SY08 - Advanced Simulation for Design and Optimization of your Plant

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

Advanced Simulation for Design and OptimizationIs It Part of Your Competitive Edge?

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 2

Agenda

Driving Competitive Advantage

Demonstration

Why Arena®

Simulation Overview

Introduction


PUBLIC INFORMATION

Case Study – Pallet Stretch Wrapping


Case Study

4

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


Case Study

5

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?


Addressing the Challenge

6

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

7


Variability Considerations (Input)

8

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

9

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


Agenda


Demonstration

Why Arena®

Simulation Overview

Introduction


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.

11

What Is Discrete Event Simulation?

Test Here Implement Here


Why Simulation?

12

Understand Complex Systems

Answer Critical “What If…” QuestionsVisualize Operations

Reduce Risk


Global Applicability

ManufacturingAutomotive

Government

Supply Chain

LogisticsFood & Beverage

Aerospace

Fin

anci

al S

ervi

ces

Retail

Minerals

Mining

Oil & GasPet

roch

emic

als

TelecommunicationsPorts & Terminals

Healthcare

Cus

tom

erS

ervi

ce

Entertainment Airports

Call Centers


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


Agenda


Demonstration

Why Arena®

Simulation Overview

Introduction


Leading global provider of innovative decision support solutions.

at A GLANCE

800+UNIVERSITIES

EasyFLOWCHART

#1Discrete Event

Simulation Tool

35YEARS IN THE

MAKING

100Fortune


Arena® Models All Business Processes

Supply Chain Management Customer Relationship Management

Who?

When?

How?

How Much?

Inventory Control

Tactical Planning

Stock Levels

Job Routing

Factory Flow

Capacity Planning

Staffing

IT and ERP

Delivery Options

Shipment Methods

Site Planning

Dispatching Rules

Front Office

Order Fulfillment

Workflow

Internal Processes

Staffing

Outsourcing

Call Routing

Issue Resolution

Supplier

Management

Warehouse

Inventory

Manufacturing

Processes

Distribution

Logistics

Business

Processes

Customer

Service


Agenda


Demonstration

Why Arena®

Simulation Overview

Introduction


Agenda


Demonstration

Why Arena®

Simulation Overview

Introduction


Benefits for OEMs

20

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

21

Training courses

Bi-monthly courses in Austin, TX

On-site, customized courses

Technical Support

Monday-Friday, 9am-5pm (Eastern Standard Time)

Phone or email

Consulting Services

Project assistance

Turnkey projects


Need Additional Information?

22

Sales

Steve Blatney

[email protected]

+1 (724) 741-4044

Technical Support

[email protected]

+1 (440) 646-6789

www.ArenaSimulation.com

mailto:[email protected]

mailto:[email protected]

http://www.arenasimulation.com/


Summary

23

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

www.rockwellautomationteched.com

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Thank You!

Technology

SY08 - Advanced Simulation for Design and Optimization of your Plant