Delmia DPM M2 - Create the Process Plan

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Module 2

Create the Process

1 Create the Working

Environment

2Create the

Process Plan

3Create the Simulation

Enhance the Simulation

Analyze the Movements

Create Output files

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Conduct Tool

Validation

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2 Create the Process

Overview Simulation studies generate valuable information to organizations regarding processing sequence and optimization. In order to develop a simulation study, an initial process must be created. Once created, processes can then be stored in libraries and re-applied to other projects at a later date. This module takes a step-by -step approach to creating a process, from creating the process library to final validation.

Objectives Topics in this module are:

Create the Process LibraryCreate the Process PlanUse the Pert ChartLink Product DataVerify the Process 3 hours

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Workbenches and Toolbars used in this Module

Workbenches

Toolbars

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Create the Process2

Create a Process Library

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C

Create a Process

Plan

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Use the PERT Chart

3 hours

Create Activity TypesCreate Activity Subtypes

EVerify the Process

Attach Process LibraryInsert ActivitiesInsert Subtype Activities

Manipulate the PERT ChartLink ActivitiesModify Process

Link Product Data to the

Process

Link Product Data to Activity

Prepare Verification Dialog BoxView Disassembly and Assembly

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Create a Process Library

Create Activity TypesCreate Activity Subtypes

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Create a Process Library Create the Process2

About Process Libraries

A Process Library allows you to arrange process activities according to manufacturing area (Bodyshop, Powertrain, etc.) or discipline (Assembly, Machining, etc). During the creation of a process library, activities and subtype activities can be defined to add detail. The activities in a process library are used to represent the actions that need to take place in order to complete a process. Once completed, a process library can than be attached to multiple processes.

More about Process Libraries can be found in the On-Line documentation.

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Create a Process Library– Procedure

1 To create a new Process Library, click File / New…

2 From the New dialog box select ProcessLibrary. Click OK.

Now that the process library has been created it will need to be populated with Activities and activity subtypes.

Locate the ProcLibCreation toolbar, and click on the Create new activity type icon.

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Create the Process2Create a Process Library

The New Type dialog box will appear. From this dialog box theActivity will be named. Notice that the option to linkthis library to a previously established library is available throughthe “Inheritance from another library” drop down menu. Attaching an already established library and manipulating it to suit the project needs can save time.

The screen will show an activity icon with the activity name printed twice at the top of the screen.


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The next step in creating the process library is to add subtype activities. Highlightthe activity to which the subtype activity will be attached, and select the Create new activity subtype icon. Name the subtype activity then click OK.

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Highlight the subtype activity just created, and select the Create new activity subtype icon.

Name the new subtype activity then click OK.

This is an example of a process library.

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Create A Process Library – Exercise

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Master Exercise – 3.5 HP Engine3.5 HP Engine (Step 5): Create a Process Library

20 min.

Scope: In this exercise you will create a process library for the assembly of a 3.5 HP engine. Later, the library will be inserted into the engineassembly process.

Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R16 DPM Assembly / PROJECT DATA

In this exercise you will:Create a process libraryCreate an activityCreate subtype activities

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Do It Yourself (1/4)

Starting point Ending point

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1. Start by creating a new process library.

2. To build the process library for the 3.5 hp engine project, you will need the ProcLibCreation Toolbar.

3. The exercise is focused on one activity, the 3.5 hp engine. Use the Create New Activity Type icon to insert “Engine assembly” into the process library.

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4. For this exercise, you will be adding subtype activities which will represent the engine’s subassemblies.

5. To add the subtype activities, click on the engine assembly activity.6. Click on the Create New Activity Subtype icon.7. When the New Type dialog box appears, type Block Assy as the subtype

name. 8. Click OK.

9. For the next subtype activity, repeat the procedure. 10. Name the subtype, Exhaust Valve Assy.

Remember to click on the Engine Assembly activity first.

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Finish the library by adding the remaining subtypes:Intake Valve Assy,Muffler Assy,Carburetor Assy, Air Filter Assy,Crankshaft Assy, Piston Assy,Piston Rod Assy,Cam Assy, Crankcase Assy, Head Assy,Coil Assy, Flywheel Assy, Cover Assy,

Your process library should look like this.

7.

SAVE AS: R16 DPM Assembly / Project Data / ProcessLib1

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Create a Process

PlanB

Attach the Process LibraryInsert ActivitiesInsert Subtype Activities

Inst.Inst.

