mb07: advanced simulation for design and optimization

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

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Advanced Simulation for Design and Optimization

Is It Part of Your Competitive Edge?

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2

Agenda

Driving Competitive Advantage

Demonstration

Why Arena

Simulation Overview

Introduction


Agenda


Demonstration

Why Arena

Simulation Overview

Introduction


PUBLIC INFORMATION

Case Study – Pallet Stretch Wrapping


Case Study

Soft Drink Pallet Wrapping Machines

Plant Layout:

Case packer line

5 Palletizer Lines feeding 2 Stretch Wrappers

Challenge:

Increased load pushing pallet wrapping machines to limits

5


Case Study

Questions:

Can the two existing Stretch Wrappers keep up with increased load?

Is an additional stretch wrapping machine required?

What directional feeding rules will ensure that palletizer lines don’t back up?

What directional feeding rules will maintain smooth, continuous operations?

6


Addressing the Challenge

7

Built a simulation model of the process using Arena simulation software

Identified variability/uncertainty around key process parameters

Package types

Pallet creation times

Pallet wrapping times

Forklift speeds

Stretch wrapper failure/downtime modes and frequencies

Run simulation scenarios to test alternate designs

Revised Feeding Rules

Addition of 3rd stretch wrapper


Visualizing the Operation

8


Variability Considerations (Input)

9

Time to create pallet (TRI dist) Min Mode Max

Time to wrap pallet ("stop to start")in minutes W

yard

Dela

y

923C

Dela

y

320 D

ela

y

923A

Dela

y

FS

800 D

ela

y

Wyard 90 137 165 Muller 808 46 44

923C - 12 Packs 102 196 235 Muller 606 44 44 44 41

320 - 6 Packs 133 784 940

923A - Cube 79 157 188 3 0

FS800 240 343 411

East West

Choose the package coming off the Wyard Forklift Speed in ft/min 250 250

9 70% % eff Stretchwrapper Failure Modes

mean time betw een failure (minutes) Uptime Downtime Uptime Downtime

Muller 808 - West 112 8 235 5

Choose the package coming off the FS800 Muller 606 - East 232 8 235 5

1 70% % eff

What is your can line efficiency 75% % eff

East West Switch at M12 (1=West, 2=East, 3=Auto)

Break Film Change


Arena Simulation Results

Developed New Palletizer Feeding Rules to Eliminate Backlogs

Line 1: Feed Left Only

Line 2: Feed Left or Right

Lines 3,4 & 5 Feed Right Only

3rd Stretch Wrapper Not Required:

$150K Capex avoidance

Reduced long-term system maintenance costs

10


Agenda


Demonstration

Why Arena

Simulation Overview

Introduction


Discrete Event Simulation Modeling events that occur over time, including all

variability and system interactions, to predict the

future performance of complex business processes

and to assess the overall system capabilities under

virtually any set of “what if” conditions.

12

What is Discrete Event Simulation?

Implement Here

Test Here

Simulation and Your Company

Understand how complex systems work

Answer critical “What if..?” questions

Visualize operations

Insurance policy for major decisions

Completely risk-free environment


Why Simulation?

13

Optimize designs/layouts

Get it right the first time

Visualize problems and solutions

Communicate ideas, gain consensus, destroy myths!

Avoid wasteful spending

Differentiate from competition


Advantages of Simulation

Compare alternative designs

Incorporate system variability

Include system interactions

Observe complex systems over time

Animation communicates ideas

Understand bottlenecks

Low risk/high return

Excel

Simulation

Enhance Competitive Advantage


Benefits from a typical Arena simulation project are

usually 10-20x the initial investment within four to six

months of initial use.


Agenda


Demonstration

Why Arena

Simulation Overview

Introduction


Arena Simulation Software

17

World’s leading discrete event simulation software

Used by majority of Fortune 100 companies

Capable of modeling virtually any system or process

Easy-to-use flowchart modeling methodology

Large university install base

35-year track record of success and proven results


Arena Models All Business Processes

Supply Chain Management

Customer Relationship Management

Suppliers Customers

Supplier Management

Customer Service

Warehousing Inventory

Manufacturing Processes

Distribution Logistics

Business Processes

- Who? - When? - How much? - How?

- Inventory-control Mechanisms - Tactical Planning - Stock Levels

- Delivery Mechanisms - Shipment Methods - Site Planning - Dispatching Rules

- Front Office - Order Fulfillment - Workflow - Internal Processes

- Multi-channel Contact - Staffing - Outsourcing - Call Routing

- Job Routing - Factory Flow - Capacity Planning - Staffing - IT and ERP


Agenda


Demonstration

Why Arena

Simulation Overview

Introduction


Benefits for OEMs

21

Validation of system design

Incorporate variability, uncertainty and constraints into design

Quantitative comparison of alternatives

Demonstrate design to customers

Optimize/enhance equipment performance

Value-add service/expertise to customers

Extension of simulation models to real-time applications


Support from Rockwell Automation

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Training courses

Bi-monthly courses in Austin, TX

On-site, customized courses

Technical Support

M-F, 9-5 (Eastern Time)

Phone or e-mail

Consulting Services

Project assistance

Turn-key projects


Need Additional Information?

23

Sales

Sean Connors

[email protected]

+1 (512) 680-3473

Technical Support

[email protected]

+1 (440) 646-6789

www.ArenaSimulation.com

mailto:[email protected]




http://www.arenasimulation.com/


Summary

24

Optimize designs and equipment performance

Visualize problems and solutions

Communicate ideas, gain consensus, destroy myths!

Avoid wasteful spending

Get it right the first time

Differentiate from competition


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Questions?


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Thank You!

mb07: advanced simulation for design and optimization

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