Forward Visibility for your business
The future in improving design and operations with
simulation technology
Rienk BijlsmaRockwell Automation
Forward Visibility for your business
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:
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