Lean Manufacturing VSM Simulation Tcm882-231688

Restricted © Siemens AG 2014 All rights reserved. Smarter decisions, better products.

Lean Manufacturing through

Value Stream Mapping & Simulation Renato Lima

Siemens Industry Software, São Caetano do Sul, Brasil

Siemens

PLM

Connection

2014

Restricted © Siemens AG 2014 All rights reserved.

June 2014 Siemens PLM Software

Tecnomatix

Make Things Right – Factory Performance Validation



Tecnomatix Plant Simulation

The Digital Factory inside of Industry 4.0

Plant Simulation provides the means to create

digital models in an efficient and productive manner

for material flow simulation and

throughput assessment based on discrete-event

modeling for the strategic optimization of complex

logistics, production and business processes.

This is accomplished largely through its:

object orientation, hierarchy, and inheritance

statistical data collection and analysis

Plant Simulation models remain clear, concise and

predictable throughout a product’s lifecycle.




Standard Object Library and Integrated Analysis Tools

Bottleneck Analyzer

Automatic analysis

of utilization

Sankey Diagramming

Automatic visualization

of transported material

Statistic Charting

Resource utilization

overtime

Gantt Charts

and, many more...



From Simulation to Optimization

Automated experimentation supports optimization for the generation of improved results.

Mechanism: Combine better solutions by using the good ones (Darwin).



Rich Digital Model of a Factory

What’s Possible Today

Digital Model contains:

• Product mix

• Material flow

• Machine metrics

• Control logic

Model allows to analyze:

Resource Statistics

Buffer Capacity Plots

KPI values, Throughput, WIP, …

Virtual Playground

for Improvements

and Optimization

Both in planning and parallel to

production



The Siemens Perspective

The critical role of Industry Software as a success factor

“Modern production processes need to be increasingly

flexible and powerful... The only way to meet this demand

is to employ new, innovative software systems...that

don’t just participate in the actual production of a product,

but also optimize the product’s entire lifecycle.”

Prof. Siegfried Russwurm

CEO of Siemens Industry Sector

Member, Managing Board

of Siemens AG

“The simulation of virtual products, virtual plants, virtual

factories and virtual production will play a huge role in

determining a company’s competitive advantage in the

future.”

Anton S. Huber CEO of Siemens Industry Automation



USA "Manufacturing Renaissance"

• Formation of a "National Network for

Manufacturing Innovation"

• Lower cost energy initiatives

• Smart Manufacturing Leadership

Coalition

Germany Maintain leading industrial position

• Sustainable investment in innovative

strength

• High level of exports

• Industry 4.0 as new guiding

principle

China Higher product quality by use of high-end

technology

• Rising wages

• Need for quality driven demand for

automation

• Energy efficiency legislation

• Intelligent Manufacturing

Japan A cohesive “innovation program” at all

levels

• Science, technology and industry

linked together

• HR development

• Retain manufacturing of complex

products

• “Innovation 25”initiative

Industry is Again Seen as an Engine of Growth and Stability - in economies

around the world



Tecnomatix

The Right Toolset targeting at Lean Manufacturing

Achieve the right plan to create lean manufacturing processes.



What is Value Stream Mapping?

Value stream mapping is a business method for improving the

production of goods by

Analyzing the production process starting at the customer and

ending at the raw parts supplier and records the value-adding

activities

Capturing the production steps as well as the material between

the production steps

Clear display by concentrating on the crucial elements

Supplier Customer Production

Value stream



Benefits of Value Stream Mapping

The classic goals of value stream mapping:

Increase variability of the production process

Increase quality of the production process

Increase speed of production process

Increase operation efficiency of the production process

Goal is the optimization of production resources, layout, production controls and

batch sizes to ensure a consistent production flow without building unnecessary

buffer inventory.

Keep delivery quality

Keep delivery capacity

Increase adherence to delivery dates

Source: K. Erlach: Wertstromdesign der Weg zur schlanken Fabrik - Springerverlag, 2010



Typical Value Stream

Workshop Result on a Wallpaper…

Sketch of the process structure

Additional information in textual form,

as note on the paper, in spreadsheets, ...

Documentation often done in pictures.



Why Tecnomatix Plant Simulation?

Computer simulation enables you to study the

dynamic effects that remain hidden in the static,

paper-based mapping of the value stream chain.

Classic, static value stream mapping is thus

extended by the time component, which is

decisive for most parameters of the size of stock.

In this way, deviations in daily production,

which are caused by batch sizes, setup

processes, product variants and failures, are

considered.

Tecnomatix Plant Simulation enables you to:

Digitally capture and dynamically evaluate

your value stream using discrete event

simulation

Reduce the products in the production

process (capital lockup)

Ensure the robustness of production

Ensure that natural deviations in the

production do not compromise the delivery

capacity



Tecnomatix Plant Simulation: Value Stream Mapping Library

Pre-defined icons based on a common standard

Comprehensible for each and every value stream

designer

Quick-and-easy to learn

Pre-defined objects that can be parameterized in

dialogs

Control logic

Analysis objects and evaluation tools



Value Stream Mapping:

Model Creation and Simulation

Modeling with drag and drop, parameterization in dialogs

Additional benefits:

Digital capturing of the value stream

Dynamic evaluation of the value stream using event-oriented

simulation

Simple check of the effects of the optimization

Process/VSM layout and all parameter kept in one digital

model

Standardized Simulation Templates



VSM Simulation: Analysis and Evaluation

Analysis of several different scenarios

Buffer and resource utilization

Value-adding and non-value-adding time portion

Throughput times

Development of the inventories over time

Stock Level Plot

Resource and Stock Level Statistics



VSM Simulation: Analysis and Evaluation

• Evaluation of dynamic Inventory and Supermarket fill levels

resulting from processing production orders

• Evaluation of throughput times, WIP and delivery reliability

• Dimensioning of Supermarkets and order limits

• Dimensioning of Kanban controlled production sections

N

um

be

r o

f P

art

s

Time (days)



VSM Evaluation: Out of Stock Example

The plotter shows critical out-of-stock situations for two

products in the right supermarket

The customer delivery will be affected and there will be

delays in the delivery.

The VSM planner needs to fix this problem e.g. by

increasing the number of parts per Kanban card

controlling the part production.

N

um

be

r o

f P

art

s

Time (days)



Example and Demo:

VSM Simulation Model and WIP Reduction

VSM model with parallel production lines, two Kanban

controlled supermarkets and customer orders for five

products.

Reduce WIP (stock

level) in the first

supermarket

through modified

Kanban settings.




VSM Simulation Done Right …

Value Stream Simulation for multi-product production facilities achieves in

Increasing the value-adding portion of the production process

Decreasing inventory and capital lockup

Ensuring delivery capacity and adherence to delivery dates

Validating test scenarios in the simulation before implementing them in the shop floor



Make Things Right

Compete more effectively with next-

generation manufacturing technology

Right ingenuity to create smarter, leaner

processes.

Right insight to maximize performance of

resources.

Right control to hit quality and

schedule targets.

Right synchronization to run a more

efficient and nimble business.



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Tecnomatix Manufacturing Discussion Forum

www.siemens.com/plm/community/tecnomatix

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Thank You!

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Lean Manufacturing VSM Simulation Tcm882-231688

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