LO 01 Introduction to Simulation Technique

7/31/2019 LO 01 Introduction to Simulation Technique

1/30

Introduction to Simulation Technique - Page 1

Introduction to Simulation Technique

Start!

Copyright

2006 oncampus Fachhochschule Lbeck/ Luebeck University of Applied Sciences, Stephensonstr.3, 23562 Luebeck, GermanyAll rights reserved

Using the Learning Objects

The learning objects and their contents (text, image, software, etc.) are protected by copyright.Learning objects are restricted for the private purpose of studying to those users who are permittedto access the online learning object by the offering institution.You are solely responsible for maintaining the confidentiality of your User Name and Password.

The legal protection of copyrights or related rights applies regardless of the form (physical ornon-physical/ online or offline) of the protected learning object that is being provided.

Simultaneous usage is restricted to one personal computer. Copies/ reproductions in whatever formare only permitted if explicitly stated or copyright does not apply.You are not allowed to change parts of the learning object and content.Likewise direct or indirect, temporary or permanent reproduction by any means and in any form, inwhole or in part, communication to the public, by any wire or wireless means, including the makingavailable to the public, as well as any form of distribution to the public by sale and otherwise of themodules and their content is prohibited.

The download of content including software from the learning platform is at your own risk. No liabilityis assumed for damage on the computer system of the user, or other technical equipment that hasbeen used. Further, no liability is assumed for the loss of data or other damages due to download orother activities in connection with the learning platform, unless the liability is based on intentional or

grossly negligent breach of duty.

No responsibility is assumed for content from external links which are included in the learning object.

Unive rs it y: UniversityDuisburg-Essen

Country: Germany

Prof. Dr.-Ing. Bernd Noche

University: University of AppliedSciences Kiel

Country: Germany

Prof. Dr.-Ing. Hans Janisch

1/30


2/30


This learning object (LO) gives a brief introduction to simulation technique.

The objective of this LO is to familiarize you with several important issues in

simulation concerning material flow and logistics, such as:

Reasons and limitations for applying simulation technique

The basis of definitions and principles

Range of applications

The procedure and steps of simulation technique

In addition, the first example of a simulation study is discussed in order to gain

first insights to possible questions and approaches.

1 Why Simulation?

2 Definitions and Guidelines

3 Range of Applications

4 The Procedure of a Simulation Study5 Steps of a Simulation Study

6 An Example of a Simulation Study

7 Utilization of Simulation Technology

8 Benefits of the Simulation Technique

9 Control Questions

In total the module requires 4 hours of your time.

Overview

Learning Objectives

Table of Contents

Duration

Learning

Objectives

Table of

Contents

Duration

2/30


3/30


To maintain their competitiveness, todays companies are forced to newly

design their production structures or flexibly adapt existing structures in ever

shortening cycles.

During this process, the structures are becoming increasingly complex, and themutual influence of the individual factors creates dynamics which are difficult to

manage by people without instrumental support.

The simulation on the screen allows dynamic and complex processes to be

made transparent. For instance, rationalization potentials, investments and

breakdowns can be simulated, and reactions can be tested.

Herein, it must be noted that the utilization of simulation only brings advantages

if it is carried out in a competent and efficient manner.

Simulation in Material Flow and Logistics

Simulation is used in numerous ways in the field of material flow and logistics.

Aside from assembly systems, conveyor technology and working systems,

even entire factories and distribution centers are tested, right through to Supply

Chain Management. To carry out simulation studies effectively, special

knowledge is required in the field of simulation technology and logistics. It

ensures that the fields of application for simulations are correctly delimited, and

the type of use and point of utilization are correctly selected.

The questions which are to be clarified with the aid of simulations must beasked precisely. Using the question, it is possible to collect the required data in

order to then carry out the required experiments after modeling. Simulation

projects often suffer from communication difficulties between the customer and

the simulation expert. Increased time requirements and substantial costs are

detrimental for all participants, and the simulation results are often

unsatisfactory. Simulation technology is fundamentally costly; that is, it is

necessary to consider in advance whether more favorable methods may be

able to deliver the desired results.

