Modeling and Simulation of a Production SystemKPP319 – 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
2
Agenda
Modeling and Simulation …
… within the development/design process
…in an information integration context
…as a process
3
Agenda
Modeling and Simulation …
… within the development/design process
…in an information integration context
…as a process
4
Dual competence areas ofdevelopment and operation
Production
system design
Production
system
operations
Experience, knowledge, data
Decisions, plans, guidelines
Competences,
Tools
Methods
Processes
Competences,
Tools
Methods
Processes
Wiktorsson (2013)
Focusing on productiondevelopment, we are moving from a sequentialscheme to a parallel one
Design andRealisation
Running-in
Operation/Maintaining
Retiring/Re-use
Operation/Refining
Planning
Designing
Realising
Running-inOperation/
Maintaining
Retiring/Re-use
Operation/Refining
Wiktorsson, 2000Wiktorsson (2000)
Task: Market, Company, Economy
Plan and clarify the task:Analyse the market and the company situation
Find and select product ideas
Formulate a product proposalClarify the task
Elaborate a requirements list
Requirements list (Design spec)
Develop the principle solution:Identify the essential problems
Establish function structuresSearch for working principles and working structures
Combine and firm up into concept variants
Evaluate against technical and economic criteria
Concept (Principle solution)
Develop the construction structure:Preliminary form design, materials selection and calculation
Select best preliminary layoutsEvaluate against technical and economic criteria
Preliminary layout
Define the construction layout:Eliminate weak spots
Check for errors, disturbing influences and minimum costsPrepare the preliminary parts list andproduction and assembly document
Definitive layout
Prepare production and operating documents:
Elaborate detail drawings and parts listsComplete production, assembly, transport
and operation instuctionsCheck all documents
Product documentation
Solution
Upgra
de a
nd I
mpro
ve
Info
rmation:
Adapt
the r
equirem
ents
lis
t
Pla
n &
cla
rify
the t
ask
Conceptu
al desig
nE
mbodim
ent
desig
nD
eta
il desig
n
Pahl and Beitz, 1996
Hubka & Eder, 1996
Rosell, 1990
Problem statement
Visions /
Objective
Requirements
Pre-
conditions
Propositions
Evaluation
Req´s - Alt´s - Eval.
Systems Engineering Fundamentals. 2001
Justification approaches for analysis of production systems
Justification Methodologies
Strategic Approaches Analytic Approaches Economic Approaches
MathematicalAnalysis
ExperimentalAnalysis
Scorecards
Linearadditivemodels
AHP Models
”Back-of-the-envelope”calculations
Queingnetworks
Spreadsheets
Payback
Net PresentValue
Internal Rateof Return
OtherDiscountedCash Flowmethods
Non DCFmethods
SensitivityAnalysis
Technicalbenefits
BusinessAdvantage
Competetivefactors
FutureExpansion
ValueAnalysis
Optimisationtechniques
Trace-drivensimulations
Monte Carlosimulations
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 Technique (SADT) (Ross and Brackett, 1976) / IDEF0 (Integrated computer-aided manufacturing DEFinition) /Astrakan
● CIM-OSA (1989) for Computer Integrated Manufacturing
● The Structured Systems Analysisand Design Method (SSADM) presented by for instance Downs et al. (1992)
A21Manufacturing
function
Inputs
Control
Output
Mechanism
A0
A1A2
A3
A2 A22A23
A23A231
A232
Feasibility study
Problem identification
Project identification
Analysis of systems operationand problems
Specification of requirements
Select technical option
Data design
Physical design
Systems analysis
System design
Req´s - Alt´s - Eval.
Value analysis models
Criterion A
Criterion B
Criterion C
Criterion XHighLow
Weight Alt. 1 ... Alt. M
Criterion A 4 3 ... 1Criterion B 2 7 ... 5Criterion C 1 4 ... 7... ... ... ...Criterion X 2 1 ... 3
Σ Weighted scores: 105 ... 77
Strategic attributes
A B C X...Level 1Categories
Level 2Attributes
Level 3Alternatives
1 M...
...
Profile charts, checklists and symbolic scorecards
Linear additive models Analytical hierarchy process (AHP)
Wiktorsson, 2000Wiktorsson (2000)
Req´s - Alt´s - Eval.
Agenda
Simulation and modeling…
…in the development process
…in an information integration context
…as a process
12
The vision on the Digital Plant is ever existing…
13
Information
plattform
Product
development, test
and optimization
Plant design and
improvement
Production
process
development and
optimization
Operative
production
planning and
control
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)
Adapted from Kuhn (2006)
Information
plattform
Plant design and
improvement
Production process
development and
optimization
Operative production
planning and control
WP1. Virtual verification of assembly system
Layout
Material flow and routing
Utilities
Performance and capacity
Planning and sequencing
Enterprise resource planning
Manufacturing execution system
Human resource planning
Virtual manufacturing and assembly
Workstation design
Equipment and tool design
Programming
Product development,
test and optimization
CAD/CAM
DPD / MBD
Product Data Management
Product Lifecycle Management
• 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 Product development
Information
plattform
Plant design and
improvement
Operative production
planning and control
WP1. Virtual verification of assembly system
Layout
Material flow and routing
Utilities
Performance and capacity
Planning and sequencing
Enterprise resource planning
Manufacturing execution system
Human resource planning
Product development,
test and optimization
CAD/CAM
DPD / MBD
Product Data Management
Product Lifecycle Management
Production process
development and
optimization
Virtual manufacturing and assembly
Workstation design
Equipment and tool design
Programming
Modeling and simulation in Process development
• Concerning process development and
optimization, many tools are available for
specific purposes.
