Modeling and Simulation of a Production System KPP319 – Product and Process Development Magnus Wiktorsson, [email protected]

You have met: - Definition of a production system - Its role for competetiveness - Its development process - Example on simulation programs

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Agenda Modeling and Simulation … … within the development/design process …in an information integration context …as a process

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Agenda Modeling and Simulation … … within the development/design process …in an information integration context …as a process

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Dual competence areas of development and operation Decisions, plans, guidelines

Competences, Tools Methods Processes

Production system design

Production system operations

Competences, Tools Methods Processes

Experience, knowledge, data Wiktorsson (2013)

Focusing on production development, we are moving from a sequential scheme to a parallel one Retiring/ Re-use

Retiring/ Re-use

Running-in

Realising

Design and Realisation

Running-in

Operation/ Refining

Operation/ Maintaining

Planning Designing Operation/ Refining

Operation/ Maintaining

Wiktorsson (2000) Wiktorsson, 2000

Task: Market, Company, Economy

Problem statement

Visions / Objective

Plan & clarify the task

Plan and clarify the task: Analyse the market and the company situation Find and select product ideas Formulate a product proposal Clarify the task Elaborate a requirements list

Propositions

Conceptual design

Req´s - Alt´s - Eval.

Concept (Principle solution) Develop the construction structure: Preliminary form design, materials selection and calculation Select best preliminary layouts Evaluate against technical and economic criteria Preliminary layout Define the construction layout: Eliminate weak spots Check for errors, disturbing influences and minimum costs Prepare the preliminary parts list and production and assembly document

Embodiment design

Preconditions

Develop the principle solution: Identify the essential problems Establish function structures Search for working principles and working structures Combine and firm up into concept variants Evaluate against technical and economic criteria

Upgrade and Improve

Requirements

Information: Adapt the requirements list

Requirements list (Design spec)

Evaluation

Prepare production and operating documents: Elaborate detail drawings and parts lists Complete production, assembly, transport and operation instuctions Check all documents

Detail design

Definitive layout

Product documentation Solution Rosell, 1990

Pahl and Beitz, 1996 Hubka & Eder, 1996

Systems Engineering Fundamentals. 2001

Justification approaches for analysis of production systems Req´s - Alt´s - Eval.

Justification Methodologies

Strategic Approaches

Technical benefits Business Advantage Competetive factors Future Expansion

Analytic Approaches

Economic Approaches Payback

Value Analysis Scorecards Linear additive models AHP Models

Mathematical Analysis

Experimental Analysis

Net Present Value

”Back-of-theenvelope” calculations

Trace-driven simulations

Spreadsheets

Monte Carlo simulations

Queing networks Optimisation techniques

Internal Rate of Return Other Discounted Cash Flow methods Non DCF methods Sensitivity Analysis

Wiktorsson (2000)

Req´s - Alt´s - Eval.

Example on Modelling techniques ● GRAI (Graphe à Résultats et Activités Interliés) (Doumeingts et al., 1987) ● Structured Analysis and Design Inputs Technique (SADT) (Ross and Brackett, 1976) / IDEF0 (Integrated computeraided manufacturing DEFinition) /Astrakan ● CIM-OSA (1989) for Computer Integrated Manufacturing ● The Structured Systems Analysis and Design Method (SSADM) presented by for instance Downs et al. (1992)

Control A0 Manufacturing function

Output

A1

A2

A3

A21 A22 A2

A23

Mechanism A23

Problem identification Feasibility study Project identification Analysis of systems operation and problems Systems analysis

Specification of requirements Select technical option Data design

System design Physical design

A231

A232

Req´s - Alt´s - Eval.

Value analysis models Profile charts, checklists and symbolic scorecards Criterion A Criterion B Criterion C Criterion X

Low

Linear additive models Weight Criterion A 4 Criterion B 2 Criterion C 1 ... ... Criterion X 2 Σ Weighted scores:

Alt. 1 3 7 4 ... 1 105

High

Analytical hierarchy process (AHP) ... ... ... ...

Alt. M 1 5 7 ... ... 3 ... 77

Strategic attributes Level 1 Categories

A

B

C

Level 2 Attributes Level 3 Alternatives

... ...

1

...

M

Wiktorsson, 2000 Wiktorsson (2000)

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Agenda Simulation and modeling… …in the development process …in an information integration context …as a process

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The vision on the Digital Plant is ever existing…

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The Digital Factory ‘‘a comprehensive network of digital models, methods and tools, including simulation and 3D/VR visualization, which are integrated through continuous data management.’’ VDI (2004) Product development, test and optimization

Plant design and improvement

Production process development and optimization

Operative production planning and control

Information plattform

Adapted from Kuhn (2006)

Modeling and simulation in Product development WP1. Virtual verification of assembly system CAD/CAM DPD / MBD Product Data Management Product Lifecycle Management

Product development, test and optimization

Plant design and improvement

Layout Material flow and routing Utilities Performance and capacity

Operative production planning and control

Planning and sequencing Enterprise resource planning Manufacturing execution system Human resource planning

Information plattform Virtual manufacturing and assembly Workstation design Equipment and tool design Programming

Production process development and optimization

• Well established area • Many commercial tools are available, such as Catia. Pro/Engineering SolidWorks, Unigraphics NX Series, Solid Edge, AutoCAD etc. • Research on standards and information integration

Modeling and simulation in Process development WP1. Virtual verification of assembly system CAD/CAM DPD / MBD Product Data Management Product Lifecycle Management

Product development, test and optimization

Plant design and improvement

Layout Material flow and routing Utilities Performance and capacity

Operative production planning and control

Planning and sequencing Enterprise resource planning Manufacturing execution system Human resource planning

Information plattform Virtual manufacturing and assembly Workstation design Equipment and tool design Programming

Production process development and optimization

• Concerning process development and optimization, many tools are available for specific purposes.

