Industrial Excellence

Transkript

1 Industrial Excellence Discrete event simulation and some examples of simulation projects Mats Jackson

2 Discussion How can discrete event simulation be used to support production improvements/ production development?

3 Agenda 1. The individual work and the project 2. The simulation project - some examples of discrete event simulation projects

4 Individual literature study An individual reflection on future development regarding simulation as a tool within production and logistics management. In a brief PM (max 5 p), reflect and discuss upon following key topics for the future of discrete event simulation: 1. Model size and complexity, future trends 2. Verification and validation techniques 3. Optimization using simulation 4. Parallel and distributed simulation 5. Internet based simulation 6. Human behavior and uncertainty modeling and simulation 7. Possible integration with ERP, PLM etc. Search and refer to sources by your self! PM physical hand in and presentation Max 5 pages reflections and discussion.

5 Project The participants perform in a group of 3 persons a project. A simulationbased study of an industrial production process, complemented by advanced production system analysis methods. A production system analysis focusing an aspects of industrial excellence Develop a logic model as well as a visualized model of the object that is analyzed Simulation using Extend Sim and Visual Components Valid and relevant modeling and analysis to the objective of study. Expected results: Simulation model and analysis Project report hand in Group presentation and

6 Projects Examples on possible projects are: 1. GKN Driveline Köping (f.d. GETRAG) Projekt Fosfatering: Bakgrund: Fosfatering är en ytbehandlingsprocess som vissa av våra produkter går igenom. Kapaciteten i anläggningen har hittills inte varit något problem. Men för att vi ska kunna möta det framtida kundbehovet måste anläggningen optimeras och kapaciteten höjas. Mål: Se över fosfateringsprocessen och komma med förslag på hur vi kan styra materialflödet för att höja kapaciteten i anläggningen. Syfte: Höja kapaciteten i anläggningen för att möte framtida kundbehovet. Projekt Kulpening: Bakgrund: Kulpening är en operation som utförs av ett externt företag som ligger i anslutning till vår fabrik. Materialflödet till och från kulpeningen är inte definierat och inte styrd. Detta bidrar till att vi inte får tillbaka rätt variant i rätt tid i rätt mängd. Mål: Se över flödet till och från kulpening och komma med förslag på hur vi kan styra och dimensionera detta flödet Syfte: Få ett flöde till och från kulpening som är tydlig och väl definierad som underlättar för operatörerna att ta beslut om vad som ska produceras och hur mycket. 2. Leax Ett tillverkningsavsnitt som är fördelat på två separata men likadana flöden. För oss är avsnittet ovanligt då det dels producerar enbart en artikel men även för att de är starkt ihopbyggda flöden med robotar och banor. Dessutom finns duplicerad kapacitet på vissa maskiner i flödet men inte alla. Det är vårt avsnitt för tillverkning av Volvos synkroniseringsringar. Anledningen till att vi väljer synkringarna är att de är starkt i fokus för optimering samt som jag bedömer det bra avgränsat för som studieobjekt. Om det skulle vara så att tanken var flöden med fler artiklar för att simulera ställ och partistorlek så har vi sådana flöden också men då får vi diskutera fram vad som passar då komplexiteten ökar rejält. Målet skulle kunna vara att simulera fram eventuella systemfel dvs de förluster som kommer av hur vi har byggt flödena för att dels se vad vi egentligen kan förvänta oss rent teoretiskt i utfall, men även ge underlag för förbättringar. 3. Build upon previous studies in KPP206

7 Agenda The simulation project - some examples of discrete event simulation projects

8 Industrial excellence Decisions, plans, guidelines Competences, Tools Methods Processes Production system design Production system operations Competences, Tools Methods Processes Experience, knowledge, data

9 Production system design Typical areas for production development projects Design of a new production cell Layout process oriented, mixed model, new products Eliminating disturbances/problems quality, delivery etc. Volume increase Investments payoff, consequences What if questions new technology, new resources, more or less shifts

10 Simulation The practice of building models to represent existing realworld systems, or hypothetical future systems, and experimenting with these models to explain system behavior, improve system performance, or design new systems with desirable performance (Khoshnevis, 1994)

11 When to use production simulation? Uncertainty Spreadsheet Computer Simulation Complex decisions support Pen and paper Spreadsheet No. of Factors

12 Using discrete event simulation?

13 What to use simulation for? Complex problems in a dynamic system with many interacting parameters... people are having different opinions lack of decisions support... Alt. A? Alt. B?

