Data Based Model Generation Gas Turbines and Turbo...

Tecnomatix Plant Simulation Worldwide User Conference 2015

Siemens Industry Software

© Siemens AG 2015 All rights reserved.

2015-06-16Page 1

Data Based Model GenerationGas Turbines and Turbo CompressorsPavel Gocev and Andreas Sowinski


2015-06-16Page 2

GAS TURBINESGAS TURBINES

LOADLOAD

SIMBOMSIMBOM

PROCESSESPROCESSES

ORDERS/JOBSORDERS/JOBSFACTORY/

SIMULATIONFACTORY/

SIMULATIONRESULTS

KPIRESULTS

KPI

BLADES &VANES

BLADES &VANES

ROTORROTOR

STATOR/CASINGSTATOR/CASING

ASSEMBLYASSEMBLYDISCSDISCS

TURBO COMPRESSORSTURBO COMPRESSORS

IMPELLERIMPELLER ROTORROTOR

STATOR/CASINGSTATOR/CASING

ASSEMBLYASSEMBLYPACKAGE/TESTING

PACKAGE/TESTING

WHEELSWHEELS

ROUTINGSROUTINGS

DIFFERENT PRODUCTS - SIMILAR CONFIGURATIONSDifferent Value Streams channeled in one Modeling and Simulation Workflow




2015-06-16Page 3

• Multiple sites, areas andproduction lines

• Many models and modules developedby several simulation experts

• Modeling of dynamic andcomplex behaviors

• Dispersed and different structures ofavailable data and information

• Different logic descriptions

DRIVERS AND CHALLENGESReduction of Modeling Effort through an Unified Approach

DRIVERS AS MOTIVATIONDRIVERS AS MOTIVATION

• Reduction of modeling effort andshortening of the modeling time

• Reusable modules andmodel structures

• Universal solution fordifferent parties

• Upgradable andadaptable model

• Improved communicationthrough standardization

CHALLENGES TO RESPOND ONCHALLENGES TO RESPOND ON

… DEFINE… DEFINE


2015-06-16Page 4

Simulation ModelPlant Simulation

LoadRoutingsBill of MaterialsProcessesResourcesShift PlanFailuresMTBF, MTTRAvailabilities

Lead TimeYieldOn Time Delivery (OTD)UtilizationWork In Progress (WIP)Fill RateQueue TimeWait to batchWait to match

3

6

9

12

2.700 4.716 6.732 8.748 10.764

Umlaufbestand

Work Orders and Routings GeneratorResources and Layout Generator

WIP-InterfaceAlternative Resources

Alternative Technology ChainsContext-sensitive selection of alternatives

Dynamic decision of batch-buildingEvent-driven process execution

InputData Base

ResultsKPI Cockpit

ONE MODELING AND SIMULATION ARCHITECTURESimulation Model is Connected to the Factory Data Base




2015-06-16Page 5

Close-to-RealityStochastic DrivenTime-based KPI’s

Rapid Scenario ValidationStatements on Time Periods

Adjustable Detail LevelArbitrary Extendable

GTRotor

Unsteady LoadMake or Buy Decision

Layout ConstraintsVariable Process TimesUtilization vs. Lead TimeCrossing Material Flow

Variety of Scenarios

IMPLEMENTATIONSIMPLEMENTATIONSCHALLENGESCHALLENGES BENEFITSBENEFITS

GTCasing

GTCombustion

PLANT SIMULATIONPLANT SIMULATIONDATA AND KNOWLEDGEDATA AND KNOWLEDGE RESULTSRESULTS

DIGITAL FACTORY SIMULATION COMMUNITY (DFSC) IN FOUNDATIONDIGITAL FACTORY SIMULATION COMMUNITY (DFSC) IN FOUNDATION

TCSRotor

TCSCasing

GTB&V

SIMULATION AS A RESPONSE TO OPERATIONAL CHALLENGESSimulation as a Central Element of Digital Factory is Already in Implementation


2015-06-16Page 6

RULESINTERDEPENDENCIES

DISPOSITIONCONTROLS

PRIORITIZATIONREWORK

OUTSOURCINGBATCHING

PLANT SIMULATIONPLANT SIMULATION

SALESSALES

ORDERSPARAMETERS

LOADLOAD

END-PRODUCTS(GT OR TCS)

SHOP-FLOORSHOP-FLOOR

WORK-IN-PROGRESS(WIP)

SIMBOMSIMBOM

SIM-RELEVANTCOMPONENTS

ORDERS/JOBSORDERS/JOBSCOMPONENTOPERATIONRESOURCES

PROCESS TIME

META-ROUTINGMETA-ROUTINGPROCESS

COMPONENTSRESOURCESPARAMTERS

RESOURCESRESOURCESWORK CENTERS

SHIFT MODELLOCATIONFAILUERS

LOAD-LISTLOAD-LIST

COMPONENTPARAMTERESDUE DATES

FROM DATA AND INFORMATION TO SIMULATION MODEL




2015-06-16Page 7

RESOURCES AND LAYOUTAutomated generation of resources and layout is based data in one simple table