1 Wh Simulation?

3/30


4/30


The VDI Guideline 3633 defines simulations as follows:

Simulation

Simulation therefore describes the model of an object and the experiments

carried out on it.

2 Definitions and Guidelines

Definition of Simulation

Simulation is a process for patterning a system with its dynamic processes in

an experimentable model to obtain knowledge which can be transferred into

reality. In a wider sense, simulation is understood as the preparation,

realization and evaluation of targeted experiments with a simulation mode.

With the aid of simulation, the timewise process flow behavior of complex

systems can be examined.

VDI 1996

A model is a simplified imitation of an existing or imagined (or past) system

with its processes in another comprehensible or representational system.

With regard to the characteristics that are being examined, it is, in terms of

the relevant characteristics, different from its role model only within

tolerances which depend on the goal of the examination. It is utilized to solve

a certain task whose realization through direct operation on the original is no

longer possible, or too costly.

VDI 1996

Definition

4/30


5/30

Modeling

In slightly simplified terms, this means that modeling in simulation includes the

realization of an existing or imagined system into an experimentable model

which is also defined as the simplified imitation. Correspondingly, simulations

usually depict only those characteristics of a process which is relevant for the

desired knowledge. For this reason, they often remain abstract and are similar

to the process which they depict only in some aspects. Therefore, thepossibility of an observer confusing the simulation with reality is excluded in

these cases.

System

In DIN 19226, a system is marked by system limits towards its environment.

The system limits define entries and exits from the system to its environment.

(VDI 1996)

Discrete Event Simulation

A simulation method defines the manner in which the time behavior of asimulation is considered. When carrying out a simulation run, the model

elements whose condition changes throughout the observed time period are

described. Fig. 1 shows the various simulation methods.

Image Continuous and discrete simulation

methods can be utilized to extrapolate

time within a model. In continuous

simulation, the models condition

variables are shown in a steady flow

over time, for instance to clarify

chemical processes.

In discrete simulations, the condition

changes are observed at discrete

points in time. A differentiation is

made between event-oriented

simulation, that is, the progress of the simulation is determined by the

beginning of an event, e.g. the start of processing. And then there is

time-controlled simulation, where the model is observed within a fixed time

period (Arnold et al. 2002).

Fig. 1: Taxonomy of conventional simulationmethods

Taxonomy of conventionalsimulation methods

5/30


6/30


Simulation technology in Material Flow and Logistics can be applied anywhere

in the life cycle of a production site or factory. Simulation makes sense when

simple calculation processes are no longer sufficient, or when numerous

variants have to be researched.

Here, the utilization of simulation technology covers:

Planning facilities or factories,

Realization and start-up of logistics systems, and

Operation of the production sites.

Simulation is currently used most frequently in planning, and less frequently in

realization. Actual utilization within the framework of production planning and

control, e.g. in simulation-supported control centers, is particularly new.

With regard to fields of application, it is also true that simulation technology is

utilized in a variety of trades. The following are simulated in the chemical

industry, in machinery construction, in electronics, in shipping, in freight, in

commerce, etc:

Order picking systems,

Assembly systems,

Production systems,Sorting systems,

Work systems, and

Organization systems.

A trend can be observed here away from the individual systems and towards

the comprehensive analysis of entire factories. Simulation technology is

introduced in the following through a first simple example.

Since the field of application for simulation is very broad, it is therefore the taskof the potential user to recognize those cases in which its utilization makes

sense. The tool is currently finding application in practically all planning phases

from rough planning via fine planning through to realization. Table 1

summarizes significant questions again. The recommended time for utilizing

simulation is as early as possible.

