The future in improving design and operations with simulation technology Rienk Bijlsma Rockwell Automation

Contents About Rockwell Automation Traditional Use of Simulation Technology Recent Software Developments Live Examples Arena Software

About Rockwell Automation

Traditional Use of Simulation Technology

Recent Software Developments

Live Examples

Arena Software

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

Technology Conglomerate since 1902

NYSE: ROK

4.500 B$ Revenue

Leading Automation Provider

Hardware: PLC, DCS, Networks, Drives

Software: PLC Code, MES, HMI, Simulation

Rockwell Automation Rockwell Brand Names Allen Bradley Reliance Electric Dodge Rockwell Software Arena, RS BizWare, RS View, RS Teststand

Rockwell Brand Names

Allen Bradley

Reliance Electric

Dodge

Rockwell Software

Arena, RS BizWare, RS View, RS Teststand

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

Simulation Traditional Use Validation/Design of New Systems Improving existing systems Application Areas Supply Chain, Business Processes, Manufacturing, Transportation/Logistics

Validation/Design of New Systems

Improving existing systems

Application Areas

Supply Chain, Business Processes, Manufacturing, Transportation/Logistics

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

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

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

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

Recent Developments Design Operate Maintain Common Architecture & Software Tools Common Repository

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

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

Process Times

Start, Stop

Failures

Order Details Resources

Operators

Login, Quality, Comments

Arena Developments Arena Factory Analyzer (Link with MES) Real Time (OPC Client) Emulation PLC Testing ADO (Data Accessibility) Building/Reports/Documenting

Arena Factory Analyzer (Link with MES)

Real Time (OPC Client)

Emulation

PLC Testing

ADO (Data Accessibility)

Building/Reports/Documenting

Typical Project Architecture Database Interface

Live Examples Packaging Line Warehouse Supply Chain

Packaging Line

Warehouse

Supply Chain

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.

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!

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

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

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:

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

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:

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                                                                         Â

Answers: Results:

Direct Order Strategy 20 % Inventory Carrying Cost Savings

Lead Time Reduction of 30 %

Different Replenishment Strategy Min-Max Best Alternative

Other Customers:

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                                                                         Â

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:

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                                                                         Â

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: