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Capacity Analytics & Simulation

Find the bottlenecks before they find you.

We build a digital twin of your plant or hospital and stress it against hundreds of demand scenarios. The result: where it breaks, when, and which levers fix it — with data, not guesswork.

How it works

From raw data to strategic recommendations in 6 weeks, not months.

STEP 01

Data

Equipment, demand, OEE, shifts, and product routing ingested into one unified plant model.

STEP 02

Digital Twin

Every resource, constraint, and flow reconstructed; scenarios tested without touching the floor.

STEP 03

Monte Carlo Simulation

Hundreds of runs against real demand variability: which resource breaks first, and when.

STEP 04

Actionable Report

Operational levers, investment roadmap, actions ranked by impact. Raw data to recommendations in 6 weeks.

Ready to see what your plant can really do?

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Hospitals

The same engine, applied before construction: given a population's demand profile — volumes, case mix, growth — we simulate how many beds, operating rooms, consult rooms, and imaging a hospital actually needs. We proved it on public data: we modeled a US$700M pediatric hospital in 48 hours — and found the press-published specifications were wrong.

Capacity Diagnostic

fixed fee, 2–3 weeks

Basic twin, baseline simulation, and the map of your bottlenecks. The starting point of every expansion decision.

Case Study

Multi-site pharma transformed

A Latin American pharmaceutical company with 3 manufacturing sites, 250+ products, and growing demand needed to know: where do we invest?

3
Manufacturing Sites
32
Resources Modeled
7
Bottlenecks Identified
100%
Bottlenecks Resolved
01

Baseline Diagnosis

Identified 7 critical bottlenecks across 3 sites, with the worst resource at 229% utilization — physically impossible to sustain.

02

Operational Levers

Adding a 3rd shift + 15% OEE improvement resolved 4 of 7 bottlenecks without any capital investment.

03

Investment Roadmap

Two CAPEX scenarios evaluated: phased equipment expansion across sites, achieving 0 bottlenecks through 2032.

Engagement Timeline

Week 1-2
Data collection & onboarding
Week 3
Plant model & baseline simulation
Week 4-5
Scenario analysis & lever testing
Week 6
Report delivery & recommendations

Want results like these?

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Frequently asked questions

What is simulation-driven capacity planning?

It's a consulting approach where we build a digital twin of your manufacturing plant and run Monte Carlo simulations to stress-test it against demand variability. Instead of spreadsheet estimates, you get statistically-backed insights into which resources will become bottlenecks and when — so you can plan investments with confidence.

How long does an engagement take?

A typical engagement takes 6 weeks from data onboarding to final report delivery. Weeks 1-2 focus on data collection, week 3 on building the plant model, weeks 4-5 on scenario analysis, and week 6 on delivering actionable recommendations. That's 3-5x faster than traditional capacity studies.

What data do you need from us?

We need production data including equipment specifications, demand forecasts, OEE metrics, shift schedules, and product routing information. We handle the data ingestion and mapping — your team typically spends a few hours gathering existing reports and spreadsheets.

What do I get at the end of an engagement?

You receive a comprehensive report with scenario-backed recommendations: a baseline diagnosis of current bottlenecks, operational levers you can pull without capital investment (like shift adjustments or OEE improvements), and a prioritized CAPEX investment roadmap with projected impact through your planning horizon.

Do I need to install any software?

No. Ettala is a consulting service, not a software product. We run all simulations and analysis on our side. You receive clear, actionable deliverables — no dashboards to learn, no software to maintain, no training required.

How do you handle data security and confidentiality?

Your data is treated as strictly confidential. We sign NDAs before any data exchange, use encrypted channels for file transfer, and limit access to the engagement team only. Production data is used solely for simulation purposes and is never shared with third parties. All client data is deleted after the engagement unless you request otherwise.

Ready to see your capacity?

Tell us about your manufacturing challenge. We'll show you what a simulation-driven approach can reveal.

Schedule a Call

contact@ettala.ai

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