Tecnomatix Plant Simulation - cards PLM Solutions · • Operational system based simulation ......
Transcript of Tecnomatix Plant Simulation - cards PLM Solutions · • Operational system based simulation ......
Predicted uncertainty Tecnomatix Plant Simulation
Ir. Auke Nieuwenhuis/ 26 May 2015
29-May-15 Page 2
Restricted © cards PLM Solutions 2015 All rights reserved.
• Introduction to Kahoot
• Tecnomatix Plant Simulation Introduction
• Plant Simulation Case Studies
• Q & A
Agenda
29-May-15 Page 3
Restricted © cards PLM Solutions 2015 All rights reserved.
Go to Kahoot
• Access WIFI network ‘WLAN-PUB’
• Go to www.kahoot.it
• Enter the game PIN (will follow)
• And join the quiz
29-May-15 Page 4
Restricted © cards PLM Solutions 2015 All rights reserved.
Tecnomatix Plant Simulation Introduction
Predicted uncertainty
29-May-15 Page 5
Restricted © cards PLM Solutions 2015 All rights reserved.
WHAT?
Principle Process Simulation
• Transparent analysis of dynamic and complex systems
• Optimization of process, capacity, lay-out, management and control
• Intelligent support of investments
• Virtual process model with real process data
Existing or new system Simulation model Experiments and results
29-May-15 Page 6
Restricted © cards PLM Solutions 2015 All rights reserved.
How to Design a New System?
Control:
Who produces what, when, which
resoures, pull or push?
Dimensioning:
Buffers, machines, #operators?
Lay-out:
Optimal location for machines, buffers,
operators, supply-chain?
Process flow:
Order of process steps, decoupling points?
Design goals:
• Predictive behavior, reliability
• Maximize system performance
• Minimize effort and investment
• Documents and communicate
29-May-15 Page 7
Restricted © cards PLM Solutions 2015 All rights reserved.
In- and Output Simulation Model
Simulation Model
Control: Who, what, when, pull
or push?
Dimensining:
Buffers, machines,
#operators
Lay-out: optimal location
resources?
Process flow: Process flow,
decoupling points?
Input
• Lay-out
• Product mix, order
pattern
• Routings
• Timings: set-ups,
processing, MTBF,
MTTR
• Capacities
• Planning, planning rules
• Failures
Output
• Efficiency
• Utillization
• Waiting times
• Throughput times
• Costs
• Revenue
• Visualisation 2D/3D
29-May-15 Page 8
Restricted © cards PLM Solutions 2015 All rights reserved.
WHAT?
Typical Users Plant Simulation
• Manufacturing companies
• Logistics service providers (3pl, warehousing, distribution, supply chain management)
• System suppliers and machine builders (material handling, process lines, etc.)
• Consultancy and engineering
• Retailers
• Healthcare
• Shipyards
• Airports, mainports & terminals
• Government (rail, water, road traffic) and defense
29-May-15 Page 9
Restricted © cards PLM Solutions 2015 All rights reserved.
WHAT?
Typical Users Plant Simulation
• High level design
• Conceptual
• Schematic and flow based simulation
• Low level of visualization, mainly for simulation purposes
• High detail design
• PLC
• Operational system based simulation
• High level of visualization, 3D, visualization also for communication purposes
29-May-15 Page 10
Restricted © cards PLM Solutions 2015 All rights reserved.
WHAT?
Advantages of Process Simulation
• Early detection and elimination of problems
• Risk-free experimental environment
• Test en compare of alternatives
• Minimize investments
• Optimize performance
• Increase process understanding with visualization
• Support on management decisions
29-May-15 Page 11
Restricted © cards PLM Solutions 2015 All rights reserved.
WHAT?
Business Issues Plant Simulation
• Increase volumes and / or efficiency. Can it be done with current process or are investments
required? If investment is required, where to invest?
• Where to invest and what improvements can be expected?
• Eliminate the effect of the bottleneck within the system
• Dynamic modelling with every day uncertainties. Other tools are static and not visual, it is
difficult to understand results or to share them with management and operators
• What should the factory of the future look like and is the system flexible to cope with demand
and product mix of the future?
• Daily planning of resources is fuzzy and general
29-May-15 Page 12
Restricted © cards PLM Solutions 2015 All rights reserved.
WHAT?
Business Drivers Plant Simulation
• Savings on investments > 5-15%
• Decrease start up costs > 5-20%
• Increase volumes > 15-20%
• Decrease stock and throughput times > 20-60%
• Rule of Thump: 1 euro invested in simulation
will return 12 euro!
29-May-15 Page 13
Restricted © cards PLM Solutions 2015 All rights reserved.
Plant Simulation Software Solution
13
Data analyze Modeling Simulation Visualization
Process analyze Experiment Draft
Optimization Process Automation
Data fit 2D, 3D, CAD,
FactoryCAD Generic modelling objects
Statistic Wizard, Bottleneck Analyzer, Sankey
chart, Attribute Explorer, Gantt Wizard
Experiment Manager, Neutral Networks, Factor
Analysis, Automatic Experiment Generation
Generic Algorithm, Optimization Wizard, Layout
Optimizer, Neural Networks, Sequencing Wizard PLC Testing, OPC Server
Generic Simulation Tools
29-May-15 Page 14
Restricted © cards PLM Solutions 2015 All rights reserved.
WHAT?