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Create a Process

Plan2 Create the Process Plan

About the Process Plan

A process plan is a collection of activities that occur in a certain order to achieve a specific outcome or product. A process plan is created by pulling activities from a process library into the process. Once activities become part of the process plan they can be edited to meet specific needs. When completed, the process plan is a visual representation of the process’s critical path.

More about Process Planning can befound in the On-Line documentation.

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Create a Process

PlanCreate the Process Plan2

Insert Library - Procedure1 The first step in creating a process plan is to attach a process library to the project.

Double click on the Process node from the PPR tree.

From the Main Menu choose INSERT, then selectInsert Activity Library

(or use the Activity Library icon on the Activity Management toolbarby clicking on the icon first, then the Process node).

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Create a Process


Insert Library - Procedure

The Dialog box will close but the screen will not appear different. What has happened isthat the link to the library has now beenestablished. This permits the activities to be placed into the process node of the PPR tree. The activities can be placed using the menu or by clicking on the Insert Activity icon.

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When the File Selection dialog box appears, locate and select the desired process libraryand click Open.

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Add Activities - Procedure

Click on the activity type in the Insert Activitydialog box, then click on the Process node in thePPR Tree. With the selection Add As Child, youwill see the activity type appear under theProcess node.

After Insert Activity has been clicked, the Insert Activity dialog box will display.

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Create a Process


It is important to understand that each action that is to be represented in the simulation has a corresponding activity in the process node. Although activities can be added or removed from the process at any time, it is more efficient to populate the process node at this time.

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Add Activities - Procedure

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A CHILD of an activity is

inserted one level beneath

its parent activity and will automatically generate a

start and stopfunction.

A SUCCESSOR of an activity is inserted into the process as the

next logical activity and will

be automatically linked to the next action.

To complete the process plan, continue inserting activities and assigning their relationships as either Child or Successor until there is a process activity that will represent everything that must be accomplished for the project. Subtype activities can be added depending on the amount of hierarchical detail needed.

The procedure for assigning subtype activities is the same as assigning activities:

1. Click on the Insert Activity icon.2. Select the item to be attached from the Insert

Activity dialog box. 3. Choose the relationship, as child or successor.4. Select the item in the process node to which the

subtype activity will be assigned.

Reassigning the child or successor relationship can be done by dragging and dropping the activity to another level on the PPR tree.

Create a Process


Inst.Inst.

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Rename Activities – ProcedureOnce the initial activities of the process have been assigned, they can be modified to reflect the specifics of the current project.

Access the Properties dialog box by highlighting an activity in the PPR tree and right clicking on it. This brings up the Properties dialog box.

Icons can also bereassigned by clickingon the icon next tothe Icon Path dialogbox. The Icon file dialog box will appearwith the icons in the Current location.

Create a Process


Inst.Inst.

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Activity names, cycle times, descriptions, as well as many other aspects associated with this activity, can be reassigned from this dialog box.

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Create A Process Plan – Exercise

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Master Exercise – 3.5 HP Engine3.5 HP Engine (Step 6): Create a Process Plan

20 min.

Scope: In this exercise you will create a process plan using the library created in the previous exercise and attaching it to Environment2 . You will theninsert activities and subtype activities into the process node.

Conditions: V5 and DPM Assembly Process Simulation workbench must be open.Access to the files in R16 DPM Assembly / PROJECT DATA

In this exercise you will:Attach a process libraryInsert activities

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Load: R16 DPM Assembly / Project Data / Process / Environment2

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This process plan will begin as a disassembly process. After the sequence has been validated, it will be reversed into an assembly sequence.

1. Open environment_2 from the Process Folder In Project Data.

2. The process library you created in previous exercise will need to be linked in order to insert its activities into the process node of Environment3. You will do this by using the Insert Activity Library icon.

A. Click on the Insert Activity Library icon.B. Click on the process node from the PPR tree.C. Locate and select the ProcessLib1 that was created.

Remember that although the environment still appears the same, the process library is now linked to the process node.

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To populate the process node with the activity and subtype Activities, use the Insert Activity icon.

From the Insert Activity dialog box, click on the EngineAssembly, then click the process node. Engine Assembly.1will appear under the process node.

Since you are building an engine disassembly, the remainingsubtype activities will be added in the reverse order that theyappear in the process library.

3.

4.

5. With the dialog box still open, click on the Block Assy subtype.With the Add As Child selection made, click on the Engine Assembly.