Modeling and simulation in Plant design WP1. Virtual verification of assembly system CAD/CAM DPD / MBD Product Data Management Product Lifecycle Management

Product development, test and optimization

Plant design and improvement

Layout Material flow and routing Utilities Performance and capacity

Operative production planning and control

Planning and sequencing Enterprise resource planning Manufacturing execution system Human resource planning

Information plattform Virtual manufacturing and assembly Workstation design Equipment and tool design Programming

Production process development and optimization

• Within plant design commercial solutions is provided by e g Delmia and Tecnomatix. • Still a lack of open integration possibilities between tools and planning levels • Optimization on a multi-criteria level is required

Modeling and simulation in Operations WP1. Virtual verification of assembly system CAD/CAM DPD / MBD Product Data Management Product Lifecycle Management

Product development, test and optimization

Plant design and improvement

Layout Material flow and routing Utilities Performance and capacity

Operative production planning and control

Planning and sequencing Enterprise resource planning Manufacturing execution system Human resource planning

Information plattform Virtual manufacturing and assembly Workstation design Equipment and tool design Programming

Production process development and optimization

• In the area of integration to the operative production planning and control down to the factory floor, much effort is still needed • The most immature part of the digital factory vision.

Information integration is key for Industry 4.0, etc… WP1. Virtual verification of assembly system CAD/CAM DPD / MBD Product Data Management Product Lifecycle Management

Product development, test and optimization

Plant design and improvement

Layout Material flow and routing Utilities Performance and capacity

Operative production planning and control

Planning and sequencing Enterprise resource planning Manufacturing execution system Human resource planning

Information plattform Virtual manufacturing and assembly Workstation design Equipment and tool design Programming

• System modeling • Information architecture

Production process development and optimization

Case: from CAD to instruction Platform Constraints

Design Konstruktör Engineer

STRUCTURE R No Art.No A 2 311487 B 1 862144

CAD-drawing with articles Manufacturing Engineer Operations engineering Proposed changes in product design

PII with TMU

Name Strip xx Strip xy

Assembly Sequence Production Engineer

Moment

Date

Variant XYZ XYZ

Variant XYZ XYZ, XY

No 156432 Adress 18725-87

PII TMU 755 320 150 755

T/U week T 9943 T 9943

Cause Structure updated

Introduction No:C16-9

Sequence list 99-XX-XX Plant: X Project: PII St W/ID Name C16-7 10 215 Ass’y X C16-2 10 215 Ass’y Y C27-1 10 215 Cut Z …

Layout Balance engineering

Stn

PICTURE 3-9943 TOOL Tool no T Tool name Operation 15424 Tool A 10, 510 28734 Tool B 15, 515 TEXT … notes and comments … CHANGES Week UF No Des No Proj. 9943 GN C39422-9 465534 XXY Name Person

Operations Sequencing

Packing

OPERATION T Op R K Operation description M 5 D Pull tape from page, … 10 AB Place the strip at the … 15 Take tool A and pull … 505 Pull tape from …

452 Max B1 335 315 625 625 90 -

B2 315 -

Balance instruction Type Name Ass’y X Date Length Made by 9935 1 N. P-son

Layout

Assembly instruction

Modified layout

Activity Open xyz Go to Y Ass’y Q

PII+S+B 16-6 S6 16-6

Op 10 20

F

Variant 88 ZX3 88

BX 335 600 -

Total Time 2547 Takt XX #/hrs Time PII S+B 110 90 15

Wiktorsson, 2000

Case: tool usage

Flow

CC-Plant

Witness

Ergoplan Process

IGRIP/RobCAD 4D-Navigator

Product

Catia

Static model: Geometric/Descriptive

Dynamic model: Kinematic/Flow simulation

Note that the tools have capabilities not used in this case, that is, the circles could be placed Wiktorsson, 2000 differently in another case Wiktorsson, 2000

The tools and methods used in the case Description

Usage in this case

Catia

CAD-system describing the product and tools.

