Tecnomatix Plant Simulation Worldwide User Conference 2015

Transcription

1 Simulation-based configuration of multideep storage systems 1 Copyright 2015 SSI Schäfer, all rights reserved 2015 SSI Schäfer, alle Rechte vorbehalten This publication may neither be reproduced, transmitted nor stored in a retrieval system, including but not limited to, written material, printed matter, punch cards, film, microfilm or microfiche, magnetic tapes or discs or any other electronic media form including optically readable tapes or discs, laser discs, and any other form of computer storage, without the prior written consent of SSI Schäfer. Diese Veröffentlichung darf ohne vorherige schriftliche Genehmigung von SSI Schäfer weder vervielfältigt, noch weitergeleitet, noch in einem Datenabfragesystem gespeichert werden; das beinhaltet, wenn auch nicht ausschließlich, Schriftstücke, Druck, Lochkarten, Filme, Mikrofilme oder Mikrofiche, Tonbänder oder CDs oder jede andere Form elektronischer Medien einschließlich optisch lesbare Tonbänder oder CDs, Laser CDs und jede andere Form der elektronischen Speicherung. Disclosed matters and/or concepts of the present documentation are or will be protected by intellectual property rights. Offenbarte Gegenstände und/oder Konzepte der vorliegenden Dokumentation sind oder werden noch durch gewerbliche Schutzrechte geschützt. 2

2 Agenda Introduction of SSI Schäfer Simulation at SSI Schäfer Multi-deep storage systems Concept/ technology used Example Discussion 3 The Schäfer Group A Strong Alliance World s leading supplier of warehousing and logistics systems as well as waste management solutions. Specialists for the development, manufacture and sale of thin steel sheet and stainless steel products. Leading Mail order company for storage and warehouse equipment, office furniture and promotional items. 4

3 The Schäfer Group Key Figures Founded in 1937 Financially independent family-run business More than 9,000 employees worldwide 16 production sites Worldwide sales organization in more than 55 countries 5 Global Presence SCANDINAVIA NORTH AMERICA EUROPE ASIA / AUSTRALIA SOUTH AMERICA 6

4 SSI Schäfer : Business Sectors Integrated Standard Solutions Systems (ISS) 2 Competence Centers: SSI Schäfer Neunkirchen SSI Schäfer Neunkirch Automation 3 Competence Centers: SSI Schäfer Giebelstadt SSI Schäfer Graz SSI Schäfer Friesach Waste Management Competence Center: SSI Schäfer Neunkirchen Scope of supply & services : Warehouse, workshop, plant and office equipment Dynamic systems Scope of supply & services : Conveying & picking systems Storage & retrieval machines IT CSS Scope of supply & services : Waste collection Recycling containers 7 What SSI Schäfer offers Conveying & picking systems Warehousing Workstations The world of IT Service, support & maintenance 8

5 Simulation at SSI Schäfer 9 Simulation at SSI Schäfer In-house team of simulation experts Plant Simulation only simulation software Simulation on a very detailed level Excessive usage of Simtalk SQLite used for WMC and data export Usage of Intralogistic Suite and SimView (by Simplan) 10

6 11 Multi-deep-storage systems Field of application Small to medium amount of SKU Standard: low medium performance Shuttle: medium high performance Non-strict Batch-FiFo (e.g. bbd) Different pallet types possible Often used in food and beverages industry as well as chemical industry Optimal SKU:Channel-Ration > 1:10 Advantages High volume utilization Small footprint High sequencing performance in matrix structure 12

7 13 Simulation aims requirements Space utilization (cost effectiveness) Performance (service quality) Optimized space utilization Dynamic channel depth Performance optimized 14

8 Storage fragmentation Inbound 15 Storage fragmentation (uniform) Inbound 48 of 128 places reserved 62,5% places free 30 of 48 places used lost places = 37% 16

9 Storage fragmentation (variable) Inbound 33 of 128 places reserved 74,2% places free 30 of 33 places used lost places = 9% 17 Model Concept Modular Scalable Different abstraction levels 18

10 Data requirements (load data) Challenging to get a valid inbound data set for extrapolated outbound data Volume flow Customer WMS system Export Article master, Inbound data, Outbound data Input Simulation model Extrapolated data 19 Key Model Components 20

11 21 Results/ Discussion 22

12 Results Channel Occupation Fully occupied channels Partially occupied channels Free channels number of channel Increasing storage fragmentation time (hrs) Constant storage fragmentation time (hrs) 23 Results Channel Occupation number of channel Amount of free channels too low pallets cannot be stored Fully occupied channels Partially occupied channels Free channels Sufficient free channels time (hrs) time (hrs) 24

13 SLR - Utilization per hour SLR Average utilization per hour Utilization [%] time [hours] 25 Shipping order lead time Ø lead-time: 24 minutes Max lead time: 64 minutes Ø lead-time: 21 minutes Max lead time: 45 minutes minutes # shipping orders # shipping orders minutes 26

14 Discussion Simulation is a very helpful method to observe the timely behavior of the system Getting a decent data set is a challenge Automatic data generation could be an option Currently no target function no automatic optimization Benefit of simulation: Improve storage topology -> reduce fragmentation -> improve utilization Improve storage strategies -> find balance between filling level and perfromance gain maximum benefit of investment 27 Questions? 28