3 Ran e of A lications

6/30


7/30

Table

Applying Simulation Technique

The use of simulation must initially be planned independently from simulation

software. From goal planning, the projects goal is formulated, and it is verifiedwhether simulation makes sense for this question. It must be noted that simpler

and more cost-effective alternatives to simulation, e.g. table calculation, will

frequently provide a solution. In spite of the fact that simulation technology is

available for use, the rule should be: Only simulate when all other means of

calculation have been exhausted or can no longer be utilized economically.

The necessity for simulation results from the degree of complexity, for instance

networked links between cause and effect, or feedback effects.

The simulation tools which are currently available in the market offer every

conceivable comfort:

Simple entry mechanisms,

Vivid representation of results,

Animation for visualizing processes,

Interfaces for data transfer.

Use of simulation

Tab. 1: Use of simulation in the various project life phases

7/30


8/30


Fig. 2 shows how simulation technology proceeds. The observed real system is

initially emulated in a model with the aid of simulation software. The various

questions can then be examined experimentally on this model through a

variation of parameters and attributes. The results are then interpreted andtransferred to the real system.

Image

Real / Planned System:

The starting point can be an existing or planned facility or manufacturing area.This system should be optimized by a simulation.

Simulation Model:

The production unit to be examined must be shown in a simulation model.

Aside form a determination of interfaces, this also includes a restriction to

significant features (reduction) and suitable translation into the available

simulation software (abstraction).

Formal Results:

Every simulation run creates output which is expressed in suitable figures andstatistics. To evaluate the value of a model, various test series (experiments)

must be carried out. At the commencement of a simulation study, an

experiment plan is created, among other things. However, experience has

shown that it will change several times in the course of a study depending on

the results of the individual experiments.

Conclusion for the Real / Planned System:

The statistics which are obtained must be compared to each other, and serve

to clarify the behavior of the facility. The interpretation of this result leads to the

conclusion (transfer) back into the real system.

This described cycle can be undergone several times perhaps because

further questions need to be clarified, or because the individual results have

4 The Procedure of a Simulation Stud

Fig. 2: Procedure in simulation

Procedure in simulation

8/30


9/30

side effects which require further measures.

9/30


10/30


The described process for executing a simulation study shows how simulation

techniques can be used to optimize the facilities. However, several steps are

necessary for creating a simulation model and carrying out suitable

experiments:

Clarification of relevant research goals

Data procurement (reduction)

Model creation (abstraction)

Model check

Experimentation

Documentation and presentation

Definition of Relevant Questions for the Investigation

The economic realization of a simulation study within the deadline is only

possible if the significant questions and research goals were formulated in

advance. This allows the formulation of conclusions regarding which partial

sector of production must re examined more closely (interfaces) and at what

level of detail one should make the representations. In principle, the following

applies: As precisely as possible, but not more precisely than necessary."

Reduction

The next step is data procurement. Depending on the problem, this includes a

description of processes, technical data such as speed, work time etc., cycle

rules of the products through the factory, control rules, batch sizes and

transport units, order algorithms, shift models, the layout of the production site,

order data or arrival data of pallets or work pieces, etc..

Example: Data structure for simulation in mechanical manufacture and

assembly

Abstraction

Model creation begins as soon as the model structure has been clarified.

Modeling also orients itself to the options of the available simulation tools.

However, it is not possible to do without relevant modeling aspects simply

because the software is incapable of them the simulation study would then

lose its purpose. If necessary, another simulation software must be used (or

possibly just rented). The users abstraction abilities and experience determine

the value of a model. The model must be as simple as possible (transparency)

and simultaneously record all characteristics which are important to the

examination (precision).

Validation of the Model

Verifying the validity of the model is an important step. For this purpose,

comparison data, plausibility checks and simple estimate calculations should

be utilized. Further possibilities for verification result from an examination of

partial models, following through the cycles of individual products, or

eliminating coincidental influences.

5 Ste s of a Simulation Stud

10/30


11/30

Experimentation

The test series commence as soon as there is sufficient trust in the models

validity. Depending on the results, a great variety of questions is often

examined in an attempt to clarify effects, explain trends, etc., until all relevant

facts are eventually gathered.