Engineering design

T

IGRIP

Detailed simulation/visualisation with OLP-abilities

Geometric simulation

O

RobCAD

Robot simulation program (similar to IGRIP)

Geometric simulation

O

4D-Navigator

Visualising product and tools

Geometric packing

L S

Ergoplan

Visualising assembly and material facades. Ergonomic considerations

Work place design

CC-Plant

Process description with attributes

Process description

Witness

Flow simulation program for material and line

Flow simulation

M E

FMEA

Checklist for failure/consequence analysis

T

VCCQ

Checklist for quality assurance

H

SAM

Time analysis of assembly activities

O D

DFA/DFM

Analysis of assemblyability and manufactureability

Wiktorsson, 2000

Agenda Simulation and modeling… …in the development process …in an information integration context …as a process

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Character of systems ’worth’ simulating Variability

Interconnectivity

Complexity (combinatorial or dynamic) Based on Robinson (2004)

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When not to simulate? ● Can the problem be solved with common sense? ● Can the problem be solved analytically? ● Less expensive to experiment directly? ● Is cost higher than gains? ● Are time or resouces available? Expertice ● No data or estimates exists? ● Too high expectations? ● Too complex system behaviour?

Adapted from Banks & Gibson, 1997

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Types of models

Discrete

Continuous

Static

Dynamic

Deterministic

Stochastic

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Examples on software For more comprehensive and up-to-date lists, see e.g.: • IEE Solutions Simulation software survey • ORMS Today Simulation software survey • The Winter Simulation Conference tutorial on Simulation software • INFORMS College on Computer simulation web site

Software

Supplier

Arena

Rockwell

AutoMod

Brooks-PRI

Awe Sim

Frontstep

Enterprice dynamics

Incontrol Enterprice dynamics

Extend

Imagine That

Flexsim

Flexsim

GPSS/H

Wolverine

Micro Saint

Micro analysis and design

ProModel

ProModel

Delmia (Quest)

Dassault Systemes

ShowFlow

Webb systems

SIGMA

Custom simulation

PlantSim /Technomatix

Siemens

Simul8

Visual8

SLX

Wolverine

3D Create

Visual Components

Visual simulation environment

Orca

Witness

Lanner Group

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When selecting software Step 1. Establish modeling requirements Step 2. Survey and short list possible applications Step 3. Establish evaluation criteria Step 4. Evaluate the software in relation to the criteria Step 5. Software selection

• Assess multiple criteria: support, applicability, level of detail, ease of learning etc • Execution speed • Be aware of demonstration objects • Try small version of Your problem • Possibility to write additional code in C, C++ or Java etc. However, best if internal logic can solve the problems. • Tradeoff between graphical software and software built on simulation buildning. All require conceptual modeling and logic representation. 28

Steps in a simulation study

29 Banks et al, 2010

The importance of conceptual modeling

Robinson et al, 2011

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The major use of simulation within Production at MDH has been in Master courses

3DCreate 2012 (visualisation) ExtendSim 7.0 (discrete event)

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Model example 1: scanned shopfloor

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Model example 2: modeled shopfloor

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Model example 3: factory walk-through

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The future of simulation ● Model size and complexity? ● Verification and validation techniques? ● Optimization using simulation? ● Parallel and distributed simulation? ● Internet based simulation? ● Agent based / network simulation ● Human behavior and uncertainty modeling and simulation? ● Possible integration with ERP, PLM etc.?

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Referenced litterature Banks J., Carson II J S., Nelson B L, Nicol D M (2010). Discrete Event System Simulation. Pearson Banks J, Gibson RR (1997) Don’t simulate when: 10 rules for determining when simulation is not appropriate. IEE Solutions. CIM-OSA (1989) Project 688: Open System Architecture for CIM. ESPRIT Consortium AMICE (Eds.). Springer Verlag. Doumeingts G, Vallespir B, Darricau D, Roboam M (1987) ”Design Methodology for Advanced Manufacturing Systems.” Computers in Industry. 9(4):271-96. Downs E, Clare P, Coe I (1992) Structured Systems Analysis and Design Method: Application and Context. 2nd Edition, Prentice Hall. Klingstam P, Gullander P (1997) ”Overview of Simulation Tools for Computer-Aided Production Engineering.” Proceedings from ASI'97, Advanced Summer Institute. Budapest, Hungary. Kuhn W. (2006) Digital Factory – Simulation Enhancing The Product And Production Engineering Process. Proceedings of the 2006 Winter Simulation Conference. Pahl G, Beitz W (1996) Engineering Design: A Systematic Approach. London: Springer Verlag. Robinson S., Brooks R., Kotiadis K, van der Zee D-J. (2011) Conceptiual modeling for discrete-event simulation. CRC Press Robinson (2004) Simulation – the practice of model development and use. Wiley. Rosell G (1990) Notes on the design process. (In Swedish) Stockholm: Kungliga Tekniska Högskolan, avd. för teknik- och vetenskapshistoria. Systems Engineering Fundamentals (2001). Defense Acquisition University VDI (Association of German Engineers) Digitale Fabrik, Technical Committee Conference, 11.05.2004. Wiktorsson M (2000) Performance assessment of assembly systems – Linking strategy to analysis in early stage design of large assembly systems. Dissertation, KTH, 2000. Wiktorsson, M (2013) “Consideration of Legacy Structures enabling a Double Helix Development of Production Systems and Products”. Accepted to Technology and Manufacturing Process Selection: the Product Life Cycle Perspective. Ed: E. Henriques, P. Peças and A. Silva. Springer. (In press).