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Blending and Packaging Challenges

Unilever (Wish-bone and Lawry's)

Over the course of a long partnership with Unilever's in-house industrial engineers, NovaSim has developed multiple discrete event simulation models to help optimize production performance. 

Project Objectives

  • Determine whether the ingredient preparation system could keep up with increased production, while considering the handling of Kosher ingredients
  • Create efficient production schedules to meet demand while minimizing losses due to changeovers and equipment availability contraints
  • Manage dedicated equipment while simultaneously meeting all product demands
  • Coordinate the batch production and the complex system of ingredient scales with fork lift delivery, pumps, mixers, and packaging lines

Model Elements

  • Daily production shedules
  • Base formulas with multiple packaging operations for a wide number of products
  • Complex changeover requirements
  • Traveling labor requirments
  • Kanban based production system
  • Mixing of both dry and wet ingredients
  • Complex process times for each product and each process step including materials handling, equipment, and labor
  • Careful management of Kosher product constraints
  • 6 different production technolgies ranging from dry blend only to colloid mills