Add all of the remaining subtypes with the Add As Successor option.6.

Remember that the Successor must be linked to the previous sub assembly and not to the engine.

Save As: R16 DPM Assembly / Project Data / Process / Dissassembly1

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Order Activities with

PERT ChartC

Manipulate the PERT ChartLink ActivitiesModify Process

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PERT ChartCreate the Process Plan2

About the PERT Chart

The PERT chart is a graphical representation of the process flow. It allows for modification of the process plan in a dynamic and friendly manner. It is a useful tool for visualizing and re-structuring the sequence of operation of the process. Since simulation is a 3D representation of the manufacturing process, the PERT chart can easily re-sequence the process. The order in which the activities are linked will be reflected in the PPR Tree.

More about PERT Charts can befound in the On-Line documentation.

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Access the Pert Chart – Procedure

From the standard view, the process plan can be seen in the PPR tree. However, when modifications need to take place or a portion of the process needs a closer look, using the Pert Chart is more appropriate.

Highlight the process node, an activity, or a subtype activity. The PERT chart is able focus on only the specific level of the process plan that needs modification.

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After the appropriate level has been selected, clickon the Open PERT Chart icon from the Data Views Toolbar.

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The portion selected from the Process plan is nowavailable in the PERT chart.

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Access the PERT Chart– Procedure

A ‘+’ sign in the upper right corner

of an icon indicates that the process contains sub processes

When you display the Pert Chart, you will see a row of Process Activity icons.

This is an example of how the PERT Chart might look from the Process Node level. Notice that the entire Engine Assembly is one icon.

3 Display sub-processes by clicking on the + sign. The block will expand to show the sub-processes.

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Access the PERT Chart– Procedure

Sub-processes are activities that are subordinate to a main activity. For example, assembling a muffler

might require that several sub-steps, or sub-processes, be performed.

The blocks hold icons for activities that were created as children of another activity. The

block represents the hierarchical position of a group of activities.

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Move PERT Chart Icons – Procedure

On the PERT Chart, activity icons can be moved around the for the purpose of organization and sequencing.

Left click and hold to move icons to any square that permits you to visualize the sequence. Icons within a blocked process will remain inside the block because the process is part of a parent-child relationship. For that reason, the block changes shape to accommodate all of the icons in that sub-assembly.

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Inst.Inst.

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Link and Unlink Activities– ProcedureThere may already be arrows on some of the

boxes. This is the result of selecting the Add as Successor option when creating the new

process.

To link the steps together, click on the Link the selected activitiesicon on the Activity Management toolbar. Make sure the icon is

highlighted orange. Select the activity to link, then select thesecond activity to link. After clicking the second activity, a link arrow will appear between the two to indicate the linkage.

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Activities can be linked to multiple activities when

necessary.

To unlink a box, click the arrow so

that it turns orange, then press

the delete key.

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PERT Chart

Link and Unlink Icons – Procedure

Create the Process Plan2

An activity inside of a blocked process can NOT be linked to an activity outside the block. Activity icons can link to another process by clicking on its surrounding

block. Doing so creates another stop activity inside the block.

Create a flow from a blocked process to an activity or another block by adding links.This will create a start and stop icon inside the block. The start icon can then bemoved to the front of the activity and linked together.

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There must be a start and stop logical activity for the entire process.

7 Click and drag activities to a different area of the PERT Chart as necessary to view hidden boxes.

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PERT Chart

Move Between Pert Chart and 3D View – Procedure

Create the Process Plan2

To return to the 3D view use the Data Views toolbar.

Click the Open PERT Chart button to display the PERT Chart view.

Click the 3D Standard Viewer button to display

the 3D View.

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Insert Logical Activities – Procedure

After the PERT Chart has been created, start and stop activities can also be inserted into the 3D Standard Viewer using the Logical Activity Creation toolbar.

Add a Start activity: This creates the basic start and

stop icons.

Add a Switch activity: When creating forks there is an option to create switches.

Add an AndInactivity: This

command gives the option of

creating more than one activity to connect to the

next activity.

Add an AndOut activity:This command gives the option of creating more

than one way to connect to the next activities.

Add a Stop activity:This creates the

basic start and stop icons.

Add an OrInactivity: When linking to more

than one activity this can create a 2nd option for the

switch.

The Logical Activity Creation toolbar provides methods for modifying the process by inserting extra Logical Activities in addition to the Start and Stop icons that come with the relationship linkage.

