Plant Simulation and the art of decision making Smarter decisions, better products.

Transcription

1 11 th of May 2015 Katharina Albert Plant Simulation and the art of decision making Smarter decisions, better products.

2 Agenda Introduction Trends & Challenges Plant Simulation Case Studies Key Take-Aways Page 2

3 Katharina Albert Managing Director of Kat Logics since 2011 Located in Dubai, UAE Industry Experience Business Process Engineering, Resource Optimization, Lean Manufacturing, IT Systems, Logistics & Supply Chain Supported: General Electric Sadara/DOW Al Majdouie Emirates FC RAK Airport Elopak/Obeikan Aptec Group Product / Process Experience Digital Manufacturing Tecnomatix - Plant Simulation B. Eng. Industrial Engineering and Logistics M. Eng. Systems Engineering & Industrial Management Page 3

4 Airport Equipment Suppliers Trends & Challenges Page 4

5 Trends & Challenges Innovation & Time to Market Global Competition Quality & Cost Pressure Sustainability Frequent product innovation required Less time & money for prototyping Time-to-market is ever more important Asia no longer just extended workbench, they offer their own products at lower prices More money needed for marketing, travel Continuously reduce production and logistics costs Meet high quality & safety standards, despite reduced time for testing and commissioning Client requires more energy efficient products Legislation demands lower CO2 emission for production & transport Page 5

6 Think for a moment "$9 billion per-year could be saved in Germany alone through the use of simulation Professor Dr. Warnecke, former President of Fraunhofer-Institute, Germany The plant is too expensive to be used as an experimental environment and time is too precious to be wasted. Therefore simulation is an efficient tool for developing and testing new and innovative production concepts! Can I afford simulation? How long can I afford not to use simulation? Page 6

7 Tecnomatix - Plant Simulation Material flow simulation for the strategic optimization of complex production and logistics processes Real System or Plan Graphical modeling, visualization, simulation and optimization Input: process times, layout, material flow logic, availabilities, utilization levels, and shift models Simulation Model Results: calculation of output quantities, throughput times, asset costs, buffer allocations Factory layout & route optimization Support of investment decisions based on objective and realistic figures Simulation Result Page 7

8 Integrated Analysis Tools Bottleneck Analyzer Automatic analysis of utilization Sankey Diagraming Automatic visualization of transported material Gantt Charting Resource utilization over time... and many more Page 8

9 Visualization 2D Fast Icon based Number oriented CAD Integration Length oriented Layout planning Space utilization 3D Impressive presentation Intuitive and understandable Page 9

10 Typical Benefits for Planning Maximize use of manufacturing resources Communication tool to optimize system Improve line design and schedule Early proof of concept and vital sales tool Page 10

11 Case Study Eisenmann Page 11

12 Eisenmann Case Study Characteristics: Medium to Large Business Revenue < $750 million Industry: Industrial machinery and equipment Location: Böblingen, Germany Products: Supplier of systems for surface finishing technology, material flow automation and process & hightemperature technology PLM Software: Tecnomatix Page 12

13 Eisenmann Case Study Business challenges: Gain bigger market share through innovative products Deliver a monorail system for food catering carts at the New Doha International Airport Shorten final onsite throughput testing We are very pleased with the discrete event simulation capabilities we have developed in Eisenmann throughout the years, especially our use of Plant Simulation. Dr. Monika Schneider Simulation Expert Keys to success: Simulate the automated material flow of complete operations Virtually commission electrified monorail systems Optimize complex material flow systems Easily build a discrete event simulation model Page 13

14 Eisenmann Case Study Results: Designed and built the New Doha International Airport s electrified monorail system Determined optimal number of trolleys and buffers Shortened final throughput testing through virtual commissioning validation Page 14

15 Case Study Plakoni Page 15

16 Plakoni Case Study Characteristics: Small to Medium Business Revenue < $5 Million Industry: Industrial Machinery & Heavy Equipment, Industrial Machinery Location: Genk and Sint Niklaas, Belgium Craiova, Romania Products: Offers production engineering services and also develops and installs turnkey production processes "FactoryCAD is especially strong because of its efficiency in modeling and simulating production operations. This is not only helpful for internal use, but is especially interesting from the sales perspective as well." Geert Kenis Owner and Manager PLM Software: NX, NX I-deas, Tecnomatix Page 16

17 Complex production processes demand digital manufacturing Business challenges: Increasingly complex production facilities Shorter production ramp-ups required to support today s shorter product lifecycles Keys to success: Computer simulations using Plant Simulation, FactoryCAD, Robcad, Process Designer and Process Simulate to optimize manufacturing processes NX I-deas software geometry used as the basis for simulations Digital feasibility studies "Software such as FactoryCAD and Robcad provide us with both commercial and technical advantages. In fact, complex production facilities can hardly be developed without these applications." Geert Kenis Owner and Manager Page 17

18 Plakoni Case Study Results: Greater innovation in production process design Shorter time to volume production despite increased complexity More effective sales presentations Page 18

19 Benefits Key Take-aways Page 19

20 Benefits of Manufacturing Simulation Enhance productivity of existing production facilities by as much as 15-20% Reduce investment in planning new production facilities up to 20% Cut inventory and throughput time by 20-60% Page 20

21 Answers for industry. Meet us at booth #6001 Page 21