Kaizoft Process Simulator – Pro Plan Features

This guide covers additional capabilities available to Kaizoft Process Simulator Pro and Pro-Plus plan users who need more sophisticated process modeling, scenario planning, and detailed simulation controls.

1. Saving Multiple Processes

You can save and manage multiple process configurations, making it easy to compare scenarios or revisit previous designs.
Use the controls above the process list to:

  • Add a new process
  • Duplicate an existing one
  • Delete a process no longer needed

This is useful for benchmarking improvements, testing alternate layouts, or presenting options to stakeholders.

2. Creating Parallel Sub-Assembly Flows and Merging Them

You can build separate sub-assembly flows and merge them into a main process stream.

Use the same add/duplicate/delete controls to manage sub-assembly groups.

To create a simple merged structure:

  1. Add three sub-assembly process flows
  2. Change the Source Type of the first two to Subassembly
  3. Merge them into the third process flow
  4. Set the Merge Ratio (e.g., 2 units from Process A + 1 unit from Process B = 1 output unit)
Image: Source object customization to support parallel process flows within the same production line

3. Setting Shift Schedules for the Simulation

Simulation results can reflect real operating schedules rather than continuous 24/7 runtime.

To configure:

  • Click the calendar icon in Simulation Settings
  • Set number of shifts per day
  • Set working days per week

This helps produce realistic throughput, capacity, and lead-time expectations.

4. Assigning Working Shifts to Individual Processes

Once a shift schedule is set, each process can be configured to run only during selected shifts.

To apply:

  • Open the Active Shifts dropdown for a process
  • Choose which shifts that process is active for
Image: Process modification pop-up: Setting working shift for each process

This is useful for support tasks, inspection steps, manual operations, or processes that run less frequently.

5. Shared Operator Assignment

Some processes may share the same operator pool rather than having dedicated staffing.

To configure:

  • Set Shared Operator to Yes
  • Select which operator(s) (Operator 1, 2, 3, etc.) are shared
  • Operators will switch between applicable processes on a FIFO basis

The model assumes the operator stays with a station for the full processing duration.

Image: Process modification pop-up: Setting shared operators for processes

6. Queue Limits (Kanban Controls)

Queue limits let you cap the number of units waiting at a process, simulating Kanban or controlled WIP environments.

Examples:

  • Prevent upstream buildup
  • Model space-limited staging
  • Test pull-based production behavior

7. Higher Simulation Time Range

Simulation time can be set up to 9000 hours, allowing long-term behavior analysis such as:

  • Stability and flow over extended runs
  • Seasonal demand patterns
  • Rare downtime event impact

(The free version is limited to 300 hours.)

8. Multi-Product Support [Pro Plus Plan]

Simulate real-world production by modeling multiple product SKUs within a single system. You can configure the source to introduce multiple SKUs and define the production sequence in which they run.

Image: Source customization pop-up: Setting up multi-product input

Each downstream process can be customized per SKU, including parameters such as processing time, standard deviation, batch size, and more. This allows you to accurately capture variations in how different products move through the same production line.

Image: Process modification pop-up: Setting process parameters for each product/SKU

This capability makes the simulator suitable for production planning and mixed-product environments, where understanding interactions between SKUs is critical for optimizing throughput and scheduling.

9. Set Starting WIP [Pro Plus Plan]

The Pro Plus plan also gives you the ability to set Starting WIP (Work-in-Progress) for each individual station. In a standard simulation, your production line typically starts empty, but real-world factories rarely begin a shift from zero.

This feature allows you to pre-load specific quantities of units at any stage of the process, effectively simulating a “steady-state” environment from the very first second. By bypassing the initial “warm-up” period, you can immediately analyze how your system handles a full load.

Need Help?

If you would like assistance configuring any of these features or testing a scenario, the support team is available for walkthroughs and guidance.

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