Information
plattform
Production process
development and
optimization
Operative production
planning and control
WP1. Virtual verification of assembly system
Planning and sequencing
Enterprise resource planning
Manufacturing execution system
Human resource planning
Virtual manufacturing and assembly
Workstation design
Equipment and tool design
Programming
Product development,
test and optimization
CAD/CAM
DPD / MBD
Product Data Management
Product Lifecycle Management
Plant design and
improvement
Layout
Material flow and routing
Utilities
Performance and capacity
Modeling and simulation in Plant design
• 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
Information
plattform
Plant design and
improvement
Production process
development and
optimization
WP1. Virtual verification of assembly system
Layout
Material flow and routing
Utilities
Performance and capacity
Virtual manufacturing and assembly
Workstation design
Equipment and tool design
Programming
Product development,
test and optimization
CAD/CAM
DPD / MBD
Product Data Management
Product Lifecycle Management
Operative production
planning and control
Planning and sequencing
Enterprise resource planning
Manufacturing execution system
Human resource planning
Modeling and simulation in Operations
• 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.
Plant design and
improvement
Production process
development and
optimization
WP1. Virtual verification of assembly system
Layout
Material flow and routing
Utilities
Performance and capacity
Virtual manufacturing and assembly
Workstation design
Equipment and tool design
Programming
Product development,
test and optimization
CAD/CAM
DPD / MBD
Product Data Management
Product Lifecycle Management
Operative production
planning and control
Planning and sequencing
Enterprise resource planning
Manufacturing execution system
Human resource planning
Information integration is key for Industry 4.0, etc…
Information
plattform
• System modeling
• Information architecture
Case: from CAD to instruction
Konstruktör
ManufacturingEngineer
OperationsSequencing
ProductionEngineer
Modifiedlayout
Layout
Proposedchanges
in productdesign
PII withTMU
CAD-drawingwith articles
DesignEngineer
PlatformConstraints
Assemblyinstruction
Operationsengineering
Layout
Balanceengineering
AssemblySequence
Packing
OPERATION PII
T Op R K Operation description Stn Variant TMU
M 5 D Pull tape from page, … XYZ 755 10 AB Place the strip at the … 320 15 Take tool A and pull … 150 505 Pull tape from … XYZ 755
STRUCTURE R No Art.No Name Moment Variant T/U week
A 2 311487 Strip xx XYZ T 9943 B 1 862144 Strip xy XYZ, XY T 9943
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. Cause
9943 GN C39422-9 465534 XXY Structure updated
Name
Person Date Introduction No:C16-9
Sequence list 99-XX-XX Plant: X Project: 452
PII St W/ID Name Max B1 B2 BX
C16-7 10 215 Ass’y X 335 315 315 335
C16-2 10 215 Ass’y Y 625 625 - 600
C27-1 10 215 Cut Z … 90 - - -
Balance instruction
No Type Name Total Time 156432 <type of balance> Ass’y X 2547
Adress Date Length Made by Takt 18725-87 9935 1 N. P-son XX #/hrs
Time Activity PII+S+B Op F Variant PII S+B
Open xyz 16-6 10 88 110 Go to Y S6 ZX3 90 Ass’y Q 16-6 20 88 15
Wiktorsson, 2000
Case: tool usage
4D-Navigator
Catia
CC-Plant Witness
IGRIP/RobCAD
Ergoplan
Flow
Process
Product
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
differently in another caseWiktorsson, 2000
Wiktorsson, 2000
The tools and methodsused 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
LS
ErgoplanVisualising assembly and material facades.
Ergonomic considerationsWork place design
CC-Plant Process description with attributes Process description
Witness Flow simulation program for material and line Flow simulation
ME
FMEA Checklist for failure/consequence analysis
T VCCQ Checklist for quality assurance
H SAM Time analysis of assembly activities
OD
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
23
Character of systems ’worth’ simulating
24
Variability
Interconnectivity
Complexity (combinatorial
or dynamic)
Based on Robinson (2004)
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?
25Adapted from Banks & Gibson, 1997
Types of models
26
Discrete Continuous
Static Dynamic
Deterministic Stochastic
Examples on softwareSoftware 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
27
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
When selecting software
Step 1. Establish modelingrequirements
Step 2. Survey and short list possibleapplications
Step 3. Establish evaluationcriteria
Step 4. Evaluate the software in relation to the criteria
Step 5. Software selection
• Assess multiple criteria: support, applicability, level of detail, ease oflearning 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 graphicalsoftware and software built on simulation buildning. All requireconceptual modeling and logicrepresentation.
28
Steps in a simulation study
29Banks et al, 2010
The importance ofconceptual modeling
30Robinson et al, 2011
The major use of simulation within Production at MDH has been in Master courses
31ExtendSim 7.0 (discrete event)
3DCreate 2012 (visualisation)
Model example 1: scannedshopfloor
32
Model example 2: modeledshopfloor
33
Model example 3: factorywalk-through
34
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.?
35
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).