Introduction to Simio Simulation-based Scheduling. Copyright 2016 Simio LLC

Transcription

1 Introduction to Simio Simulation-based Scheduling 10/13/2017 Copyright 2016 Simio LLC 1

2 Agenda Simio Company Background What is Simio Risk-based Planning and Scheduling (RPS)? Simio Key Capabilities Scheduling Project Approaches Software Demonstration Simio Scheduling Workflows Case Studies Summary 10/13/2017 Copyright 2016 Simio LLC 2

3 Simio Company Background C. Dennis Pegden, PhD. Founder and Chief Executive Officer 2 nd Generation Simulation invented SIMAN/CINEMA Develops simulationbased scheduling foundation for Preactor 400 Rockwell Automation acquires ARENA & TEMPO 4 th Generation simulation invented (Patent for Flexible Object Designing) SIMIO 1 st Scheduling invented with patented simulation-based risk analysis (RPS) 623 Universities actively teach simulation worldwide st Generation Simulation invented SLAM 3rd Generation Simulation invented ARENA (Market Leader) 1 st Scheduling with Simulation invented TEMPO Dr. Pegden founds Simio LLC with the same core engineering team Cloud-based access for simulation and scheduling execution PORTAL EDITION Systems Modeling Corp. Simio LLC 10/13/2017 Copyright 2016 Simio LLC 3

4 Simio Risk based Planning and Scheduling (RPS) Simulation Visualize and understand the systems. Analyze system performance. Evaluate alternatives. Minimize risk of implementation. Planning and Scheduling Deliver services on time and budget in the presence of uncertainty. Add automated Risk Analysis to assess plan feasibility. Correctly allocate resources to improve daily operations. 10/13/2017 Copyright 2016 Simio LLC 4

5 Simio Key Capabilities 1 Accurately captures Complexity Complex Material Handing and Secondary Resources Cranes, robotic equipment, transporters, workers, etc. Specialized Operations / Resource Allocations Changeovers, sequence dependent setups, etc. Experience-based Decision Logic and operating rules Order priorities, work selection rules, buffering, etc. 10/13/2017 Copyright 2016 Simio LLC 5

6 Simio Key Capabilities 2 Effectively deals with Variability Breakdowns and Unplanned events Worker and Resource schedules Setup, Processing and Teardown times Material and Order arrivals 10/13/2017 Copyright 2016 Simio LLC 6

7 Simio Key Capabilities 3 Executes Concurrent planning and scheduling Simultaneous, in memory, solving for: Demand (sales order, stock orders, production orders, etc.) Capacity (workers, machines, transporters, cranes, etc.) Material (raw material, purchased material, intermediate material, etc.) The schedule generated through this process will fall within the window of feasibility. Demand Capacity Window of Feasibility Material 10/13/2017 Copyright 2016 Simio LLC 7

8 Simio Key Capabilities 4 Provides for Interoperability between systems Manual data entry Excel and CSV table binding (Excel) Database table binding (SQL/Oracle, etc.) XML transformation (ERP/SAP/Oracle, etc.) Connecting to Wonderware MES using the standard API. MES 10/13/2017 Copyright 2016 Simio LLC 8

9 Simio Key Capabilities 5 Facilitates Cloud based results distribution Schedule Results Gantt charts Reports Dashboards Experimentation 10/13/2017 Copyright 2016 Simio LLC 9

10 Where does Simio RPS Fit? Typical Architecture ERP (SAP, Oracle, etc.) Master planning (SAP APO, etc.) Scheduling (Excel, Board, etc.) MES (Wonderware, etc.) Add Simio for Scheduling Specified execution window Typical production campaign Multiple shifts Operational time fence Transactional ERP (SAP, Oracle, etc.) Master Planning (APO, etc.) Simio RPS Scheduling (Excel, etc.) MES (Wonderware, etc.) Operational 10/13/2017 Copyright 2016 Simio LLC 10

11 Scheduling Project Approaches A scheduling project can be approached in one of two basic ways (or hybrid) as follows: Model driven approach Simulation design and/or optimization project as the initial phase of the project New facility with no existing data (Greenfields project) Current facility but the MES that will contain the data is still in the implementation phase Current facility with no MES implemented and poor ERP/MRP data Data driven approach Current facility with MES installed and operational (rich data) Current facility and Simio will integrate to the ERP/MRP system Current facility with all process, material and resource data in Excel data tables Complex systems with many process steps, parts, routings and final products 10/13/2017 Copyright 2016 Simio LLC 11

12 Simple Scheduling Model To illustrate the process of building a simple scheduling model using a model driven approach we are going to build the process shown below in various Steps. Order Arrivals Random Distribution Order Table Cutting Operation Drilling Operation Painting Operation Shipping Operation Workers Forklift 10/13/2017 Copyright 2016 Simio LLC 12

13 Data Driven Model To illustrate the process of building a data driven scheduling model we are going to build the Order based process shown below by using the Simio data add-in. Intermediate Storage Store Red Mixing 1 Products Tankfill 1 Filler 1 Packer 1 Order Entry Mixing 2 Store Blue Tankfill 2 Filler 2 Packer 2 Workers Mixing 3 Store Green 10/13/2017 Copyright 2016 Simio LLC 13

