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The Future In Improving Design And Operations With Simulation Technology
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The Future In Improving Design And Operations With Simulation Technology

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  • 1. The future in improving design and operations with simulation technology Rienk Bijlsma Rockwell Automation
  • 2. Contents
    • About Rockwell Automation
    • Traditional Use of Simulation Technology
    • Recent Software Developments
    • Live Examples
    • Arena Software
  • 3. 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
  • 4. Rockwell Automation
    • Rockwell Brand Names
    • Allen Bradley
    • Reliance Electric
    • Dodge
    • Rockwell Software
      • Arena, RS BizWare, RS View, RS Teststand
  • 5. Seamless Integration Manufacturing BusinessWare Modelling / Scheduling / Tracking/HMI/Scada C ondition B ased M aintenance Automation Platforms Automation Components Legacy Devices C omputerised M aintenance M anagement S ystem Smart Devices Control / Advanced Diagnostics e-Procurement Supply Chain Partners The Web Enterprise Systems Supply Chain Management i2 MRO Suppliers ERP RA.com OEM’s
  • 6. Simulation Traditional Use
    • Validation/Design of New Systems
    • Improving existing systems
    • Application Areas
      • Supply Chain, Business Processes, Manufacturing, Transportation/Logistics
  • 7. 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
  • 8. 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
  • 9. Recent Developments Design Operate Maintain Common Architecture & Software Tools Common Repository
  • 10. Recent Developments Factory Talk (SP95) Product View Facility 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 Data
      • Process Times
        • Start, Stop
      • Failures
      • Order Details Resources
      • Operators
      • Login, Quality, Comments
    Design Operate Maintain
  • 11. Arena Developments
    • Arena Factory Analyzer (Link with MES)
    • Real Time (OPC Client)
      • Emulation
      • PLC Testing
    • ADO (Data Accessibility)
    • Building/Reports/Documenting
  • 12. Typical Project Architecture Database Interface
  • 13. Live Examples
    • Packaging Line
    • Warehouse
    • Supply Chain
  • 14. What have customers done with Arena ? Redesigned assembly line and finished goods storage processes, saved $350,000 in reduced labor costs and increased productivity. Redesigned finished goods handling and storage processes, saved millions by avoiding unnecessary construction of new loading docks. Redesigned distribution system of 14 plants, 6 DC’s, and 25 whse’s, saved $500,000 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.
  • 15. What have customers done with Arena ? Redesigned their worldwide supply chain, saved over $20,000,000. Avoided purchasing unnecessary packaging line equipment, saved $850,000. Avoided purchasing unnecessary accumulator conveyors, saved over $500,000 . Designed problem-free material flow systems in a new engine assembly plant, avoided their worst nightmares. Avoided building a new production facility 23’ too short to meet forecasted production requirements, saved their careers!
  • 16. Some References Yes Yes Yes Yes Yes Yes Yes Yes No Yes No Yes No No Yes Yes Yes Yes Yes No Contingency Planning Production Strategy Replenishment Strategy Network Redesign Customers
  • 17. Chemical Industry
    • Answers: Results:
    • Number of Railcars necessary for SC Saved 2.5 M$ 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:
    Yes Yes Yes No Contingency Planning Production Strategy Replenishment Strategy Network Redesign Customers
  • 18. Apparel Industry
    • 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:
    No Yes Yes Yes Contingency Planning Production Strategy Replenishment Strategy Network Redesign Customers
  • 19. Food &Beverage Industry
    • Answers: Results:
    • Direct Order Strategy 20 % Inventory Carrying Cost Savings
    • Lead Time Reduction of 30 %
    • Different Replenishment Strategy Min-Max Best Alternative
    • Other Customers:
    No No Yes Yes Contingency Planning Production Strategy Replenishment Strategy Network Redesign Customers                                                                             
  • 20. CPG Industry
    • 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:
    Yes Yes Yes Yes Contingency Planning Production Strategy Replenishment Strategy Network Redesign Customers                                                                             
  • 21. Electronics Industry
    • 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:
    Yes Yes Yes Yes Contingency Planning Production Strategy Replenishment Strategy Network Redesign Customers