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Pert Chart – Exercise

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Master Exercise – 3.5 HP Engine3.5 HP Engine (Step 7 ): Use the Pert Chart

20 min.

Scope: In this exercise you will use the PERT chart to examine the process. Afterconsidering the order in which the activities have been placed, you maywish to manipulate the process and add the appropriate links.

Conditions: V5 and DPM Assembly Process Simulation workbench must be open.Access to the files in R16 DPM Assembly / PROJECT DATA.

In this exercise you will:Use a PERT chart Link blocks and activitiesManipulate the process

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Load: R16 DPM Assembly / Project Data / Process / Disassembly1

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Now that your process plan contains the activities needed to disassemblethe 3.5 hp engine, you will take a closer look at it using the Pert chart.

1. Click on the Process node, then the Open Pert Chart icon.

2. Examine the Pert chart for the engine process created earlier. It should look like this once you have expanded it by clicking on the “+” in the upper right corner of the engine assembly box.

The arrows connecting the boxes represent a link from one action to the next. Remember that the links were established by choosing either a child or successor relationship while being inserted to the process.

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Link the engine assembly to its start and stop operations.3.

4. Examine all of the links and delete any that seem wrong.5. Assign any missing links so that every box of the process is linked in a flow that makes

sense. 6. To create the links you need, click on the Link Selected

Activities icon.

7. Select the box from which the link starts followed by the box you wish to link.

8. Notice that when you linked the engine assembly to its start and stop boxes, new start and stop boxes appeared. These will also need to be repositioned and linked.

Your Pert chart should look similar to this.

NOTE: With your instructor’s help, you may choose to create parallel processes or insert other logical activities. However, the subsequent exercises will assume that the sequential state described here is present.

Save As: R16 DPM Assembly / Project Data / Process / Disassembly1

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Process

Link Product Data to Activity

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Inst.Inst.

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Process 2

About Linking the Product Data to the Process

Create the Process Plan

After the process is built and it has been sequenced using the Pert Chart, the next step is to associate the product data to the process activities. Prior to linking the data, the process has been given the instructions needed to carry out the task. By associating the product (parts or assemblies), to the process activities, the process is being assigned products on which to perform its tasks.

More about Linking Product Data can befound in the On-Line documentation.

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ProcessCreate the Process Plan2

Link Product Data to the Process - Procedure

Open the Process Node of the PPR tree so that all of the activities in the process are visible.

Open the Product node of the PPR tree so that the parts of the product are visible.

Collapse the rest of the Product nodes (if needed) until they are at a discreet part level. Look for the BLUE gear icon to identify a part, and the PINK gear icon to identify a product assembly.

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Go to the Activity Management toolbar and findthe “Assign an item” icon.4

Select the drop down arrow to see theadditional features behind this icon.

ERROR RECOVERY: Note the Unassign an item icon.

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Each item in the product list should be assigned to a Process activity. Use the Assign an Item icon to link product nodes (assemblies or parts) to process activities.

a. Click on the Product item.b. Click on “Assign an Item” icon.c. Click on the process activity to which the product should be assigned.

Make linkages at the same hierarchical level. For example, link product assemblies to process assemblies and product parts to assembly components.

Example: The crankshaft gear must appear in each activity that calls for a crankshaft gear or it will not be visible in the simulation.

Link Product Data to the Process - Procedure


ProcessCreate the Process Plan2

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Process 2

Link Product Data to the Process - ProcedureCreate the Process Plan

You can use the View menu (or Toolbar) to check whether or not allassignments have been made by selecting List unassigned Products.

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Link the Data – Exercise

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Master Exercise – 3.5 HP Engine3.5 HP Engine (Step 8 ): Link the Product Data to the Process Activities

20 min.

Scope: In this exercise you will link the product subassemblies to the subtypeactivities in the process node. Further, you will find any unassigned productcomponents and decide if a link is needed.

Conditions: V5 and DPM Assembly Process Simulation workbench must be open.Access to the files in R16 DPM Assembly / PROJECT DATA.

In this exercise you will:Link the process to the productFind unassigned products

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Ending pointStarting point

Load: R16 DPM Assembly / Project Data / Process / Disassembly1

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Do It Yourself (2/3)The Engine

assembly does not get linked

Now that the process is In order, Link the process to the product.

1. Start by expanding both the Processlist and Productlist nodesin the PPR tree.

From the Activity Management Toolbar, use the Assign An Item icon to create the link between process and product. Assign thepink Assembly icon to the subassembly level of the process.