14 Demonstration Let s look at a more detail demonstration: 10/13/2017 Copyright 2016 Simio LLC 14

15 Simio Scheduling Workflow Manual Scheduling with MES integration Actual Production Data New Order Data MES Order/Shop floor Status Production Schedule MES Operator Screen Master planning Operator View Production Orders, WIP, etc. Schedule Production Data Manual Planning Master Scheduler Production Floor 10/13/2017 Copyright 2016 Simio LLC 15

16 Simio Scheduling Workflow Automated Scheduling with MES integration (Solver mode) Actual Production Data New Order Data MES Order/Shop floor Status Production Schedule MES Operator Screen Master planning Operator View Production Orders, WIP, etc. Automated Schedule Production Data Simio Portal View Production Schedule Production Floor 10/13/2017 Copyright 2016 Simio LLC 16

17 Simio Scheduling Workflow Automated Scheduling with MES & Manual Intervention Actual Production Data New Order Data MES Order/Shop floor Status Production Schedule MES Operator Screen Master planning Operator View Production Orders, WIP, etc. Automated Schedule Production Data Manual Intervention Production Floor 10/13/2017 Copyright 2016 Simio LLC 17

18 User Financial Impact Examples Global Manufacturer saves $300 million per annum with vessel reduction Agricultural Equipment - $240,000 per annum less labor while trailer-to-door processing time drops 50%. Number of dock doors reduced with growth without more dock doors. Air Force increased process output 30% that increased revenue $10.35 million John Deere - production scheduling tool was used to create a feasible schedule that stabilizes production operations from increased throughput Vancouver Airport saved $100 million by avoiding unnecessary terminal expansion BAE Systems helped meet production deadlines and decrease overtime Retirement Clearinghouse shows Americans can add $115 billion to their savings with auto portability Cosan - predicted unnecessary sugar cane transport purchases that saved $500,000 Virgin Airlines - showed that a new gate plan would decrease OTP by 50 points and drop them from 1st place market leader to 2nd 10/13/2017 Copyright 2016 Simio LLC 18

19 Denmark Capitol Region Challenges Size of scope and complexity of the environment. No compromise environment. Sterile equipment availability. Delivery performance to other hospitals. Solution Sequences that respect all process constraints. Quick and efficient re-planning and scheduling. Fully automated solution. Awareness of all variability in the process. Value Meet committed performance targets. Real-time integration to the execution systems. Optimized resource schedules. Forward visibility based on expected demand 10/13/2017 Copyright 2016 Simio LLC 19

20 John Deere Challenges Ineffective planning in Excel. Infeasible production schedules. Schedules are disconnected from the MES and ERP. Poor production performance and throughput. Solution Integrated scheduling and MES solution. Sequences that respect all process constraints. Quick and efficient re-planning and scheduling. Schedule presented on the MES operator screens. Value Greater production stability. Improved production throughput and efficiency. Data integration and integrity. Time feedback and re-planning. 10/13/2017 Copyright 2016 Simio LLC 20 20

21 Shell Vessel Scheduling Challenges Size of scope and complexity of the environment. Weather and delivery constraints. Equipment availability. Delivery performance to offshore facilities. Solution Sequences that respect all process constraints. Quick and efficient re-planning and scheduling. Discrete event simulation. Awareness of all variability in the process. Value Measure the quality of the schedule. Allow users to react to changes in the system. Schedule visibility to all parties in the supply chain. Visibility allows running tighter operation. One tool for LT planning and ST scheduling 10/13/2017 Copyright 2016 Simio LLC 21 21

22 Steel Corp. The Company: Produces build-to-specification rolledsteel. Most important metrics: quality & on-time delivery. The Challenges: Current tools do not capture key scheduling considerations. Worker schedules and qualifications Equipment availability Material allocation complexity Random aspects of the process The Solution: A simulation model takes into account all of the factory process complexity, production order/material matching algorithms, and due date considerations. The Results: Additional market share expected with existing capacity. 10/13/2017 Copyright 2016 Simio LLC 22

23 F35-Joint Strike Fighter Problem Statement Ramping up production of the F-35 Joint Strike Fighter from 1 aircraft per month to 1 per day. Response time and accuracy of decision support techniques is insufficient to evaluate the outcomes of complex and highly interconnected operations environments. Business Rationale Mitigates risk to production cost and schedule by providing increased visibility of potential production problems and the ability to judge the effectiveness of possible solutions. Expected Results F-35 Joint Strike Fighter Reduce lost days 50% Less workstation delays $3.67M/yr. Less rescheduling review $173K/yr. 5-Year NPV ROI 18.6 : 1 10/13/2017 Copyright 2016 Simio LLC 23

24 Summary Provide both simulation and scheduling Unique capabilities Captures and represents complex processes Manages process variability Concurrent planning creating feasible schedules Provides for an Integrated solution (WW MES) Creates unprecedented value Enables repeatability and corporate wide rollout 10/13/2017 Copyright 2016 Simio LLC 24

25 Благодарим за внимание!