Virtual Plant Design with Arena® Simulation

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Virtual Plant Design with Arena® Simulation
Is It Part of Your Competitive Advantage?

Agenda
Driving Competitive Advantage
Demonstration
Why Arena®
Simulation Overview
Introduction

Agenda
Demonstration
Why Arena®
Simulation Overview
Introduction

www.rockwellautomation.com
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Pallet Stretch Wrapping
Case Study:

Case Study: Pallet Stretch Wrapping
 Soft Drink Pallet Wrapping Machines
 Plant Layout:
 Case packer line
 5 Palletizer Lines feeding 2 Stretch Wrappers
 Challenge:
 Increased load pushing pallet wrapping machines to limits

Case Study: Pallet Stretch Wrapping
 Questions:
 Can the two existing Stretch Wrappers keep up with increased load?
 Is an additional stretch wrapping machine required?
 What directional feeding rules will ensure that palletizer lines don’t
back up?
 What directional feeding rules will maintain smooth, continuous
operations?

Case Study: Addressing the Challenge
 Built a simulation model of the process using Arena simulation software
 Identified variability/uncertainty around key process parameters
 Package types
 Pallet creation times
 Pallet wrapping times
 Forklift speeds
 Stretch wrapper failure/downtime modes and frequencies
 Run simulation scenarios to test alternate designs
 Revised Feeding Rules
 Addition of 3rd stretch wrapper

Case Study: Visualizing the Operation

Variability Considerations (Input)
Time to create pallet (TRI dist) Min Mode Max
Time to wrap pallet ("stop to start")
in minutes
WyardDelay
923CDelay
320Delay
923ADelay
FS800Delay
Wyard 90 137 165 Muller 808 46 44
923C - 12 Packs 102 196 235 Muller 606 44 44 44 41
320 - 6 Packs 133 784 940
923A - Cube 79 157 188 3 0
FS800 240 343 411
East West
Choose the package coming off the Wyard Forklift Speed in ft/min 250 250
9 70% % eff Stretchwrapper Failure Modes
mean time betw een failure (minutes) Uptime Downtime Uptime Downtime
Muller 808 - West 112 8 235 5
Choose the package coming off the FS800 Muller 606 - East 232 8 235 5
1 70% % eff
What is your can line efficiency 75% % eff
East West Switch at M12
(1=West, 2=East, 3=Auto)
Break Film Change

Case Study: Arena® Simulation Results
 Developed New Palletizer Feeding Rules to Eliminate Backlogs
 Line 1: Feed Left Only
 Line 2: Feed Left or Right
 Lines 3,4 & 5 Feed Right Only
 3rd Stretch Wrapper Not Required:
 $150K Capex avoidance
 Reduced long-term system maintenance costs

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Primary Steelmaking Operations
Case Study:

Case Study: Primary Steelmaking Operations
 ArcelorMittal Dofasco Steel - Hamilton, ON
 Shipping 4.5M net tons of flat carbon steel annually
 One of ArcelorMittal’s best performing sites
 Primary Steelmaking Operations
 Linear process (5 main process steps)
 Eleven (11) different steel grades
 Entire system constrained by slowest element in the process
 SIP Capital Improvement Project to Improve Production

Case Study: The Challenges
 Challenges:
1. Uncertain if current system can meet/exceed yearly production goals
2. Expecting increase in demand
3. Four (4) alternative shop configurations proposed
 Assumption:
 Current steel making process is capable of achieving yearly production goal (3.1M
Tons) by making incremental improvements to sub-systems
 Full Analysis of Steelmaking Operations
 Understand True Throughput Capacity
 Identify & Eliminate Bottlenecks
 Quantify Impact of Changes to the System

Case Study: Goals
 Questions:
 What is constraining the output potential of the operation today?
 Will incremental sub-process changes deliver the required productivity
increase?
 Or are major capital equipment investment required?
 What is the most sustainable solution?

Case Study: Addressing the Challenge
 Define the system
 Iron Making & Desulph, Steelmaking (KOBM), Ladle Metallurgy Facility (LMF), Vacuum Degassing
(VD), Casting
 87 unique system processes/activities
 Identified variability/uncertainty around key process parameters (100+)
 Steel Grades
 Production Schedule
 Hot Metal parameters, Steel Making parameters, LMF parameters, Casting parameters
 Maintenance, Failures, and Downtime frequencies
 Verification & Validation
 Ran model with historical data
 Compared model run results to the actual production data
 Simulation results were within 1% of actuals for the calendar year

Case Study: Visualizing the Operation

Case Study: Arena® Simulation Results
 Output / Key Performance Indicators (KPI)
 Total Casting Overall and by Product
 Number of Ladles Cast Overall and by Day
 Casting Cycle Time
 Caster Shutdowns
 Specific Queue Times (Determine Bottlenecks)
 Hot Metal Production Delivered to Steel Making & Coffining
For each KPI, Arena provided: Average, Minimum, and Maximum with Confidence Interval

Case Study: Results Continued…
 More Realistic View of the “As Is” System
 Identified 20 Key Areas Constraining Output of Current System and Impact of Each (narrowed from 100+)
 Past methods overstated potential results
 Better Understanding of Relationships Between Sub-Processes
 Quantified Impact of Changes to Sub-Processes
 Confidently Predict True Throughput Capacity of Current State
 Determined Which “To Be” System Would Provide Greatest Benefit
 Justify Capex Before Spending
 Operational Decision Making Tool

Agenda
Demonstration
Why Arena®
Simulation Overview
Introduction

Is Simulation Right For Me?
1. Variability or uncertainty impacting the process
2. Constraints or limitations on resources (people or equipment)
3. Some degree of system interaction or complexity
Arena provides value to an organization when they are faced with at least one of these challenges:

What is Discrete Event Simulation?

Global Applicability
CustomerService
FinancialServices

Why Simulation?

Agenda
Demonstration
Why Arena®
Simulation Overview
Introduction

Arena® Models All Business Processes

Advantages of Simulation
 Compare alternative designs
 Incorporate system variability
 Include system interactions
 Observe complex systems over time
 Animation communicates ideas
 Understand bottlenecks
 Low risk/high return
Enhance Competitive Advantage
Excel
Simulation

Agenda
Demonstration
Why Arena®
Simulation Overview
Introduction

Benefits for SIs & OEMs
 Validation of system design
 Incorporate variability, uncertainty and constraints into design
 Quantitative comparison of alternatives
 Demonstrate design to customers
 Optimize/enhance equipment performance
 Value-add service/expertise to customers
 Extension of simulation models to real-time applications

Support from Rockwell Automation
 Training courses
 Bi-monthly courses in Austin, TX
 On-site, customized courses
 Technical Support
 M-F, 9-5 (Eastern Time)
 Phone or E-mail
 Consulting Services
 Project assistance
 Turn-key projects

Need Additional Information?
 Sales:
Steve Blatney
sfblatney@ra.rockwell.com
+1 (724) 741-4044
 Technical Support:
ArenaSupport@ra.rockwell.com
+1 (440) 646-6789
 www.ArenaSimulation.com

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Primary Steelmaking Operations
Case Study:

Virtual Plant Design with Arena® Simulation

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