Layout TableLayout Table Visualization of real layoutVisualization of real layout Deep Dive: Machine AreaDeep Dive: Machine Area

Simple table to describe the resources

(=Machine Area)

x-y-Coordinates

x-y-Size

Rotation angle

Color

Layout of Machine Areas (red rectangles)

is created based on the x-y-coordinates

automatically (SimTalk-Method)

No direct connectors between areas as

there are no simple flows in a job-shop

Machine Area = [Frame]

Within each Machine Area each resource

is represented by a Queue for incoming

goods (Qin) the Resource itself (Res) and

a Queue for outgoing goods (Qout)

Qin / Qout = [PlaceBuffer]

Res = [SingleProc]

Machine-Area A


2015-06-16Page 8

WORK ORDERS AND ROUTINGSEach job is moved from Machine Area to the next Machine Area according to the particular Routing

Jobs

/Par

ts

Processing Steps

SUBTABLEContains information regarding…

Main Processing Resource

Possible alternative resources if main resource is busy

Times (Setup and Processing)

Batching rules if necessary




2015-06-16Page 9

TRANSPORT ALTERNATIVE RESOURCES ASSEMBLY BATCHING

CONTROL LOGICBasic model is extended by a number of modules to improve the accuracy of the simulation results

BASIC-MODEL

Machine-Area A Machine-Area B

+ + +

Machine Area A

BMachine Area B

y

Distance = x + y

Ax Res A

Res B

Res C

WorkOrder

?

?

? Workstation

+


2015-06-16Page 10

PRIORITIZATION AND DISPATCHINGTwo levels of prioritization of jobs within the model

Jobs waiting in front of a resourceto be processed(e.g. FIFO, Due Date, Slack Quotient)

Jobs waiting to bedispatched into the system(e.g. via ConWIP-Logic)

StationA

StationB

StationC

Micro

Macro - Dispatching

Micro

Production System

Micro




2015-06-16Page 11

LOADThree types of possible load can be simulated

Work-In-Process

Upcoming Orders

Arbitrary Load

Projects that are currently being processed

WIP does not necessarily start with Step 1

New orders according to sales forecast

Processing starts always with Step 1

Projects that are not based on “real” orders

Used for scenario-modellingWIP

Upcoming

Arbitrary

Today= Start of Simulation

Time

Load


2015-06-16Page 12

ANALYSIS OF SIMULATION RESULTSTimestamps guarantee that the processing of every single part can be traced

Batching

TBin

Queue 1 Processing Queue 2 Transport

TQ1in TPin TQ2in TTin TTout

Time spent within Machine Area

*Quality Control / Rework / Scrap neglected




2015-06-16Page 13

RULESINTERDEPENDENCIES

DISPOSITIONCONTROLS

PRIORITIZATIONREWORK

OUTSOURCINGBATCHING

PLANT SIMULATIONPLANT SIMULATION

SCENARIOSSCENARIOS

EXPERIMENTSEXPERIMENTS

RESULTSRESULTS

JOB-SCHEDULEJOB-SCHEDULE

EVALUATIONEVALUATION ACTIONSACTIONS

SIMULATION FOR CONTINUOUS IMPROVEMENTScenario-based Experiments Validate the Actions to be Taken


2015-06-16Page 14

• Modeling and Simulation Architecture forcomplex and dynamic value streams

• Lean and easy model generationthrough standardized structures

• Scalable from macro to micro level• Extendable and adaptable for arbitrary

products, processes and resource

SUMMARY AND NEXT STEPS

SUMMARYSUMMARY

• Further standardization andharmonization of the structures

• Module for flexible scenarios thatconsider personnel qualifications

• Module for integration of timingbehaviors of different resources

• Detailed monitoring and reportingof the resource status

• Integration of costs and energy aspects

NEXT STEPSNEXT STEPS




2015-06-16Page 15

Pavel GocevPG GT LGT LT BLN

Huttenstr. 1210553 Berlin

Phone: +49 30 3461 1424Mobile: +49 172 6343 397

[email protected]

BE INVENTIVE – USE PLANT SIMULATION

siemens.com

Andreas SowinskiPG CP TCS DBG MF

Wolfgang-Reuter-Platz 447053 Duisburg

Phone: +49 203 605 2918

[email protected]

mailto:[email protected]

mailto:[email protected]

Date post:	07-Apr-2018
Category:	Documents
Upload:	vantuyen
View:	215 times
Download:	0 times

Data Based Model Generation Gas Turbines and Turbo...

Documents