2.

Click on the product. Find and click on the Assign an item icon.Click on the activity from the process node with which the product corresponds.

3.

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Repeat the steps until all of the engine parts and all of its subassemblies have been assigned to the appropriate activities.

4.

5. Use the List Unassigned Products icon to view the engine components without assignments. Correct any unassigned subassemblies.

SAVE AS: R16 DPM Assembly / Project Data / Process / Disassembly2

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EVerify the Process

Prepare Verification Dialog BoxView Disassembly and Assembly

Inst.Inst.

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Verify the Process2 Create the Process Plan

About Process Verification

Process Verification is a visual representation of the process and product link. The Process Verification function permits the user to validate the product flow according to the sequence of the process plan. Running this procedure allows for the viewing of the parts and assemblies as each process activity calls for them. It is a method to validate the process prior to constructing a simulation.

More about Process Verification can befound in the On-Line documentation.

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Verify the Process2 Create the Process

Process Verification - Procedure

Select the Process node from the PPR tree. From the Simulation toolbar select the Process Verification Icon. The Process Verification dialog box will appear.

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From the dialog box, click on the More button to Activate more options. Set the options in the box to:

• Check the Animation box

• Show Activity’s Products

• Show All Resources

• Reframe OFF

More details on the button functions are located on the

next page.

Go to next

activity.

After the options have been set, click on the Go tonext activity button. The Process Verification will follow the process plan.Notice the time box keeps the overall cycle time.

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The animation check box will cause the process to proceed automatically

Go to parent activity

Go to the beginning of

process

Go to the beginning of process within level

Go to the end of

process

Go to the end of process within

level

Repositions view to enhance simulation

Applies user-defined descriptive statements

Activates hyperlink activities

Shows part-specific descriptions

Activates user-defined pauses

Go to previous activity

Create the Process

The Process Verification dialog box contains selections that will control the viewing of the process.

Verify the Process

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As process verification occurs, the nodes will highlight and the parts will be displayed. This validates that links are established and that the process is ready for simulation. The validation

process can be followed on the PPR tree

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When working in manual mode, if you did NOT click through the entire Validation process you will need to restore the initial state to return to the beginning.

Select the “Restore Initial State” icon on the Simulation Toolbar.

Click OK in the “Restore Initial Condition” box to restore the original condition of the world for all products and resources and all of their attributes.

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Reverse the Process - Procedure

It is sometimes easier to see the verification of the process in reverse order. For example, a disassembly sequence may be easier to follow if product items appear in the assembly order. For these situations, it is simple to reverse the process and then run the verification.

1 Select the Process node on the PPR Tree and then click on the Reverse the Process icon on the Activity Management toolbar

2 When the dialog box comes up select the Reverse the entire process option. Notice that you can reverse only certain segments of the process. This option is useful after the simulation has been constructed using move activities.

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Verify the Process – Exercise

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Master Exercise – 3.5 HP Engine3.5 HP Engine (Step 9): Link the Product Data to the Process Activities

20 min.

Scope: Before the process can move on to the next step, you need to validate the process. During the validation process, you will observe the process node to see that all products are linked to their respective activities.

Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R16 DPM Assembly / PROJECT DATA.

In this exercise you will:Validate the processWatch the assemble process

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LOAD: R16 DPM Assembly / Project Data / Process / Disassembly2

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1. You can verify the process after the products are linked to the processes. From the simulation toolbar, open the Process Verification dialog box.

Set the following options: A. Animation on.B. Show Activity’s products.C. Show all Resources.D. Reframe off.

The validation process can be followed on the

PPR tree

Once the disassembly process has been established, it can be viewed in the assembly order. Use the Reverse the Process function to do this and then watch the engine assemble.

Click OK to Revere the entire process.Notice that the PPR Tree reverses.

2.

3.

Make changes to the process by using the Pert Chart.

SAVE AS: R16 DPM Assembly / Project Data / Process / Disassembly3

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2 Create the Process – Module Summary

SummaryWhether it is done in DPM Assembly or in another software, such as Process

Engineer, creating the process is the necessary first step to constructing a simulation. This module has demonstrated how to create and validate the process intention. As the simulation is built, modifications to the process are likely and can be easily accomplished using the techniques demonstrated here.

Coming UpCreate the Simulation

Build a Basic Simulation and Refine the Moves.

3 hours

Documents

Delmia DPM M2 - Create the Process Plan