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FlexSim
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| FlexSim | |
|---|---|
.svg){kind=small} | |
| Developers | FlexSim Software Products, Inc. |
| Initial release | 2003 |
| Stable release | 24.2.1
/ August 17, 2024 |
| Written in | C++ |
| Operating system | Windows 11 / Windows 10 / Windows 8 / Windows 7 |
| Available in | English, Chinese (traditional), Chinese (simplified), Japanese |
| Type | Simulation software |
| License | Proprietary |
| Website | www.flexsim.com |
FlexSim is a discrete-event simulation software package developed by FlexSim Software Products, Inc. The FlexSim product family currently includes the general purpose FlexSim product and healthcare systems modeling environment (FlexSim HC).
History
[edit]FlexSim development began in late-2001 as an unnamed development project of F&H Simulations, Inc., a U.S. distributor of F&H Holland's Taylor II and Taylor ED products. Development was initially led by Dr. Eamonn Lavery, with lead developer Anthony Johnson joining in April 2002. Before the end of 2002, the development project was renamed FlexSim, which coincided with F&H Simulations, Inc. changing its name to FlexSim Software Products, Inc.[1] FlexSim was acquired by Autodesk, Inc. in 2023.[2]
FlexSim 1.0 was released in February 2003. FlexSim used a major.minor.build software versioning scheme until version 7.7.4; beginning with version 16.0.0 on March 14, 2016, FlexSim transitioned to a year.update.bugfix versioning scheme.[3]
| Version | Release date | Notable Features |
|---|---|---|
| 1.0 | February 2003 | Initial Release |
| 2.0 | May 21, 2003 | Task Sequences |
| 3.0 | February 2, 2005 | OptQuest integration, User Libraries |
| 4.0 | March 7, 2007 | Fluid Library, FlexScript Model Logic (no need to compile C++) |
| 4.5 | January 9, 2009 | FlexScript Bytecode |
| 6.0 | March 23, 2012 | Multi-core Experimenter, FlexSim Web Server |
| 7.0 | October 14, 2013 | Module SDK, 64-bit, Stereoscopic 3D |
| 7.1 | March 10, 2014 | AGV and A* Modules |
| 7.5 | January 28, 2015 | Conveyor Module |
| 7.7 | November 23, 2015 | Process Flow Module, Virtual Reality |
| 17.0 | December 12, 2016 | FlexScript Machine Code |
| 18.0 | December 15, 2017 | People Module |
| 18.2 | August 8, 2018 | Cloud-based Experimentation/Optimization |
| 19.0 | January 4, 2019 | JT files import, bone direct animation |
| 19.2 | September 5, 2019 | RTX mode for real-time ray tracing |
| 20.1 | April 10, 2020 | HTTP FlexScript API |
| 20.2 | August 11, 2020 | Agent Module |
| 21.0 | December 4, 2020 | JSON FlexScript API, Chromium Embedded Framework |
| 21.2 | August 9, 2021 | GIS Module, object templating system |
| 22.0 | December 6, 2021 | Reinforcement learning tool |
| 22.1 | April 4, 2022 | Python connector |
| 23.2 | August 7, 2023 | Omniverse connector [5] |
Usage
[edit]Manufacturing
[edit]FlexSim has been used in a variety of simulation projects involving both standard and flexible manufacturing systems.[6] Some examples include studies to determine optimal buffer sizes,[citation needed] optimizing blend components in feed production,[7] rescheduling problems in mixed-line production planning,[8] optimizing electronics assembly lines,[9] and steel production scheduling.[10]
Industry 4.0
[edit]FlexSim has been used to automate simulation model development for more than a decade; a 2008 study described a FlexSim-based solution that communicates with Product Lifecycle Management (PLM) software to generate simulation models.[11] With the ongoing trend of Industry 4.0 pushing manufacturers toward automation and improved communication, FlexSim has been used to develop computer simulation models for these applications.[12]
FlexSim can be extended through C++, which allows the software to be integrated into systems involving real-time data communication.[13] The software has been used for nearly real-time production planning, which improves upon the Master Schedule approach (which can get out of date and miss on-site changes).[14] In one study, FlexSim was integrated into a dynamic data-driven application system to automatically generate simulation models via the XML language.[15]
Robotics and Crane
[edit]FlexSim's standard object library contains a 6-axis robot object capable that contains both pre-built motion logic and the ability to create customized motion paths.[16] FlexSim has been used to model and analyze robotic cells in manufacturing environments, including dynamic scheduling and control of a robotic assembly cell.[17]
The standard object library also contains a crane object, "designed to simulate rail-guided cranes such as gantry, overhead, or jib cranes."[18] FlexSim, through the use of the crane object, has been used to evaluate solutions to crane scheduling in a shipbuilding environment.[19]
Healthcare
[edit]In April 2009, FlexSim Software Products, Inc. released a standalone healthcare simulation product named FlexSim HC. It was developed as simulation package focused on modeling patient flows and other healthcare processes.[20] The final release in original FlexSim HC development path was version 5.3.10 on February 19, 2019; beginning with FlexSim version 19.1.0 on April 29, 2019, FlexSim HC functionality was merged into the core FlexSim development and became a modeling environment within the software.[21]
In practice, the FlexSim HC environment is used by healthcare organizations to evaluate different scenarios in their healthcare processes and validate the scenarios before they are implemented.[22] The environment has been used in various patient care improvement initiatives, including studies to understand different treatment options in Labor & Delivery,[23] deploying advanced practice nurses in treating non-urgent patients,[24] and demonstrating simulation-based design of a breast-screening facility as both a process improvement tool and as a management training tool.[25]
During the COVID-19 pandemic, FlexSim HC was used to analyze vaccination rollout efforts and improve patient flow at vaccination sites.[26] Outside of the traditional healthcare setting, FlexSim has been used to dynamically calculate and visualize radiation exposure.[27]
Academia
[edit]FlexSim has been used extensively in academic research and conference proceedings worldwide. A refereed journal article from 1991 describes a simulation tool for manufacturing systems named FLEXSIM,[28] and refers also to the corresponding doctoral dissertation.[29] The software package is usually taught as part of an industrial engineering or systems engineering curriculum, often in a Systems Simulation course; however, FlexSim has also been introduced as part of undergraduate or graduate coursework in manufacturing engineering, operations research, business management, health systems engineering, and nursing.[citation needed]
Other
[edit]As general purpose simulation software, FlexSim is used in a number of fields:
- Material handling: Conveyor systems, AGV, packaging, warehousing
- Logistics and distribution:[30] Container terminal operation, supply chain design, distribution center work flow, service and storage layout, etc.
