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BioSim FAQs

1. Who will find this tool invaluable?

Process development, industrialization, operations and procurement personnel. BioSim allows detailed analysis of real-life complex manufacturing scenarios providing insight into key areas where performance can be improved and assessment of short-term planning options for campaigns.

2. How does BioSim work?

The simulation toolset consists of two major components: a discrete event simulation model used to simulate activities in the facility, and a user configurable database used to hold the data required by the simulation. The model consists of a file and a number of software libraries that utilise a specialist, commercially available, simulation platform named “Extend”. The database is used to drive the model and contains all the required data on both the processes and the facility. The database is held in Microsoft Excel as sets of tables in a series of worksheets.

3. What is included in the simulation?

BioSim simulates the process steps in detail. The model also takes into account other factors such as: support, utilities, vessel availability, labour, scheduling, probability of success for the production of entire campaigns for multiple products where required. Multiple production suites and products can be modelled in one simulation model.

4. What information does BioSim provide?

The BPS Simulation toolset is a discrete event simulation package focused on the needs of the bioprocess industry. It is a tool that can be used to assess real-life processes that are too complex to analyse using spreadsheets or flowcharts including:

• Identifying potential bottlenecks and analysing how to remove them
• Evaluating the impact of new products and process revisions prior to their introduction to a bioprocess facility
• Validating conceptual and detailed designs
• Optimising the use of capital
• Defining equipment sizes
• Formulating operating procedures
• Defining and validating expansion plans
• Building and proving complex production schedules
• Validating shift patterns
• Providing detailed planning for future operations
• Analysing different technology options
• Reproducing and resolving problems experienced on a plant
• Determining absolute capacity for different facility designs, product mixes and operational scenarios

5. How long does it take to set up a new process for a product?

Once an Extend model has been configured new processes can be defined in the Excel model database. New processes can be created in seconds by copying an existing process that can then be subsequently modified. The model database can hold multiple process definitions. Once the database has been populated with required process information the new process can be imported into the Extend model and simulated.

6. Can I add my own unique unit operations?

Processes are defined in the Excel model database. Unit operations can be created and modified by the user as required.

7. How long does a model take to run?

Depending upon the complexity of the model a run can be completed within minutes. Longer simulation of production campaigns and multi-product facilities with significant constraints can take up to an hour.

8. Where does the data in the model come from?

The database will typically contain real information about your facility and processes. BPS can help to build this data set for you by carrying out a data gathering exercise. We also have a wealth of standard information which has been built up during our long experience in the industry. This data has been benchmarked against real facilities.

9. What are the outputs from the model?

The simulation model can generate considerable amounts of data. To aid insight into your process this data is arranged graphically in Gant charts and also in tables that contain process data and support data. Key outputs include:

• Process results – Results associated with the main process equipment and operations. These include batch cycle time data, equipment utilisations, and information about delays accumulated by the process as the model runs.
• Support results – Results associated with support equipment and operations. These include CIP, SIP, process solution, process utilities, and vessel allocation information recorded as the model runs.

The model output can also be exported to a simplified BioSolve cost module to enable the calculation of cost of goods driven by the detailed output of the simulation model.

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