Documentation and PresentationFundamentally, all simulation results must be documented. A presentation of

the results increases acceptance when realizing the obtained knowledge, and

also provides the necessary trust in the relevance of the results.

Documentation of the results should be structured as follows: Definition of the

task and goal setting, data foundation, modeling and depiction, experiment

progression and significant conclusions, as well as a clear summary.

11/30


12/30


In the following, the progress and benefits of simulation technology will be

shown, using a small study as an example.

6 An Example of a Simulation Study

6.1 Real System

6.2 Modeling

6.3 Formal Results

6 An Exam le of a Simulation Stud

Table of Contents

Table of

Contents

12/30


13/30


The material flow system which is to be analyzed through simulation

technology is sketched out in Fig. 3. It is a contour control of the type which can

be found in various places in automated systems, such as in goods receipt

areas.

Image

The contour control is operated manually. A certain percentage of pallets is

ejected when the contour control is triggered. These pallets must then be

moved by a worker.

The following questions are to be answered within the framework of the

simulation study:

What weak areas are there in the material flow system?

How large is the throughput in the desired solution?

What influence does the utilization of a second worker have on follow-up

work (re-palletizing)?

What throughput times result for the pallets in the material flow system?

How does the facility behave in the event of malfunctions?

Are the buffers sufficiently dimensioned?

How high is the working load on critical components?

6.1 Real S stem

Fig. 3: Example of a contour control

Example of a contour control

13/30


14/30


Model creation took place with a component-oriented simulation system. The

following components were required: Source, accumulation conveyor, merging

switch, order picking station, distribution switch and sink. The layout of the

material flow system according to the modeling is shown in animation 1.

Rollover

There are initially no direct correspondences in reality for the source and sink.

These model elements are introduced for purely practical reasons. |they

represent the interfaces between the system which is being examined and the

environment. The pallets enter the material flow system via the source, and

vanish into a subsequent area again at the sink. Furthermore, the system load

can be easily varied with the aid of these interfaces.

The data of the small model are:

Arrival rate of the pallets: 30 sec.

Conveyor speed (accumulation conveyors and work station): 0.2 m/sec.

Pallet length: 1 m

Handling time for the pallets at contour control: 10 sec.

Handling time for the pallets in follow-up work: 30 sec.

Follow-up work quota 20 %.Number of workers: 1 person

Workers travel time 30 sec.

Priority of the combining station for the source.

Buffer capacity in re-circulation 1 place respectively.

Buffer capacity at goods receipt (after the source) and goods exit (ahead

of the sink): 10 places

6.2 Modelin

In the online version an interactive multimedia element is shown here.

14/30


15/30


After entering the components and the parameters into the simulation software,

a complete system blockage is shown after the first simulation (see animation

2).

Animation

As a reaction to the first simulation run, the re-circulation strand was now

prioritized in a second simulation run. This measure did prevent a system

blockage, but the load was not handled the buffers after the source filled up

after only approx. 30 minutes. Fig. 4 shows the fill level of the buffer and the

source. The buffer was continuously filled up to 100 % after only 2 hours. The

backup in the source is also evident. After 10 h, the source had a fill level of

approx. 60 %.

Image

Fig. 5 shows the buffer load ahead of the sink showing that it is utilized at

barely 50 %.

6.3 Formal Results

In the online version an interactive multimedia element is shown here.

Fig. 4: Buffer load

Buffer load

15/30


16/30

Image

Fig. 6 shows the load on the work stations. Contour control has a load of

approx. 100%, and the follow-up work station has a load of 30 %. However, the

statistics also show high shares of the condition Waiting for Worker. That is,

the work stations are busy or the worker is busy at another work station at the

moment.

Image

The work station statistics of the worker in Fig. 7 show a load of approx. 85 %

with approx. 25 % travel path. The workers waiting time is created while thepallets are transported into the work stations.

