Modeling and Simulation of a Production System -...

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


…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)


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


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)


Agenda

Simulation and modeling…

…in the development process


…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




Layout


Utilities








CAD/CAM

DPD / MBD



Production process

development and

optimization


Workstation 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









Workstation design


Programming



CAD/CAM

DPD / MBD



Plant design and

improvement

Layout


Utilities


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


Layout


Utilities



Workstation design


Programming



CAD/CAM

DPD / MBD









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


Layout


Utilities



Workstation design


Programming



CAD/CAM

DPD / MBD









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


…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).

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