- Transportation:[31] Highway system traffic flow, transit station pedestrian flow, maritime vessel coordination, custom traffic congestion, etc.
- Others: Oil field or mining processes, networking data flow,[32] etc.
Main features
[edit]Robust standard objects
[edit]FlexSim includes a standard object library, with each object containing pre-built logic and task execution to mimic the resources found in real-world operations. FlexSim objects[33] are defined and programmed in four classes: fixed resource class, task executer class, node class and visual object class. FlexSim uses an object-oriented design.
Logic building tools
[edit]The logic for a FlexSim model can be built using very little or no computer code. Most standard objects contain an array of drop-down lists, properties windows, and triggers that allow the user to customize the logic required for an accurate model of the system. FlexSim also includes a flowcharting tool to create the logic for a model using pre-built activity blocks.
Drag-and-drop controls
[edit]Users can build the model by dragging and dropping predefined 3D objects into a "model view" to layout and link the model. Experienced users also have the option to specify and modify object parameters and behaviors using FlexScript and C++ programming languages.[34]
See also
[edit]References
[edit]- ^ "About Us - FlexSim". FlexSim. Retrieved 2021-01-22.
- ^ Stephen Hooper. "Autodesk signs definitive agreement to acquire FlexSim". Autodesk News. Retrieved 2024-08-26.
- ^ "FlexSim Version Numbering - FlexSim Community". FlexSim Answers. 7 December 2018. Retrieved 2021-01-22.
- ^ "Release Notes and History". FlexSim Documentation. Retrieved 2021-01-22.
- ^ "FlexSim 2023 Update 2: NVIDIA Omniverse, USD, Restricted Models, and more". FlexSim. 7 August 2023. Retrieved 2023-08-21.
- ^ Tikasz, Laszlo G.; McCulloch, Robert I.; Pentiah, Scheale Duvah; Baxter, Robert F. (2012). "Simulation Tools to Complement Cast House Design and Daily Operation". Light Metals 2012. pp. 993–997. doi:10.1007/978-3-319-48179-1_173. ISBN 978-3-319-48570-6.
- ^ Kaczmar, Ireneusz (2015). "Cost optimization of blend preparation with the use of the FlexSim environment". Agricultural Engineering. 4 (156): 51–60. doi:10.14654/ir.2015.156.151. ISSN 2083-1587.
- ^ Huang, Hsiang-Hsi; Pei, Wen; Wu, Horng-Huei; May, Ming-Der (2013). "A research on problems of mixed-line production and the re-scheduling". Robotics and Computer-Integrated Manufacturing. 29 (3): 64–72. doi:10.1016/j.rcim.2012.04.014. ISSN 0736-5845.
- ^ Gebus, Sébastien; Martin, Olivier; Soulas, Alexandre; Juuso, Esko (2004-09-21). "Production optimization on PCB assembly lines using discrete-event simulation". Control Engineering Laboratory. Report A. Vol. 24. University of Oulu. ISBN 951-42-7372-9.
- ^ Yao, Liufang; Zhu, Weifeng (2010). Visual simulation framework of iron and steel production scheduling based on Flexsim. 2010 IEEE Fifth International Conference on Bio-Inspired Computing: Theories and Applications (BIC-TA). Changsha: IEEE. pp. 54–58. doi:10.1109/BICTA.2010.5645359.
- ^ Burnett, Gabriel A.; Medeiros, D. J.; Finke, Daniel A.; Traband, Mark T. (2008). "Automating the development of Shipyard manufacturing models". 2008 Winter Simulation Conference. pp. 1761–1767. doi:10.1109/WSC.2008.4736264. ISBN 978-1-4244-2707-9. S2CID 3107244.
- ^ Luściński, Sławomir; Ivanov, Vitalii (September 2020). "A Simulation Study of Industry 4.0 Factories Based on the Ontology on Flexibility with using FlexSim Software". Management and Production Engineering Review. 11 (3): 74–83. doi:10.24425/mper.2020.134934.
- ^ Fan, Shu-hai; Zhou, Zhi; Shen, Qian (2009). "A Virtual MCQA Information System Based on Flexsim". 2009 Second International Symposium on Knowledge Acquisition and Modeling. pp. 111–113. doi:10.1109/KAM.2009.50. ISBN 978-0-7695-3888-4. S2CID 9348862.
- ^ Dallasega, Patrick; Rojas, Rafael A.; Rauch, Erwin; Matt, Dominik T. (2017). "Simulation Based Validation of Supply Chain Effects through ICT enabled Real-time-capability in ETO Production Planning". Procedia Manufacturing. 11: 846–853. doi:10.1016/j.promfg.2017.07.187. ISSN 2351-9789. S2CID 51933201.
- ^ Krenczyk, Damian (2012). "Data-driven modelling and simulation for integration of production planning and simulation systems". Selected Engineering Problems (3): 119–122. Retrieved 2021-01-22.
- ^ "Robot". FlexSim Documentation. Retrieved 2021-01-22.
- ^ Mihoubi, B; Gaham, M; Bouzouia, B; Bekrar, A (2015). "A rule-based harmony search simulation-optimization approach for intelligent control of a robotic assembly cell". 2015 3rd International Conference on Control, Engineering & Information Technology (CEIT). pp. 1–6. doi:10.1109/CEIT.2015.7233172. ISBN 978-1-4799-8212-7. S2CID 16851230.
- ^ "Crane". FlexSim Documentation. Retrieved 2021-01-22.
- ^ Wen, Charlie; Ekşioğlu, Sandra Duni; Greenwood, Allen; Zhang, Shu (2010). "Crane scheduling in a shipbuilding environment". International Journal of Production Economics. 124 (1): 40–50. doi:10.1016/j.ijpe.2009.09.006. ISSN 0925-5273.
- ^ "FlexSim HC version 1.0 has been released - FlexSim Community". FlexSim Community Archive. Retrieved 2021-01-22.
- ^ "Release Notes and History (19.1)". FlexSim Documentation. Retrieved 2021-01-22.
- ^ Wolford, Ben (2018-04-18). "Computer Simulation Can Improve Patient Flow". Birmingham Medical News. Retrieved 2021-01-22.
- ^ Thomas, James; Giannakopoulos, Allen J. (2014). "Employing Modeling and Simulation to Improve Patient Care" (PDF). I/Itsec. 2014. S2CID 204845029.
- ^ Abdulkadir, Atalan; Donmez, C.C. (2019). "Employment of Emergency Advanced Nurses of Turkey: A Discrete-Event Simulation Application". Processes. 7 (1): 48. doi:10.3390/pr7010048. hdl:11424/242752.
- ^ Macleod, Kenny; Moody, Robert (March 14, 2017). "Chapter 31: Simulation modelling and analysis to test health systems". In Nestel, Debra; Kelly, Michelle; Jolly, Brian; Watson, Marcus (eds.). Healthcare Simulation Education: Evidence, Theory and Practice. John Wiley & Sons. pp. 209–213. doi:10.1002/9781119061656. ISBN 978-1-119-06159-5.
- ^ Windsor, Matt (2021-03-04). "Simulations help vaccine rollout and cut the wait in UAB clinics". UAB Reporter. The University of Alabama at Birmingham. Retrieved 2021-03-04.
- ^ Tompkins, G.H.; Kornreich, D.E.; Parker, R.Y.; Koehler, A.C.; Gonzales-Lujan, J.M.; Burnside, R.J. (2004). "Dynamic Radiation Dose Visualization in Discrete-Event Nuclear Facility Simulation Models". Proceedings of the 2004 Winter Simulation Conference, 2004. Vol. 2. pp. 472–478. doi:10.1109/WSC.2004.1371496. ISBN 0-7803-8786-4. S2CID 9961278.
- ^ Gelenbe, Erol; Guennouni, Hatim (1991), "FLEXSIM: A flexible manufacturing system simulator", European Journal of Operational Research, 53 (2): 149–165, doi:10.1016/0377-2217(91)90131-E
- ^ FLEXSIM : UN SIMULATEUR D'ATELIERS FLEXIBLES INTERFACE A UN SYSTEME DE GESTION DE BASE DE DONNEE RELATIONNELLE / HATIM GUENNOUNI ; SOUS LA DIRECTION DE EROL GELENBE (Thèse; version d'origine)
- ^ Liu, Miaomiao; Dong, Mingwang (2008). "The Simulation Technology of Port Container Logistics System Based on Flexsim". Logistics. pp. 2547–2552. doi:10.1061/40996(330)376. ISBN 9780784409961.
- ^ Wang Weiping, Zhao Wen, Zhu Yifan and Hua Xueqian, "Survey on the Object oriented Simulation Method", Journal of National University of Defense Technology, 1999-01.
- ^ Pierre G. Paulin, Faraydon Karim and Paul Bromley, "Network Processors: A Perspective on Market Requirements, Processor Architectures and Embedded S/W Tools", Design, Automation and Test in Europe Conference and Exhibition, p. 0420, 2001.
- ^ Garrido, Joés M. (2009). Object Oriented Simulation. Springer. ISBN 978-1-4419-0515-4.
- ^ William B. Nordgren. "Flexible simulation (Flexsim) software: Flexsim simulation environment", Proceedings of the 35th conference on Winter simulation: driving innovation, 2003.
Further reading
[edit]- Beaverstock, Malcolm; Greenwood, Allen; Nordgren, William (2017). Applied Simulation: Modeling and Analysis Using FlexSim (5th ed.). Orem, UT: FlexSim Software Products, Inc. ISBN 978-0-9832319-5-0.
- Pawlewski, Pawel; Greenwood, Allen, eds. (2014). Process Simulation and Optimization in Sustainable Logistics and Manufacturing. Springer. ISBN 978-3-319-07347-7.
- Qin, Tianbao (2013). Zhou, Xiangyang (ed.). 实用系统仿真建模与分析—使用Flexsim [Practical System Simulation Modeling and Analysis with Flexsim] (in Chinese). Beijing, China: Tsinghua University Press. ISBN 978-7-302-31322-9.
- Kim, Jun Woo (2019). 3D 팩토리 시뮬레이션을 이용한 생산 시스템 모델링 Handbook (FlexSim 소프트웨어 활용법 - 입문편) [Handbook of Production System Modeling using 3D Factory Simulation (FlexSim Software for Beginners)] (in Korean). Seoul, South Korea: Chungsol. ISBN 978-89-94364-67-4.
- Law, Averill M. (2006). Simulation Modeling and Analysis (4th ed.). McGraw-Hill Science. ISBN 978-0-07-329441-4.
External links
[edit]FlexSim
View on Grokipediafrom Grokipedia
FlexSim is a powerful 3D simulation modeling software package developed by FlexSim Software Products, Inc., a subsidiary of Autodesk, Inc., designed for discrete event simulation to model, analyze, visualize, and optimize complex systems in industries including manufacturing, material handling, healthcare, warehousing, logistics, and mining.[1] It enables users to simulate real-world processes, predict outcomes, test resource allocation, reduce wait times, and improve efficiency before physical implementation, thereby minimizing costs and risks.[2]
FlexSim Software Products, Inc. was founded in 1993 in Orem, Utah, originally as F&H Simulations, Inc., by engineers Bill Nordgren, Roger Hullinger, and Cliff King, with a focus on advancing simulation technology for industrial applications.[3] The company rebranded to FlexSim Software Products, Inc. in 2000 and released the first version of FlexSim in February 2003, establishing it as an industry standard for object-oriented, 3D discrete event simulation.[3] It was acquired by Autodesk in 2023.[4]
Key features of FlexSim include an intuitive drag-and-drop interface for building models, advanced 3D visualization for realistic process representation, and seamless integration with programming languages such as C++ for custom logic and experimentation.[5] Widely adopted by Fortune 500 companies, it supports applications like optimizing product flow, staffing, and floor plans, as well as enhancing communication through interactive simulations for training and decision-making.[3]
Overview
Description and Purpose
FlexSim is a 3D discrete-event simulation software package designed for modeling, analyzing, and visualizing complex systems in production, logistics, and service environments through immersive virtual representations.[5] Developed to emulate real-world processes with high fidelity, it enables users to replicate dynamic flows, resource interactions, and variability using statistical distributions and realistic 3D graphics.[5] The primary purposes of FlexSim include optimizing system throughput, pinpointing operational bottlenecks, and evaluating hypothetical scenarios to inform decision-making without the costs or risks of physical alterations.[5] By simulating "what-if" conditions, it supports process improvements in industries requiring precise analysis, such as material handling and supply chains.[6] FlexSim emphasizes a user-friendly interface that integrates intuitive drag-and-drop controls for rapid model assembly with advanced scripting options, including FlexScript—a C-like language—for customization by engineers and analysts.[5] This balance facilitates both quick prototyping and sophisticated extensions, such as integrating external data or algorithms. The software's development marked an evolution from traditional 2D simulation tools to fully immersive 3D environments beginning in the early 2000s, enhancing visualization and validation of models.[3] FlexSim finds applications in sectors like manufacturing and healthcare for testing process efficiencies.[1]Editions and Accessibility
FlexSim offers three primary editions to cater to different user needs and industries. The general-purpose FlexSim edition serves as the flagship software for modeling, simulating, and analyzing complex systems across sectors like manufacturing, logistics, and warehousing, providing comprehensive 3D visualization and optimization tools.[5] The FlexSim Healthcare Edition (HC) is specifically designed for healthcare environments, focusing on patient flow simulation through drag-and-drop process flow builders and resource allocation analysis, including staff scheduling and utilization dashboards to address challenges in hospitals and clinics.[7] FlexSim Express functions as a free, limited version ideal for initial testing, education, and model viewing, restricted to 30 objects and 35 process flow activities with no commercial modeling capabilities.[8] Licensing for FlexSim includes flexible options to support various users. Perpetual licenses were historically available, but following Autodesk's acquisition of FlexSim in November 2023, the primary model shifted to annual subscriptions, with node-locked enterprise licenses sold through Autodesk accounts for bundled access and easier management.[4][9] Academic discounts and free student licenses are provided for educational purposes, allowing up to 100 objects in student mode or unlimited in educational mode, upon registration via a FlexSim account.[10] Free 14-day trials are offered to evaluate full features without commitment.[11] Accessibility is enhanced through broad compatibility and user-friendly options. FlexSim supports 64-bit Windows operating systems under current Microsoft extended support (as of 2025, including Windows 11), with minimum requirements of a modern 64-bit x64 Intel or AMD processor (within the last 5 years), 16 GB RAM, and a graphics card supporting OpenGL 3.1 or higher, such as NVIDIA GeForce or AMD Radeon series.[12] Cloud-based experimentation is available via distributed computing, enabling users to run simulations and optimizations remotely using FlexSim's Experimenter tool on cloud providers for scalable processing without high local hardware demands.[13] The user base primarily consists of industrial engineers optimizing production and logistics, but the software's free academic licensing makes it accessible to students and educators for teaching simulation concepts and research projects.[14]History and Development
Founding and Early Development
FlexSim Software Products, Inc. traces its origins to 1993, when it was established in Orem, Utah, by Bill Nordgren, Roger Hullinger, and Cliff King under the name F&H Simulations, Inc.[3][15] Nordgren, a co-founder of ProModel Corporation in 1988, contributed significant expertise in discrete event simulation software, which informed the company's early direction.[3] In its initial years, F&H Simulations operated primarily as a distributor, providing sales, support, and training for Taylor II, a simulation product developed by F&H Holland. By 1998, the company collaborated with F&H Holland on the creation of Taylor ED (Enterprise Dynamics), recognized as the first-generation 3D object-oriented engine for discrete event simulation, emphasizing flexible modeling of dynamic systems like manufacturing and logistics processes.[3] This partnership highlighted the founders' focus on advancing simulation tools beyond traditional 2D representations toward more intuitive, hierarchical object-based designs.[3] The company gained independence in 2000 after F&H Holland's acquisition by another entity, prompting a rebranding to FlexSim Software Products, Inc. That same year, Dr. Eamonn Lavery and Anthony Johnson joined to spearhead software development. FlexSim's core product emerged from an internal project launched in late 2001, leading to the release of version 1.0 in February 2003. This debut version delivered a robust discrete event simulation engine integrated with 3D visualization and C++ scripting capabilities, alongside a foundational library of standard objects optimized for manufacturing simulations.[3]Key Milestones and Acquisitions
FlexSim's versioning scheme evolved significantly over time. Prior to 2016, the software followed a major.minor.build format, with version 7.7.4 released in 2016, introducing enhanced visual realism through features like bone-based animations and the Process Flow tool for logic building.[16][17][18] Beginning with version 16.0.0 in 2016, FlexSim adopted a year-based numbering system aligned with its release year, facilitating clearer tracking of annual updates; this continues to the present, with FlexSim 26.0.0 released in 2025.[17][19] Key technical advancements marked FlexSim's development. Version 2.0, released in 2003, introduced foundational 3D animation capabilities, enabling dynamic visualization of simulation processes. The OptQuest optimization engine was integrated in version 3.0 in 2005, allowing users to automate scenario testing and identify optimal model parameters through advanced algorithms. In 2016, version 7.1 added the AGV module, providing specialized tools for simulating automated guided vehicle systems in material handling environments.[20] Corporate growth included the launch of the FlexSim Healthcare edition in 2009, tailored for modeling patient flows and resource allocation in medical settings. A pivotal corporate milestone occurred in November 2023, when Autodesk completed its acquisition of FlexSim Software Products, Inc., integrating the simulation platform into Autodesk's ecosystem for enhanced factory design workflows.[21] This acquisition enabled seamless interoperability with Autodesk's Factory Design Utilities, supporting advanced digital twin creation and Industry 4.0 applications such as real-time operational analysis.[4] Post-acquisition developments in FlexSim 2025, released on December 11, 2024, included new Container objects for modular modeling, Task Sequence Queues for improved task management, and USD export functionality to boost compatibility with broader 3D pipelines.[22][23] FlexSim 26.0.0, released in 2025, introduced Submodels for reusable model components, Japanese language support, and enhanced Box Plot options in dashboards.[19]Applications
Manufacturing and Logistics
FlexSim is widely applied in manufacturing to simulate production lines, including assembly processes and material flow, enabling engineers to identify bottlenecks and optimize layouts before physical implementation. In logistics, it models warehouse operations and distribution networks, facilitating the analysis of inventory management and transportation efficiency to minimize costs and delays. These simulations support the evaluation of system performance under varying conditions, such as demand fluctuations, by replicating real-world dynamics in a virtual environment.[6] Key applications include the modeling of material handling equipment like conveyors, automated guided vehicles (AGVs), and cranes, which are essential for streamlining logistics in factories and warehouses. For instance, FlexSim's AGV module allows for the simulation of fleet routing and task allocation, optimizing paths to reduce travel times and congestion. Additionally, the software integrates with Industry 4.0 concepts, such as digital twins, to create virtual replicas of smart factories that incorporate real-time data from sensors for predictive maintenance and process refinement. In mining, FlexSim simulates haulage systems, truck fleet management, and ore processing operations, as seen in partnerships for open-pit mine optimizations and studies of underground copper ore handling to improve equipment utilization and reduce operational delays.[6][24][25][26][27] In automotive manufacturing, FlexSim has been used to simulate assembly lines and inbound logistics, as demonstrated in a case study of a car coating and assembly process where production time was reduced from 73.38 hours to 35 hours through optimized workflows and machine utilization. Another example involves e-commerce fulfillment centers, where simulations help manage peak demands; a cosmetics distribution center project utilized FlexSim to balance order sequencing, staffing, and system capacity, resulting in improved operator utilization rates and workload distribution across zones.[28][29] These applications deliver measurable benefits, including reduced cycle times and inventory costs by up to 50% in optimized scenarios, alongside enhanced throughput. For example, in a material handling improvement for a warehousing operation, FlexSim modeling increased pallet throughput from 70 to 100 items per hour—a 43% gain—by alleviating conveyor congestion without additional hardware. In global manufacturing, simulations supported the consolidation of production sites from six to five facilities, enabling better volume pooling and cost-effective imports while maintaining delivery timelines for 600,000 annual orders. Such outcomes quantify return on investment (ROI) through metrics like throughput (items per hour) and equipment utilization rates, often exceeding 80% in refined models, allowing companies to justify expansions or redesigns with data-driven confidence.[6][30][31]Healthcare and Services
FlexSim is widely applied in healthcare to simulate patient flows, optimize hospital operations, and enhance resource allocation through discrete event simulation. Primary uses include modeling emergency departments (EDs) to analyze triage processes, patient routing, and wait times; simulating operating rooms (ORs) for scheduling surgeries and equipment utilization; and developing staffing schedules to balance nurse and physician workloads against fluctuating patient volumes. These simulations enable healthcare providers to test scenarios that minimize bottlenecks, such as overcrowding during peak hours, without disrupting real operations.[32] The FlexSim Healthcare edition features a specialized library of built-in objects tailored for medical environments, including beds for inpatient tracking, staff resources for shift modeling, and patient entities that represent diverse acuity levels and treatment paths. This edition supports the creation of detailed process flows using an internal flowcharting tool, allowing users to define treatment tracks, resource constraints, and stochastic elements like arrival variability. While direct compliance with standards like HL7 is not explicitly documented in core product materials, the software facilitates data import from healthcare systems to populate models with real-world inputs such as patient demographics and historical volumes.[33][7] Beyond hospitals, FlexSim extends to service industries involving human-centric queuing and dispatching, such as airports where it models passenger flows through security checkpoints and boarding gates to reduce congestion and improve throughput. In call centers and similar customer service operations, the software's People Module simulates resource dispatching, agent allocation, and queue management to handle variable call volumes and optimize response times. These applications leverage FlexSim's 3D visualization to depict dynamic interactions, providing insights into layout adjustments and policy changes.[34][35] Evidence-based outcomes from FlexSim simulations have demonstrated significant improvements in healthcare efficiency. For instance, Baptist Health South Florida used FlexSim to model ED processes, resulting in a 46% reduction in door-to-provider time through rapid evaluation protocols and a 27% decrease in length of stay for lower-acuity patients via a dedicated rapid care unit. Similarly, MD Anderson Cancer Center applied the software to optimize clinical space allocation between facilities, saving two full clinical spaces while maintaining capacity for patient care. These results underscore FlexSim's role in enabling data-driven planning that reduces operational strain and enhances patient satisfaction across healthcare settings.[36][37]Academic and Research Use
FlexSim has been widely adopted in educational settings through its free academic licensing program, which provides universities with no-cost access to the software for teaching and learning purposes. This initiative enables integration into curricula across disciplines such as operations research, industrial engineering, and supply chain management, where students use FlexSim to build and analyze discrete-event simulation models of real-world systems.[14][38] For instance, institutions like Politecnico di Torino have incorporated FlexSim into classroom instruction for departments focused on management and production systems, supported by academic licenses valued at significant amounts to facilitate hands-on learning.[39] In research applications, FlexSim supports the modeling of complex systems, particularly in optimization studies, through tools like the Experimenter, which automates scenario testing and result collection to evaluate performance under varying conditions. Researchers frequently publish simulation outcomes derived from FlexSim in prominent venues, including proceedings from the Winter Simulation Conference, where the software has been highlighted for its object-oriented environment in simulating manufacturing, warehousing, and material handling processes.[40][41] Additionally, FlexSim is commonly employed in graduate theses for scenario analysis, allowing detailed what-if explorations to inform decision-making in industrial contexts without the need for physical prototypes.[42][43] FlexSim's academic toolkit includes built-in tutorials, pre-built example models, and FlexScript—a C++-like scripting language—for developing custom experiments tailored to pedagogical or investigative needs. These resources facilitate self-paced learning and advanced customization, such as integrating process flows with 3D visualizations to demonstrate system dynamics.[44][45] The academic version provides full features without limitations on model size or advanced capabilities, as detailed in FlexSim's licensing documentation.[46] With adoption at over 400 universities worldwide, FlexSim has cultivated a robust academic community that drives innovations, including post-2020 advancements in AI-integrated simulations, such as reinforcement learning for demand forecasting and digital twin applications in smart warehouses.[38][47][48] This widespread use has resulted in hundreds of citations in peer-reviewed papers, underscoring FlexSim's role in advancing simulation-based research across engineering and logistics fields.[38]Core Features
Modeling Objects and Environment
FlexSim provides a comprehensive library of pre-built 3D objects designed to model the physical components of discrete event systems, enabling users to simulate entity flows in manufacturing, logistics, and other environments. The standard object library includes fixed resources such as processors for performing operations on flow items, queues for buffering entities with configurable release strategies like first-in-first-out, and combiners for assembling multiple items into a single unit.[49] These objects support essential properties including processing speeds, capacities, and failure modes to replicate real-world variability and downtime. Additionally, the library features material handling objects like conveyors for linear transport, automated guided vehicles (AGVs) for flexible navigation, and cranes for overhead movement, all tailored to handle entity flows efficiently.[50][51][52] The 3D environment in FlexSim facilitates immersive scene creation, where users can build and visualize models using a drag-and-drop interface for placing objects. Navigation within the environment incorporates A* pathfinding algorithms, particularly for AGV networks, to optimize routes and avoid collisions dynamically.[53] Lighting options allow for realistic illumination through adjustable light sources, enhancing model presentation and analysis.[54] Camera controls provide tools for orbiting, panning, and resetting views, supporting detailed inspection and flypath creation for demonstrations.[55][56] Object interactions in FlexSim are primarily event-driven, triggering behaviors based on simulation events such as arrivals or completions. Task executers, including AGVs and cranes, manage these interactions by receiving task sequences and executing movements or operations on flow items.[57] Flow assignment occurs through send-to-port logic, where upstream objects direct entities to specific downstream ports based on availability or custom criteria, ensuring logical progression without manual intervention.[58] In the 2025 release, FlexSim introduced the Container object to support modular sub-models, allowing users to encapsulate and reuse complex assemblies as single entities for streamlined model building.[22] Additionally, dynamic load types for AGVs enable runtime adjustments to travel speeds based on cargo characteristics, improving simulation accuracy for variable payloads.[23]Logic Building and Controls
In FlexSim, logic building begins with drag-and-drop controls accessible through the Quick Properties panels, which allow users to configure object behaviors without extensive coding. These panels enable the assignment of states, such as "Processing" or "Idle," to define operational modes for 3D objects like processors or queues. Triggers, such as OnEntry and OnExit, can be set to execute predefined actions when flow items enter or leave an object; for instance, OnEntry might increment a counter label on the entering item to track its progress through the system. Labels, which store dynamic data like priority values or timestamps, are similarly assigned via these panels to facilitate decision-making and data passing between objects.[59] For more complex process flows, FlexSim's Process Flow module provides a visual flowchart interface where users drag and drop activity blocks to construct logic sequences. The Decide activity, for example, routes tokens based on conditions like label values, probabilities, or queue states, enabling branching logic such as directing high-priority items to a dedicated path while others follow a standard route. The Assign Labels activity modifies or creates labels on tokens or 3D objects, supporting data manipulation for subsequent decisions, such as updating a flow item's processing time based on its type. Similarly, the Release Resource activity frees up acquired resources, like operators or machines, after task completion, ensuring they become available for new assignments and maintaining efficient resource allocation in the model. This block-based approach allows for intuitive construction of multi-step processes, such as patient routing in healthcare simulations, without writing code.[60][61][62][63] Event logic in FlexSim operates on a discrete-event simulation paradigm, where the model advances time to the next scheduled event, such as an arrival or state change, rather than continuous time steps. This supports multimethod modeling by integrating discrete events with agent-based or continuous flows, allowing state changes—like shifting a resource from available to busy—to trigger subsequent actions across the system. Users define these events through triggers and process flows, ensuring precise control over timing and interactions, such as scheduling maintenance downtimes that halt processing until resolved.[45][64] Variability in model behaviors is incorporated via built-in statistical distributions directly within object setups and process flow activities, modeling real-world uncertainties like arrival patterns or service times. For instance, the Inter-Arrival Source activity in Process Flow uses distributions such as the exponential distribution to generate tokens at random intervals, simulating Poisson arrivals in queuing systems; parameters like mean arrival rate are set through a user-friendly interface, with the software handling random number generation internally. This integration ensures stochastic elements, such as variable processing delays, are seamlessly embedded into triggers or delays without manual scripting. For advanced customizations beyond these tools, FlexSim supports FlexScript coding.[65][66]Analysis and Visualization Tools
FlexSim provides robust built-in tools for analyzing simulation results and visualizing data, enabling users to evaluate model performance, test scenarios, and derive insights from stochastic simulations. The Experimenter tool automates the execution of multiple simulation runs by defining scenarios with varying parameters, such as resource capacities or arrival rates, and replicating each scenario a specified number of times to account for randomness.[67] It incorporates a warm-up period to discard initial transient behavior, ensuring steady-state statistics are captured accurately.[67] For outputs like average wait time, the tool computes confidence intervals based on the mean of sampled data across replications, adjusted by the standard error to quantify uncertainty.[67] Dashboards in FlexSim serve as customizable interfaces for real-time visualization of simulation data, integrating seamlessly with the 3D model environment to display updates as the simulation progresses.[68] Users can add various chart types from a library of templates, including histograms to show distributions of metrics like processing times, bar charts for comparing object utilizations (calculated as active time divided by total simulation time), and time plots for tracking evolving statistics over the run duration.[68] These visualizations support both basic manual connections to data sources and automated templates that generate underlying collectors for common metrics, facilitating quick setup for performance analysis.[68] The OptQuest optimizer, integrated directly into FlexSim, employs a hybrid optimization approach, including scatter search and tabu search, to search for optimal parameter combinations that maximize or minimize defined objectives, such as minimizing total cost or maximizing throughput.[69][70] Users specify decision variables, constraints, and multiple objectives, allowing the tool to explore trade-offs efficiently without exhaustive enumeration.[69] It supports sensitivity analysis through export to Excel, where users can further examine how changes in inputs affect outputs.[69] Statistics collection in FlexSim is handled primarily through the Statistics Collector, which tracks user-defined events and variables during simulation runs, such as entity entry and exit times to compute throughput as entities processed per unit of run time.[71] The collected data populates tables that can be queried, transformed via calculated tables, and exported in formats like CSV for integration with databases or external analysis tools.[71] This approach ensures raw data is preserved for detailed post-processing while enabling on-the-fly monitoring of key performance indicators.[71]Integration and Extensions
Software and Data Integrations