14 What to use simulation for? Work station layout

15 What to use simulation for? Production system design and simulation at different levels

16 What to use simulation for? Robot system design and programming

17 What to use simulation for? Discrete event simulation can be used: Operational - Operational decision support - Supporting planning - Test of operational alternatives as e.g. mix of products Strategic - Analysis disturbances, waste etc. - Economic analysis decision support - Test of different change alternatives

18 The simulation project

19 How to work with a simulation project? Data collection Implementation of simulation result Model Simulation More data? Evaluation Result from simulation

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21 Simulation is not an optimizing tool which gives answers to all questions... WIP? GT? Product Mix? Education? Productivity?...it is rather a powerful tool that, through iterative work, can help identify and test ideas for improvement

22 Examples from simulation projects? 1. Operational simulation

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29 Project description An updated forecast of the workload - a support for resource allocation? Forecast (Simulation) Present situation Resource allocation

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31 The prototype planning tool Company information system Data; order, type, where, number, release, delivery date, routing File Picture Picture PC SERVER 1. Read data PC 2. Start simulation PC PC PC 3. Simulation reads data SCREENSAVERS 4. Simulation writes data 5. Build graph 6. Save graph

32 Information on screen savers 400 FORECAST 350 N U M B E R Late Present Hour 1 Hour 2 O F P C B REG NIT TEJP YT1 DIP VCD RAD YT2 BANA MEK DIL HALV 7 LOGG LÖMA KAP Hour 3 Hour 4 Hour 5 Hour 6 MACHINES

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36 Examples from simulation projects? 2. Strategic change outsourcing

37 First International Workshop on Intelligent Manufacturing Systems CALCULATING THE COST OF POOR QUALITY USING DISCRETE EVENT SIMULATION - Strategic decision support when developing a production system - a case study Mats Jackson ABB Management Consultants SWEDEN Christer Johansson Department of Mechanical Engineering Linköping University SWEDEN

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41 ABB Transformers was experiencing a reduction of the market price, which is forcing them to investigate all possible alternatives for improvements. P-div produce in-house or buy from an external supplier? Produce In-house Buy Externally TANK KITTING

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43 Is it possible to use discrete event simulation to calculate the cost of poor quality? By using discrete event simulation it is possible to: - Analyze different scenarios > production volumes > product mixes > different estimates of the non-value adding activities - Possible to include stochastic variables for e.g. random breakdowns or failures - Combine an economic cost analysis with a production flow analysis and see the effect on the financial result

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45 The process of simulating the COPQ can be summarized as follows: 1. Collecting data from the present production system 2. Building a model of the present system 3. Simulation of present state, turnover and costs 4. Verification and validation of the model by comparing with reality 5. Data gathering of quality problems and non-value added activities 6. Simulating costs and revenues without non-value added activities with different alternatives and scenarios 7. Calculation of the COPQ by comparing the financial results of the different models

46 Results from the simulation SIMULATION SCENARIO PROFIT (KSEK) COPQ (KSEK) % OF TURNOVER RUN 1 Present Direct cost Direct + indirect cost Table 1: Results from simulating COPQ due to design and engineering problems

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49 Examples from simulation projects? 3. Capacity analysis of a production system

50 ATLAS Redesign of the production system at ABB Robotics => Make the delivery capability an order winner

51 Background to project Atlas Delivery time to long Time and resources spent on internal transport Queues, unsynchronized production and waste due to manufacturing at different locations No testing area for robots 6600 and 7600 A need for more productivity improvements to stay in Sweden

52 Robotics future delivery process Special mek Stor mek Prov AbsAcc MPA Dressning Samprov Pack Distr Pull Coordination

53 100% 90% 80% 70% 60% 50% 40% On Time Delivery ( OTD ) Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec Jan Feb Mar Apr OTD Customer OTD Supplier

54 A need to analyze the impact of disturbances from suppliers on the workshop

55 Model of analysis - Robotics Production plan Disturbances Model - Material - Quality - Productivity - Delay of material Delivery time Delivery capability Hours Through-put time Queues

56 Examples - simulation SVP - PV5 Förutsättningar: - SVP-plan - stopp vecka 8 - Medelstörningar 6400 Leveranssäkerhet - Produktion Antal Stop week Leveranssäkerhet Vecka Körplan Producerat Taylor Leveranssäkerhet % Taylor

57 Examples - simulation SVP - PV5 Förutsättningar: - SVP-plan - stopp vecka 8 och 9 - Medelstörningar Leveranssäkerhet - Produktion Stop week Antal Leveranssäkerhet Vecka Körplan Producerat Taylor Leveranssäkerhet % Taylor 0

58 Examples - simulation SVP - PV5 Förutsättningar: - SVP-plan - 6 timmar prov - Medelstörningar Leveranssäkerhet - Produktion 6 hours test Antal Leveranssäkerhet Vecka Körplan Producerat Taylor Leveranssäkerhet % Taylor 0

59 Actions Stock level Buffer sizes The need for test space

60 Simulation is not an optimizing tool which gives answers to all questions... WIP? GT? Product Mix? Education? Productivity?...it is rather a powerful tool that, through iterative work, can help identify and test ideas for improvement