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The future in improving design and operations with

simulation technology

Rienk BijlsmaRockwell Automation

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Contents

• About Rockwell Automation

• Traditional Use of Simulation Technology

• Recent Software Developments

• Live Examples

• Arena Software

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Rockwell Automation

Technology Conglomerate since 1902• NYSE: ROK• 4.500 B$ Revenue• Leading Automation Provider• Hardware: PLC, DCS, Networks,

Drives• Software: PLC Code, MES, HMI,

Simulation

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Rockwell Automation

Rockwell Brand Names

• Allen Bradley

• Reliance Electric

• Dodge

• Rockwell Software– Arena, RS BizWare, RS View, RS

Teststand

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Seamless Integration

Modelling / Scheduling / Tracking/HMI/Scada

Condition BasedMaintenance

Automation Platforms

Automation Components

Legacy Devices

Computerised Maintenance Management System

Smart Devices

Control / Advanced Diagnostics

e-Procurement

Supply Chain Partners

The Web

Enterprise Systems

Supply Chain Management

i2

MRO Suppliers

ERPRA.comRA.com

OEM’s

Manufacturing BusinessWare

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Simulation Traditional Use

• Validation/Design of New Systems

• Improving existing systems

• Application Areas– Supply Chain, Business Processes,

Manufacturing, Transportation/Logistics

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Simulation Traditional Use

• Simulation Pro’s– What If Analysis– Variability & System Complexity– Communication Possibilities, animation– Flexibility

• Simulation Con’s– Data Requirements– One Time Effort– No Clear Answers, requires interpretation– Time Consuming, even with experts

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Future Directions

• Design Automation– Business Driver: Reduce Time to Market

• Testing of PLC Code• Generating PLC Code from Design Objects• Share Data across design applications

• Operational Decision Support– Business Driver: Optimize Manufacturing

• Interact with HMI & ERP User Interfaces• Real Live Data Access• Replacing custom code applications

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Recent Developments

DesignDesign OperateOperate MaintainMaintain

Common Architecture Common Architecture & Software Tools& Software Tools

Common Repository

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Recent Developments

DesignDesign

OperateOperate

MaintainMaintain

FactoryFactoryTalkTalk

(SP95)(SP95)

Product ViewProduct View Facility ViewFacility View

Activity Areas

Site, Area, Line, Work Cell

Equipment Resources / Sets

Labor Resources / Sets

Shift Patterns

Manufacturing Orders

Materials (Make/Buy)

Production Lots

Segment Data

Phase Times

Resource Actions

Material Actions

Constraints

Actual DataActual Data

Process Times

Start, Stop

Failures

Order Details Resources

Operators

Login, Quality, Comments

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Arena Developments

• Arena Factory Analyzer (Link with MES)

• Real Time (OPC Client)– Emulation– PLC Testing

• ADO (Data Accessibility)

• Building/Reports/Documenting

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Typical Project Architecture

Database

Interface

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Live Examples

• Packaging Line

• Warehouse

• Supply Chain

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What have customers done with Arena?

Redesigned assembly line and finished goods storageRedesigned assembly line and finished goods storageprocesses, processes, saved $350,000saved $350,000 in reduced labor costs and increased in reduced labor costs and increasedproductivity.productivity.

Redesigned finished goods handling and storage processes,Redesigned finished goods handling and storage processes,saved millionssaved millions by avoiding unnecessary construction of new by avoiding unnecessary construction of newloading docks.loading docks.

Redesigned distribution system of 14 plants, 6 DC’s, and 25Redesigned distribution system of 14 plants, 6 DC’s, and 25whse’s, whse’s, saved $500,000saved $500,000 in reduced transportation costs in reduced transportation costs

Increased throughput by 13% to 20% in several different lines,saved $650,000 in reduced labor costs, increased productivity,and reduced wastewater discharge costs.

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What have customers done with Arena?Redesigned their worldwide supply chain, Redesigned their worldwide supply chain, saved oversaved over$20,000,000.$20,000,000.

Avoided purchasing unnecessary packaging line equipment, Avoided purchasing unnecessary packaging line equipment, saved $850,000.saved $850,000.

Avoided purchasing unnecessary accumulator conveyors, Avoided purchasing unnecessary accumulator conveyors,

saved over $500,000saved over $500,000.

Designed problem-free material flow systems in a new engine

assembly plant, avoided their worst nightmares.

Avoided building a new production facility 23’ too short to meet

forecasted production requirements, saved their careers!

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Some References

Customers Network Redesign

Replenishment Strategy

Production Strategy

Contingency Planning

No Yes Yes Yes

Yes Yes No No

Yes No Yes No

Yes Yes Yes Yes

Yes Yes Yes Yes

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Chemical IndustryCustomers Network

RedesignReplenishment Strategy

Production Strategy

Contingency Planning

No Yes Yes Yes

Answers: Results:

Number of Railcars necessary for SC Saved 2.5 M$ in Capital Expenditure

Best Rubber Production Strategy Improve Throughput by 35 %

Combining Cargo on Chemical Vessels Saving 12 % of Logistical Transportation costs, 2M$ Annually

SKU resizing & locations in existing SC Saving 1.6M$ in Supply Chain Cost

Other Customers:

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Apparel IndustryCustomers Network

RedesignReplenishment Strategy

Production Strategy

Contingency Planning

Yes Yes Yes No

Answers: Results:

Direct Order Strategy Planning/Production Lead Time Reduction 55 %

Different Collaboration Strategies Finished Goods Inventory Reduction of 80 %

Retailer’s Lead Time Reduction 52 %

Order Lead Time Decrease 49 %

Other Customers:

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Food &Beverage IndustryCustomers Network

RedesignReplenishment Strategy

Production Strategy

Contingency Planning

Yes Yes No No

Answers: Results:

Direct Order Strategy 20 % Inventory Carrying Cost Savings

Lead Time Reduction of 30 %

Different Replenishment Strategy Min-Max Best Alternative

Other Customers:

                                                                          

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CPG IndustryCustomers Network

RedesignReplenishment Strategy

Production Strategy

Contingency Planning

Yes Yes Yes Yes

Answers: Results:

27 alternative scenario’s analyzed Throughput Increase of 70 %

Make-to-Order Policy Cost Decrease of 70.2M$

WIP Dropped 66 %

Cycle Time Improved by 84 %

Potential Customer:

                                                                          

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Electronics IndustryCustomers Network

RedesignReplenishment Strategy

Production Strategy

Contingency Planning

Yes Yes Yes Yes

Answers: Results:

5 Different Designs Evaluated 39 % Inventory Reduction

Covers Repair Strategy, Inventory Strategy 16 % Reduction Transport Costs

Logistics structure, etc. Direct Ship with ASN best option

Overall Savings of 50 M$

Other Customers: