From the desk of Michael T Clason,

What are the costs?

The initial and ongoing costs associated with deciding whether or not process simulation is to be in your process engineering toolbox is a question you may or may not ever get answered (from some). You may feel you need a consultant to to intelligently hire a consultant!  I know I did when I first started in the business of process engineering.  But fear not, I will attempt to be as transparent about what you can expect as I can.

Again, what are the costs?

A process simulation project is not unlike a construction project.  You will need a project manager, a project engineer, collaboration with your purchasing department and "buy-in" from your higher-ups. If you're the forward-thinking proactive engineer that is looking into this new company idea, here's what to expect:

     1.   Anywhere from $1,000 to $20,0000 for a simulation package.

The above "list" is a compilation of your expenses.  I realize that you know there is more to it than this, but please bear with me.  You no doubt consider the time and availability of yourself and/or others involved as part of your monetary investment as well.  In fact, it's without a doubt the biggest part.  Imagine a simulation platform that is so intuitive that you can figure out everything you need to know as easily as you would design a spreadsheet.  This is unfortunately hardly ever the case.  With most advanced manufacturing or service processes, the details are so complicated that our clients many times have much difficulty in even verbally describing it!

If you are contemplating building a process simulation yourself (while not precisely knowing how to), expect as much time and effort as learning French, or C++, or any other language.  While it is true that most simulation platforms like Rockwell's Arena or Lanner's Witness have very graphical interfaces, intuitive tools, and high-level languages, you will not manage to complete much of a simulation without knowing the ins-and-outs of the programming interface.  Even more than this, a knowledge of essential process efficiency algorithms is essential.

But for argument's sake, let's suppose that for your first project, you will hire a consultant and have him or her teach you what they can till that first project is completed.  In this scenario, here's what you can expect:

     2.   Anywhere from $1500 to $5000 a week, depending on your consultants' expenses, scope of the project and the speed of your consultant.

A "rough" model can be completed in about a week.  A detailed model spanning several departments can take a month for an experienced programmer to complete.  The "rough" model "blackboxes" what is absolutely not necessary while highlighting those areas that are and usually includes only one department as well as minimal interface with external applications.  The detailed model however has many 3rd party application and spreadsheets, many areas (departments), and takes up to a week to learn the process in enough detail to begin the model-build.

So you're looking at anywhere from 5 to 25 grand for a project if you hire it out.  I hope this helps in getting you started in your thinking as to whether process simulation is cost-prohibitive or not.  But even here, you have much more research to do if you are like me when I did my first project.  If it helps, I have more reading for you. 

Regards,

Michael Clason
FCP Consulting Services
General Manager