Following Autodesk's acquisition of FlexSim in November 2023, the software has gained enhanced interoperability with the Autodesk ecosystem, enabling seamless CAD-to-simulation workflows. This includes direct import and export capabilities with Autodesk Inventor and Factory Design Utilities (FDU), allowing users to transition factory layouts designed in these tools into dynamic FlexSim models for process simulation and analysis. As of 2025, integrations have expanded to include AutoCAD and Revit, further bridging design and simulation tools.[4][72][73][74] For instance, layouts created in Inventor or AutoCAD via FDU can be imported into FlexSim, where object positions, connections, and attributes are synchronized to support iterative design and optimization without manual reconfiguration.[75] FlexSim supports robust data integrations for importing parameters and exporting results, facilitating integration with external data sources in simulation workflows. The Excel Interface provides tools for bidirectional input/output of data across multiple worksheets and workbooks, enabling users to populate global tables with scenario parameters or output simulation statistics for further analysis.[76] Additionally, SQL database connectivity via the Database Connectors tool uses the SQLAPI++ library to pull real-time data from sources like Microsoft SQL Server, supporting dynamic model updates during runtime.[77] For enterprise resource planning (ERP) systems such as SAP, FlexSim enables indirect integration by exporting data from SAP into Excel or accessible databases, which can then be imported into models for scenario testing.[78] In terms of file formats, FlexSim incorporates support for Universal Scene Description (USD) to enhance export capabilities, particularly in collaborative and immersive environments. Introduced in FlexSim 2023 Update 2, USD export allows FlexSim models to be shared in a standardized format compatible with NVIDIA Omniverse, enabling real-time bidirectional editing and visualization for applications like AR/VR factory planning. Enhancements in FlexSim 2025 Update 1 include improved property exports to USD.[79][80] FlexSim's native use of XML for model, library, and tree files also promotes extensibility, though direct interoperability with other simulation tools like Arena or AnyLogic requires custom XML parsing rather than built-in converters.[81] For industry-specific integrations, FlexSim includes protocols tailored to sector needs, such as OPC UA for IoT-enabled manufacturing simulations. The Emulation module supports OPC UA connections to external PLCs or servers, allowing real-time data exchange for virtual commissioning and control of industrial processes like automated material handling.[82] This feature, available since FlexSim 2020, enables simulations to mirror live IoT data streams from manufacturing equipment, improving accuracy in predictive modeling.[83]Customization and Advanced Development
FlexSim offers advanced customization through its FlexScript programming language, which enables users to create tailored logic and functions beyond the standard graphical interface. FlexScript features a C++-like syntax, including case-sensitive keywords, semicolons to terminate statements, curly braces for code blocks, and support for control structures such as if-else, while, for, and switch statements.[84] For instance, users can define custom user commands as functions likedouble myFunction(double param) { return param * 2; }, allowing for reusable code in triggers, distributions, or model events to implement specific behaviors such as conditional processing or data manipulations.[84]
For performance-intensive tasks, FlexSim supports integration with external dynamic link libraries (DLLs) written in C or C++, facilitating the incorporation of optimized algorithms without embedding them directly in FlexScript. This approach is particularly useful for computations like custom pathfinding or complex mathematical solvers, where native C++ efficiency outperforms interpreted scripting.[85] To implement this, users compile a DLL using Visual Studio with FlexSim's provided project template, ensuring functions follow a specific signature such as visible double function_name(FLEXSIMINTERFACE), and then reference the DLL in FlexSim code via formats like "mydll.dll" "function_id". The DLL is placed in the model directory, and FlexSim handles type conversions between its tree-based data structures and C++ parameters, enabling seamless calls during simulation execution.[85]
Further extensibility comes from the FlexSim Modules SDK, which allows developers to build reusable module libraries that add industry-specific objects and behaviors to the core software. Modules can introduce new 3D library entries, such as custom robotic arms with specialized kinematics, by combining FlexScript classes, C++ code, and UI modifications like custom toolbars or picklists.[86] The development process involves creating a module node in the model tree, setting up a dedicated directory under FlexSim's installation, and using "Addition" or "Replacement" mechanisms to override or extend existing functionality— for example, altering a processor's default processing time or adding proximity-based logic for automated guided vehicles. Once built as a DLL and packaged, modules can be distributed and loaded into FlexSim installations, promoting standardized customizations across teams or clients.[86]
Advanced users leverage FlexSim's support for multimethod simulations, combining discrete-event modeling with agent-based paradigms to handle hybrid systems like crowd dynamics in logistics or adaptive manufacturing processes. The Agent System tool integrates agent behaviors—such as proximity detection and state-based decision-making—directly into the discrete-event engine, allowing agents to interact dynamically while respecting event-driven time advancement.[87] This variant capability enables simulations where traditional flow items coexist with autonomous agents, providing flexibility for scenarios requiring both structured queues and emergent behaviors without separate modeling environments.
To enhance data science workflows, FlexSim includes Python bridging, permitting the invocation of external Python scripts and libraries from within the simulation for tasks like statistical analysis or machine learning integration. Users specify connections using syntax like external python "mymodule" "myfunction", where FlexSim automatically converts its data types (e.g., maps to dictionaries, arrays to lists) to Python equivalents and vice versa upon return.[85] This facilitates workflows such as exporting simulation outputs to Pandas for processing or importing optimization results from libraries like SciPy, all while maintaining the simulation's real-time execution, thus bridging discrete-event modeling with broader data analytics pipelines.[85]