Toolkit for Highly Complex Assembly and Logistics Processes

Transcription

1 Tecnomatix 2nd Plant Simulation Wordwide User Conference 2015 Toolkit for Highly Complex Assembly and Logistics Processes Dirk Steinhauer Head of Simulation Team Benefits of Using Simulation in Production and Logistics Detailed analysis of production or logistic systems concerning dynamic relationships and interactions Cost efficient trials without any risk New production facilities or concepts New ships New schedules Transparency of processes Objective basis for communication Planning reliability Flexibility in planning

2 Tecnomatix Application Fields for Simulation of Production and Logistics at Flensburger Production flow Facility layout planning Production planning Loading / discharging of ships Port logistics Civil engineering Offshore wind parks Development of Simulation Tools Using Plant Simulation (Siemens PLM / Tecnomatix) Simulation tools Pre-Production Applications Transport control Final Assembly Logistics Crane Outfitting Shift calendar Ship s Logistics

3 Tecnomatix STS: Simulation Toolkit Shipbuilding Library of simulation tools for complex assembly and logistics, e.g. Site production of one-of-a-kind products Outfitting procedures Terminal logistics Space allocation challenges Wind farm installation Software Environment: Plant Simulation (Siemens PLM) Currently supported versions: Established in 2000 Provided by Flensburger Shipyard SimPlan AG Philosophy of STS Efficient and effective model building Implementation of well-proven modelling approaches Provision of best practice scenarios Individual adjustability of models Interfaces for user rules and specific settings Cooperative development SimCoMar ( SIMoFIT ( Technical University of Berlin Interbranch applicability Construction industry Plant construction industry Machine building industry

4 Tecnomatix Modelling Approaches Supported by STS 1. Abstract process definition Worksteps Ressource allocation Constraints Workstep Workstep Workstep 2. Facility oriented modelling Material flow follows facilities Resource Resource Resource Resource 3. Combination of 1. and 2. STS: Administration in Model File Management by tool STS_Administration Basic functions Loading STS into a model file Updating STS Administration of basic settings (e.g. language, directories) Loading and updating of specific tools - STS_DataInterface - STS_ModelTester Management of methods

5 Tecnomatix Structure of STS Including Add-on Libraries (Simulation Toolkit Shipbuilding) STS_ShipLog - Load and discharge ships Steel - Cutting machines - Welding machines - Assembly sites - Painting facilities Transport - Floor conveying syst - Cranes - Roller conveyors - Streets / crossings - Transport control Logistics - Storage control - Supplier - Packaging Basics - Space - Model administration - Personnel control - Statistics Material - Steel parts - Steel elements - Outftting parts STS_PortLog - Container terminals - RoRo terminals - Ferry terminals Outfitting - Outfitting sites - Assembly control Interior fitting - Compartment STS_OWEA - Offshore windpark installation STS: Selection of Tools Crane Statistics Stiffener erection portal Outfitting compartment Logistics - Storage control - Supplier - Packaging Steel - Cutting machines - Welding machines - Assembly sites - Painting facilities Outfitting - Outfitting sites - Assembly control Basics - Space - Model administration - Personnel control - Statistics Transport - Floor conveying syst - Cranes - Roller conveyors - Streets / crossings - Transport control Interior fitting - Compartment Material - Steel parts - Steel elements - Outftting parts Transport control Space Assembly control Cutting plant

6 Tecnomatix Selection of Application Fields for STS Tools Space allocation Complex assembly procedures Complex logistics Steel fabrication Railway traffic STS: Tool STS_Space Allocation of space by objects considering Size or geometry (shape) (Safety) distance required Definition of Areas for special purpose (building site, storage area,...) Blocked areas (temporarily if necessary) Various allocation rules available Starting point and direction Circular search Closest to specific object Maximum available space...

7 Tecnomatix STS: Characteristics of STS_Crane Management of transports by cranes of several types (gantry, bridge, container, construction,...) Easy use Method.m_Request(part, target) Qualified and available crane vehicle is selected. Crane motion is generated automatically. Option: Specification of individual transports: Linking of gantries for heavy transports Turning of parts Personnel for transport Definition of transport path Mobile crane on vehicle... STS: Generation of 3D Model from 2D Model STS tool ModelGenerator3D Scaled 2D model 3D model

8 Tecnomatix STS: Example Models for Space Allocation Model Structure for Assembly Processes STS_WorkShiftControl STS_ResourceControl STS_ConstraintManager Constraints Orders STS_TransportControl Transport of parts Assembly site STS_MaterialAdministration STS_OrderGenerator STS_ProcessControl Assembly of construction Assembly parts Process templates Process parameters STS tool Process Input data

9 Tecnomatix STS: Tool STS_ProcessControl Control of several parallel worksteps considering Standardized or individual process patterns Selection of worksteps Sequence of worksteps Consideration of part characteristics Allocation of required qualifications Hard and soft assembly constraints Spatial constraints STS: Example Models for Assembly

10 Tecnomatix Simulation of Hull Erection Simulation Model of Refurbishment Procedures in a Passenger Zone

11 Tecnomatix Simulation Model of the Logistics for Wind Park Installation STS: Tool STS_TransportControl Definition of transport means The MU class for transporter can either be STS transporters or user-defined MU class. Transporters can be specified individually and organized in groups. For selected vehicles the specific kinematics of loading and discharging can be shown in 3D, e.g. the fork movement for STS_Forklift. Management of transport requests Management of transport procedures by the assigned destination control

12 Tecnomatix STS: Example Models for Logistics Simulation of a Container Terminal Operated by Straddle Carriers

13 Tecnomatix Simulation of a Container Terminal Operated by Reach Stackers Simulation of a Planned Ferry Terminal

14 Tecnomatix STS: Example Models for Steel Fabrication Simulation Based Development of a New Profile Cutting Line

15 Tecnomatix STS: Tool STS_Statistics Standardized functionality for collecting and analysing tool statistics Tool STS_Statistics is integrated in material flow and administration tools Throughput statistics GANTTcharts Utilisation chart STS: Tool ModelStatistics Aggregation of statistics of the entire simulation model Automatic generation of html-reports Interface to external analysis Utilisation of plants, transport means or personnel GANTT charts Lists of parts, processes or transports

16 Tecnomatix Administration of STS External developer STS Administration (FSG) Manual STS External developer STS Homepage Online help STS User STS User STS User STS can be updated - Model settings will remain Research Project HEPP High Efficient Production Planning for Prototype Competence Goals: Methods to prepare, check and improve the data basis for planning especially in early project phases Continuous simulation aided production planning in shipbuilding Term: Partners: FSG (Coordinator) Meyer Werft SimPlan AG Center of Maritime Technologies e.v. Ruhr University Bochum Technical University Hamburg-Harburg

17 Tecnomatix Thank you for your attention! Dirk Steinhauer Head of Simulation Team