Users Plant Simulation
Automotive OEMs
Audi
Autovaz
BMW DaimlerChrysler
Honda
Mazda
Mitsubishi
Nissan
PSA
Rolls-Royce Suzuki
Vauxhall Volkswagen
System Suppliers
Bosch
EBM Papst
Faurecia
Hella
Magna
Modine
Recticell
SKF
St. Gobain
ZF
Machine Builders
Comau
Duerr
Eisenmann
Hoermann
ibk
Krones
Kuka
Nothelfer
Thyssen Krupp
TMS
Voest Alpine
Shipyards
Babkock
Chantier de l’Atlantique
Fincantieri
Flensburger Schiffsbau
Gesellschaft
Kockums
Kvaerner Warnow Werft Meyer
Werft Papenburg Thyssen
Nordseewerke
29-May-15 Page 15
Restricted © cards PLM Solutions 2015 All rights reserved.
WHAT?
Users Plant Simulation
Engineering
DRC
EDAG
Fraunhofer
Icarus
Industrie
Planung Fischer
Isilog
Life Sciences
Logplan
Pitotech
PPI
Protema
Airports
Dallas
Denver
Frankfurt
Munich
Schipol
Process
Industry
BASF
Bayer
Ciba
Henkel
Proctor & Gamble
Ratiopharm
Wacker
Semiconductor
Logistics
SSI Schaefer
Duerr
Hoermann
psb
UPS
PPI
iSILOG
Heavy
Industry
Caterpillar
Freightline
Volvo Trucks
MAN
Iveco
Daimler Chrysler
Trucks
DAF Trucks
Mack Trucks
Aviation
Airbus
Rolls-Royce
MTU
BAE Systems
Fairchild Dornier
Healthcare
Erasmus MC
LUMC
Vreelandgroep
AMC
UMCG
29-May-15 Page 16
Restricted © cards PLM Solutions 2015 All rights reserved.
DAF Trucks
Challenges
• Simulation of a complex production line
• Check the proposed investments
• Optimization of the batch sizes and automation rules
Approach
• Plant Simulation software (realistic and complete model)
• Customized training for DAF Trucks personnel
• Modelling done by DAF Trucks users
Results
• Very accurate and realistic models of a complex line
• Investment in additional production equipment not necessary (€ 800.000
saving)
• Extension of material handling necessary to reduce and relieve manual tasks
• Highly improved knowledge of the production process
29-May-15 Page 17
Restricted © cards PLM Solutions 2015 All rights reserved.
Procter & Gamble - warehousing
Challenges
• Simulation of several newly build warehouses world wide
• Optimization of strategies and early validation
• Required capacity definition
Approach
• Plant Simulation software (realistic and complete model)
• Warehousing and Logistics Library
• Modelling and simulation done by cards, result analysis by
cards and P&G
Results
• Investment of construction work reduced to minimum
• Early identification of bottlenecks and precise elimination if
needed
• Reduce startup time for new processes
29-May-15 Page 18
Restricted © cards PLM Solutions 2015 All rights reserved.
Constellation Brands – Corona case 1
Challenges
• Simulation of LGV transportation from bottle and can filling lines to
the ASRS
• Over 100 LGVs work in a tight and limited space
• Validation that the proposed system can work
Approach
• Plant Simulation software (realistic and complete model)
• Warehousing and Logistics Library
• Modelling and simulation by cards, result analysis by cards en CBi
Results
• Savings on the number of LGVs needed (over $450.000 savings)
• Allocation algorithm of LGV trip improved
• In depth knowledge on system behavior during the implementation
(predictive)
29-May-15 Page 19
Restricted © cards PLM Solutions 2015 All rights reserved.
Constellation Brands – Corona case 2
Challenges
• Simulation of train movements around brewery
• Over 360 train lorry movements per day
• Stress test and sensitivity analysis of train movements and
connected processes
Approach
• Plant Simulation software (realistic and complete model)
• Modelling and simulation by cards, result analysis by cards and CBi
Results
• Define the maximum process timing of the sub-processes
• Define the daily throughput and relocation of the train lorries
• Improve the negotiation position of CBi with the train operator
29-May-15 Page 20
Restricted © cards PLM Solutions 2015 All rights reserved.
Nuplex
Challenges
• Simulation of a continuous flow process
• Increase of the capacity of a complete plant
• Validate the effect the proposed of investments
Approach
• Plant Simulation software (realistic and accurate model)
• Runtime model and user interface
• Modelling done by cards, simulation done by cards and Nuplex
Results
• Realistic and accurate model of a continuous process
• Nuplex gets the maximum benefit of their investments at lowest cost
• Strong increase in process knowledge
29-May-15 Page 21
Restricted © cards PLM Solutions 2015 All rights reserved.
Marel
Challenges
• Simulation of two alternative welding robots
• Proof the need for the robot cell with the expected growth
Approach
• On site modelling of the two options with the same input data
• Modelling done by cards, simulation done by cards and Marel
Results
• Models proofs by quantitive and qualitative numbers what cell is
preferred with respect of throughput and WIP
• Model demonstrates the importance of throughput and WIP
29-May-15 Page 22
Restricted © cards PLM Solutions 2015 All rights reserved.
Questions?
29-May-15 Page 23
Restricted © cards PLM Solutions 2015 All rights reserved.
International user meeting
Upcoming events
Plant Simulation International User Meeting
Siemens offices, Stuttgart, Germany
June 16 and 17
Complementary
Plant Simulation Warehouse and Logistics training
Siemens offices, Stuttgart, Germany
June 18
Complementary
29-May-15 Page 24
Restricted © cards PLM Solutions 2015 All rights reserved.
Contact
Auke Nieuwenhuis Business Development
cards PLM Solutions
De Maas 22a | 5684PL Best
T: +31 499 371990 | F: +31 499 372690 | M: +31 6 224 85984
[email protected] | www.cardsplmsolutions.com
From good to great, from great to Best.