Fig. 5: Buffer load ahead of the sink

Buffer load ahead of the sink

Fig. 6: Load diagram of work stations

Load diagram of work stations

16/30


17/30

Image

The throughput statistics in Fig. 8 show the time shares of maximum and

minimum throughput times. The average throughput time (the middle bar)

rises from hour to hour this is an indicator that the small material flow system

cannot handle the prescribed system load.

Image

Of course, the results of these first two runs are not satisfactory. The material

flow system cannot handle its load. The causes might lie in the unfavorableload on the worker, who runs to the follow-up station whenever there is

follow-up work and therefore works very inefficiently for the facility would

have to be running, on a calculation basis.

Fig. 7: Work station statistics of the worker

Work station statistics of the worker

Fig. 8: Throughput time statistics

Throughput time statistics

17/30


18/30


In the following chapter, practical examples will be used to explain the

relevance of simulation technology. Aside from the questions, the costs for

carrying out the study will also be shown.

7 Utilization of Simulation Technology

7.1 Advance Warehousing Zone with Driverless Transport System

7.2 Order Picking Advance Zone

7.3 Production System

7 Utilization of Simulation Technolo

Table of Contents

Table of

Contents

18/30


19/30


We are looking at a production warehouse which is cleared out by a DTS

(Driverless Transport System). The small facility is shown in Fig. 9. It consists

of the warehousing areas, the stock removal nozzles, the transfer point to the

DTS, as well as the route of the vehicles.

Image

The system is described by the following data:

Block route length of the vehicle route 2.4 m,

Vehicle speed 0.8 m/sec,

Transfer time 22 sec (including positioning time).

The following questions should be answered with the aid of the simulation:

What is the maximum throughput?

How do variations in transfer times influence throughput?

How should the block route division be selected in order to further

increase throughput?

All relevant model elements are considered in the simulation model: The

source which offers sufficient vehicles -; the length of the block routes; the

intersection; the transfer times.

About 20 experiments are carried out: Various block route divisions, various

intersection controls (notification when the intersection is clear), different

variations in transfer times (rhythmic, normally distributed, exponentiallydistributed).

7.1 Advance Warehousin Zone with Driverless Trans ort S stem

Fig. 9: Sketch of the advance warehousing zone with the DTS route

Sketch of the advance warehousing zone with the DTS route

19/30


20/30

Image

A result of the runs is shown in Fig. 10. Throughput is significantly influenced

by the variations in transfer time (up to approx. 15 % deviation).

The manual solution (normally distributed transfer times) shows a lower

throughput than an automatic conception. In an exponential transfer time (for

instance, by a person who is also utilized for other activities which are not

shown), the throughput worsens significantly once again. Due to the scatter in

the operation times, the required throughput is not reached in a manual system.

The requirement for this study is approx. 3 h.

Fig. 10: Throughput rates with different variants

Throughput rates with different variants

20/30


21/30


The object being planned is an order picking advance zone in a plastics plant,

by the principle "Goods to Man". The layout of the order picking zone is shown

in Fig. 11.

Image

The pallets run from the warehouse via the circular conveyors to the order

picking stations. Here, the goods are removed and re-packed into a waitingpallet (not shown). The pallet which was removed from the warehouse is then

re-warehoused with an automatic warehousing site specification. The system

consists of 4 warehousing aisles and 4 order picking stations. Empty and

complete pallets are removed from stocks on a special stock removal route.

Goods from production (delivery by truck) are brought into the warehouse from

time to time via a warehousing route.

The questions to the simulation study are:

How high is the turnover performance of the system?What effects does the monitoring of stock removal in the correct order

have on throughput?

What effects does the restriction of the maximum permitted number of

pallets have on the cycle?

How high is the load on the pallet sites?

What duplicity share shows itself in the shelf operation devices?

