tecnomatix plant simulation - cards plm solutions · • operational system based simulation ......

Predicted uncertainty Tecnomatix Plant Simulation

Ir. Auke Nieuwenhuis/ 26 May 2015

29-May-15

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


Go to Kahoot

• Access WIFI network ‘WLAN-PUB’

• Go to www.kahoot.it

• Enter the game PIN (will follow)

• And join the quiz

http://www.kahoot.it/

29-May-15


Tecnomatix Plant Simulation Introduction

Predicted uncertainty

29-May-15


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


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


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


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


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


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


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


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


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


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


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


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


Procter & Gamble - warehousing

Challenges

• Simulation of several newly build warehouses world wide

• Optimization of strategies and early validation

• Required capacity definition

Approach


• 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


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


• 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


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


• 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


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


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


Questions?

29-May-15


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


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.

mailto:[email protected]



http://www.cardsplmsolutions.com/