretical models – we have validated them with real production data. This means that our models reflect real production conditions and we ensure that they are accurate enough to predict the impact of investments.

Read more about our services and products or contact us!

Written by Sami Jortikka, Senior Project Manager

Structural steel design: agile solutions to industrial challenges

Industrial challenges and the importance of steel structures

We are constantly facing challenges in industry that require quick and sustainable solutions. Steel structures play an essential role in many production facilities, providing the necessary strength and flexibility in demanding environments. The use of steel enables the construction of complex and large structures that can withstand intensive use and extreme weather conditions.

The design of steel structures requires in-depth specialist knowledge to ensure that the end result is technically and economically optimal. The design process focuses on safety, durability and functionality. It is also critical that our design solutions support customer productivity growth and meet future needs.

Agile design processes respond to rapid needs

When we face production problems, fast and effective action is essential. Our agile design processes enable solutions to be found and implemented quickly. This requires the ability to react quickly to changing requirements and circumstances.

Our agility allows us to avoid long waiting times and get your plant back up and running as quickly as possible, minimising downtime and production losses. Our flexibility also allows us to adapt our design to new needs and challenges as they arise during the project.

Customer focus and problem-solving skills

Our customer-centric approach is the cornerstone of our success in structural steel design. By listening to our clients’ needs and understanding the heart of the problem, we are able to create solutions that address practical challenges. This requires close collaboration with the client and a thorough understanding of their business and processes.

Problem-solving skills are particularly important when faced with demanding production problems. Creative and innovative solutions are needed that not only fix the problem, but also improve long-term production efficiency. Our expertise and experience ensure that our solutions are sustainable and add value to our customers.

Responsibility and quality assurance

Responsibility is a key part of our approach to structural steel design. When we embark on a design project, we take responsibility for the whole process from start to finish. This means committing to the project’s objectives, timelines and budget. Guaranteeing quality is essential, and this is achieved through careful planning and execution.

Our high-quality steel structures are long-lasting and will stand up to decades of hard use. That’s why we can offer a lifetime guarantee on our products, a testament to the high quality and reliability of our design work. As a responsible operator, we ensure that our customers can rely on our service and the end result.

Technical and economic optimisation

Technical and economic optimisation is of great importance in the design of steel structures. It is important that the solutions we design are cost-effective and support the growth of the customer’s business. Technical optimisation means designing structures to meet all technical requirements and standards.

Economic optimisation ensures that our design solutions are cost-effective and provide the best possible return on investment. This is achieved by analysing different options and selecting the best overall solution. Correctly sized and designed steel structures are key to improving industrial efficiency and competitiveness.

Machine design: an expert’s guide

Basics of machine design

Machine design is a complex and multi-step process that requires in-depth technical knowledge and creative thinking. It covers everything from ideation and conceptualisation to final production and testing. The goal of machine design is to create functional, efficient and safe machines that meet the needs and requirements of users.

The design process usually starts with defining needs and requirements. This stage is critical as it defines the direction and objectives of the project. It then moves on to conceptual design, where preliminary ideas and solutions are created. The concepts are evaluated and the best option is selected for further development.

Design tools and methods

Today, a variety of computer-aided design (CAD) tools are widely used in machine design. CAD software allows the creation of accurate and detailed designs, which speeds up the design process and reduces errors. They also offer the possibility to simulate and test designs before actual manufacturing.

Another important method is the finite element method (FEM), which allows the strength of structures and components to be calculated. FEM simulations help to predict how machine parts will behave under different loading conditions, improving design reliability and safety. These tools allow us to ensure that the machines we design meet all required standards and regulations.

Material choices and their importance

Material choices are a key part of machine design. Choosing the right material directly affects the performance, durability and cost of the machine. Several factors such as strength, weight, corrosion resistance and temperature resistance must be taken into account when selecting materials.

For example, steel is a commonly used material because of its strength and durability, but it can be too heavy for certain applications. Aluminium is a lighter alternative, but it is not as strong as steel. Composite materials offer an excellent strength-to-weight ratio, but can be more complex and expensive to manufacture. Material choices must be made carefully to support the machine’s design objectives and operational requirements.

Ergonomics and user experience

Ergonomics is an important part of machine design, as it directly affects the safety and comfort of the operator. A well-designed machine takes into account the physical and cognitive needs of the operator, which improves work efficiency and reduces the risk of accidents. Taking ergonomics into account in the design can also reduce operator fatigue and improve the overall user experience.

To improve the user experience, it is important to collect feedback from users and make the necessary design changes. This can include improving the layout of controls, the clarity of displays and the intuitiveness of the user interface. User-centred design ensures that machines are easy to use and meet user expectations.

Sustainable development and environmental impact

Sustainability is an increasingly important part of machine design. Designers need to consider the environmental impact of machinery throughout its life cycle, from material sourcing and manufacturing, through use, to recycling and disposal. This requires energy efficiency, material efficiency and recyclability to be taken into account in the design process.

Developing environmentally friendly solutions can include using energy-efficient engines and components, choosing lighter and more durable materials, and designing recyclable parts. Sustainable development not only reduces environmental impact, but can also bring financial savings and enhance a company’s reputation as a responsible corporate citizen.

Innovation and future prospects

Mechanical engineering is a constantly evolving field where innovation plays a key role. New technologies such as artificial intelligence, robotics and 3D printing are opening up new opportunities and challenges for designers. Exploiting these technologies can improve the efficiency, accuracy and flexibility of the design process.

In the future, machine design is expected to focus more and more on intelligent and self-learning systems that can adapt to changing conditions and user needs. This will require continuous learning and adaptation to the development of new technologies and methods. At Hefmec, we are committed to staying at the forefront of developments and providing our customers with innovative and sustainable solutions.