The procurement of data for carrying out this simulation takes place through the

customer. Planning is founded on estimated turnover volumes and order

picking time per item. The technical data are obtained from catalogues from

conveyor manufacturers.

7.2 Order Pickin Advance Zone

Fig. 11: Layout of the order picking zone

Layout of the order picking zone

21/30


22/30

Model creation takes place with a simulation system which offers components

from the material flow field, namely work stations, compression conveyors,

combiners, ejectors etc.

The simulation runs show that the system does not provide the required

performance when strict adherence to the correct order is demanded.

Furthermore, it is determined that the load on the order picking stations varies

greatly: 80 % for order picking station 1 and 70 % for order picking station 4.

Significant savings can be realized by changing the division of the conveyor

segments and increasing the conveyor speed (the number of drives is cut in

half!) without reducing throughput. With the aid of the simulation, a system

specification for warehouse management is created.

Fig. 12 shows the system throughput in dependence on the maximum

permissible cycle load. It is shown that throughput is highest when the load on

the cycle is only approx. 50 %. With higher load rates, there are blockades

which range through to system standstills; with lower loads, the system"starves.

The requirement for this study is approx. 12 man days.

Image

Fig. 12: Throughput in dependence of maximum cycle load

Throughput in dependence of maximum cycleload

22/30


23/30


The starting point is an existing production facility, consisting of 40 machines

which manufacture approx. 2,000 pallets of paper products, such as napkins or

tissues, daily (Fig. 13).

Image

There is a differentiation between 6 machinery groups; one machinery group is

determined for each product group. In principle, there is free assignment of

machinery to products within the product group sometimes with very

significant setup time.

The questions to the simulation are:

To what degree are the machines under load in a future order mix?

By how much can production be increased subsequently?

How large will the warehouse need to become?

What delivery service can be reached?

What effect do shift models have?

What happens when production planning is carried out daily (instead of in

a weekly rhythm)?

Model creation when depicting an entire factory includes scheduling (order

receipt and production program creation), production (machinery, setup times,

control center logic) and shipping (warehousing, shipping regulation).

Standardization when depicting entire factories is not yet far advanced. For thisreason, aside from utilizing the components, a significant share of programming

also becomes necessary for depicting the control strategies.

7.3 Production S stem

Fig. 13: Schematic layout of a production system

Schematic layout of a production system

23/30


24/30

The results of the study show that the factory has already reached its

performance limits. Without purchasing additional machinery, neither

just-in-time production nor a production increase is possible. This result

surprised all participants in planning. The assumed reserves have been

completely utilized by the masters on site through an ingenious dispatching

strategy. The disadvantage of this strategy is, however, a high amount of

finished product stocks and low flexibility in reacting to customer wishes. The

warehouse space requirements can be reduced to 50 % of the planned base.

The requirement for this study is approx. 40 man days.

24/30


25/30


It would be nice if the benefit of the simulation technology could be expressed

in Euros immediately before carrying out a simulation study. This, however, is

only rarely possible. The benefit of simulation technology is very widely spread

(VDI Guideline 3633).

Security gains:

Confirmation of planning specifications

Minimization of entrepreneurial risk

Functionality of the planned system

Functionality of control

Quality of the requirements specifications

More cost-effective solution:

Savings or simplification of system elements

Savings or simplification of control elements

Optimization of buffer sizes and warehouse stocks

Optimization of work processes (contents)

Better understanding of the system:

Parameter sensitivities

Ability to give reasons for the selected solution, and to verify it

Avoidance or elimination of bottlenecks

Training of plant personnel

Dynamic analysis and representation of the entire process (animation)

More favorable process control:

Decision-making support in operation problems

Process optimization in accordance with desired target functions (e.g.

throughput time, load, output)

Productivity increase

Optimization of facility controls

Minimization of standstill costs in case of failures

Shortened start-up phase

Judging by an analysis of numerous simulation studies and examinations, it

can be concluded that simulation studies have lowered costs in many cases in

which they were applied.

However, the prerequisite is that a professional course of action is chosen and

8 Benefits of the Simulation Techni ue

25/30


26/30

the questions concern targeted aspects.

It is also important to secure the corresponding data quality. Animation 3

contains a summary of questions / examination aspects which, depending on

their field of application, were tested in simulation studies.

Click-InteractionIn the online version an interactive multimedia element is shown here.

26/30


27/30


Question 1

Which iteration steps are repeatedly run through when planning with simulation

technology?

Show answer!

Question 2

Of which stages does a simulation study consist?

Show answer!

Question 3

Which advantages are offered by the utilization of simulation technology?

Show answer!

Question 4

The assembly of an electrical device (e.g. a vacuum cleaner, hair dryer,

shaver, iron) is to be researched in a simulation study.

Which data are commonly required?

Name data classes and one typical data set for each.

Show answer!

Question 5

Plant-internal transport is to be researched in a plant. What questions can

typically be expected? Please name 10 aspects.

Show answer!

Question 6

What is a system blockage?

Show answer!

9 Control Questions

27/30


28/30


The cost and benefit of simulation technology have changed extraordinarily

over the past five years. On the one hand, high-performance simulation tools

(simulators) have appeared on the market; on the other hand, the

acceptance of results has increased considerably as well. The visualization

of results through animation has meant that the planners and operators of

production sites can estimate the proper depiction detail, and interpret and

realize results. Animation shows a momentary situation in the facilities.

Together with this, curve progressions, graphics and figures enable an

evaluation of a systems performance capabilities throughout the entire

simulation period.

To do a simulation, a system is created in a model, and this model is shown

on the computer with the aid of the software. By varying the parameters,

experiments are carried out, and the results are subsequently evaluated.

However, it must be noted that a complex process cannot be rendered less

complex through the utilization of simulations. The results of a simulation

depend on the model, the underlying data, and the interpretation of the

results, and not on the utilized software.

The utilization of simulation technology only brings advantages if it is applied

properly and efficiently.

Summar

28/30


29/30

Introduction to Simulation Technique - Specialwindow

1. Order quantity structure

Order file with the following entries:

Product (type)

Number of items

Dispatch date

End date

2. Work plans

File which states the run through manufacturing for all relevant products:

Product (type)

Work order

Machine

Processing time

3. Item list

Composition of products for showing assembly:

Type assignment

Number of items (end products end figure)

4. Transport units

For showing transport intensity and storage requirements:

Type - container (if various are present)

Type - product (assignment to the container)

Number of items per container (maximum value)

5. Layout of the facilities

Machine, transport and storage arrangement

Machine identification

Buffer capacities

Machine control

Set-up times

Set-up logic (when does set-up or cleanup take place?)

Interruption rules

Failure times (where relevant)

Rejection quotas (depending on the machine?)

6. Conveyance technology data

Example: Data structure for simulation in mechanical manufactureand assembly

29/30


30/30

Speeds of conveyance technology

- Shelf operating device

- Assembly lines (constant conveyor)

Control logic

- Keeping the transport or production batch together

- Branching logic (combining logic

7. Shelf facility

Technical data:

Capacities

Dimensions

Organization

Container distribution (zoning)

Reach-through (location)

Occupied places (blocked places)Operation range of the shelf operating devices

8. Process strategy in the manufacturing control system

Control logic

Order of the orders, depending on machine group

Handling logic for batches (splitting, overlapping)

Amount adaptation

9. Planning regulations of the PPS

Superior regulations

Batch sizes

Time of order clearance

Transfer times (planning times)

Order in which orders are dispatched (regulations)

10. Control station shelf facilityTasks of the control station:

In normal production

In malfunctions

For rush orders

What other manual tasks occur?

Process logic in the shelf facility

Strategy in shelf space occupation

Strategy of removal from storage (Which container when?)Strategy of placement in storage (Which order first?)

Documents

LO 01 Introduction to Simulation Technique