FactoryFLOW Class Guide v. 1.2

Transcription

1 FactoryFLOW Class Guide v. 1.2 February 6, 2002 FactoryFLOW Training Manual v.1.2 1

2 Proprietary & Restricted Rights Notices 2002 Unigraphics Solutions Inc. All Rights Reserved This software and related documentation are proprietary to Unigraphics Solutions Inc. Restricted Rights Legend: This commercial computer software and related documentation are provided with restricted rights. Use, duplication, or disclosure by the U.S. Government is subject to the protections and restrictions as set forth in the Unigraphics Solutions Inc. commercial license for the software and/or documentation as prescribed in DOD FAR (a), or for Civilian agencies, in FAR (b)(2)(i), and any successor or similar regulation, as applicable. Unigraphics Solutions Inc., Hope Street, Cypress, CA All company and trademark names referenced herein are trademarks or registered trademarks of their respective owners. 2 FactoryFLOW Training Manual v.1.2

3 Contents Overview... 5 Stages in a FactoryFLOW analysis Identify the goal(s) of the study and determine areas or products affected Determine the level of detail Adopt data naming conventions Gather and organize the input data Produce an AutoCAD plant layout drawing Produce reports and diagrams for analysis...10 Understanding the FactoryFLOW data structure FactoryFLOW Equations Exercise in mechanics of FactoryFLOW Complete the Input Data...15 Calculate...15 Basic FactoryFLOW Exercises Starting FactoryFLOW Setting up the Product Structure Specifying Material Handling Devices Creating Routes for the parts and assemblies Adding Activity Points to a Drawing Performing a Euclidian Calculation Querying a material flow path Deleting Material Flow Paths Creating an Aisle Network Joining Activity Points to the Aisle Network Performing an Actual Path Calculation Creating Charts and Reports Filtering the Material Flow Diagram Creating a Congestion Diagram Moving an Activity Point Advanced Flow Exercises Review of Basic FactoryFLOW exercises Setting up Company Defaults Creating a default FactoryFLOW.flo file...29 Creating Default Time Templates...30 Setting up the order of selecting templates...31 Setting up time equations...31 Setting up templates...33 Setting up the Global Matrix...34 Summary...34 To use the templates in all future studies...34 FactoryFLOW Training Manual v.1.2 3

4 Importing Data...35 Data Contained in worksheet...35 Importing a partial workbook...35 Importing a complete workbook...36 Calculating Tugger material handling...37 Tugger Optimization...38 Optimization of the tugger route...39 Route simplification...40 Without Grouping...40 With Grouping...41 Grouping...41 Container Packing...41 FLO Data Setup...42 Drawing Setup...43 Container Packing Exercise...44 Assembly line Packing...48 Reconstruction of the Store1 area...50 Locating Objects in the Factory Layout...52 Cell Analysis FactoryFLOW Training Manual v.1.2

5 Overview FactoryFLOW is a software application that generates material flow and aisle congestion diagrams and reports. By presenting flow information graphically in a factory layout drawing, FactoryFLOW makes it possible to readily identify: Critical paths Potential flow bottlenecks Production flow efficiency Storage space requirements Material Handling Requirements These representations of flow and material handling events over the analysis time period significantly boost understanding of the production system. FactoryFLOW enables rapid, easy modeling of changes to the layout, routings, production volume, material handling systems, and material handling activities. FactoryFLOW is useful in many situations: Planning or improving the layout of a single work cell, a production line, a department, or a plant Working to improve the material flow efficiency of a product, a part, or groups of parts or products Calculating storage requirements Calculating material handling system requirements Changing product mix, adding new production, or working to improve plant efficiency Implementing new production philosophies, such as Just-In-Time or Group Technology Presenting layout alternatives Typical goals of a FactoryFLOW analysis: Evaluating material handling requirements Eliminating non-value-adding material handling Reducing total product travel FactoryFLOW Training Manual v.1.2 5

6 Improving product throughput Reducing work-in-process inventories Redesigning material flow for Just-In-Time or Group Technology Identifying storage space requirements Analyzing layout feasibility for operator walk paths Basic data required to perform a FactoryFLOW analysis: An AutoCAD layout drawing Production quantity information Parts routing information Material handling equipment information Material handling activity information The amount of data and detail required depends on the level of analysis. You may already have much of the required data available, since FactoryFLOW can import data from a variety of other software systems. Comparisons FactoryFLOW can illustrate and evaluate: Different levels of production Various storage, machine, line, and dock locations Alternate product routings Different material handling methods Effect of activity time on operator walk paths Stages in a FactoryFLOW analysis The following sections describe six common stages of a FactoryFLOW analysis. 1. Identify the goal(s) of the study and determine areas or products affected A FactoryFLOW study can help effectively accomplish Adding new products or changing existing products 6 FactoryFLOW Training Manual v.1.2

7 Expanding or contracting a facility Constructing a new facility Creating manufacturing cells Planning storage or work-in-process locations Moving manufacturing lines Adding new equipment or relocating existing equipment Improving material handling system efficiency Estimating material handling labor requirements As these goals are identified, you can determine what areas or products are affected. Affected areas might be Multiple sites Multiple buildings on a plant site Areas within a building Cells within an area Machines within a cell Affected products might be Finished products Major subassemblies Logical part or product groupings Classes of material Receiving or delivery locations Effectively determining areas and products helps you limit the analysis to an appropriate level, assign names, and gather and structure your data. 2. Determine the level of detail While it is possible to include multiple levels of areas in a single analysis, you should analyze only one level at a time. FactoryFLOW Training Manual v.1.2 7

8 Example: To revise the layout of an area containing several work cells, first concentrate on cell locations within the area. All moves within the cells could be ignored, and all moves to/from a cell could be considered to have a single destination or origin within the cell, regardless of the actual individual machine locations within the cell. You may also choose to analyze only high-volume products, specific areas, expensive handling devices, and so on. You should choose the level of abstraction to match your situation. Careful selection maintains reasonable accuracy while reducing complexity. Example: Tests with complete data sets for an automobile assembly factory showed that roughly the top 20% of the flows accounted for over 80% of the total travel, and so a meaningful flow study could be accomplished with a relatively small data set. 3. Adopt data naming conventions For your own benefit, the names you assign to products, parts, material handling devices, and activity points should be easily recognizable. Example: During the course of an analysis, FactoryFLOW might prompt you to specify the location of an activity point. You should be able to quickly, if not instantly, identify what the activity point is. The names can include letters, numbers, blank spaces, and any special character not reserved by Microsoft Windows or AutoCAD for other purposes. All fields for FactoryFLOW can contain up to 255 characters. Special characters created with Unicode fonts and characters reserved by Microsoft Windows or AutoCAD cannot be used in names for products, parts, material handling devices, or activity points. As listed in the AutoCAD User's Guide, reserved characters include the following: / \ forward slash and backslash " quotation mark : colon ; semicolon? question mark, comma * asterisk = equal sign ` backquote vertical bar 8 FactoryFLOW Training Manual v.1.2

9 4. Gather and organize the input data The type of analysis you intend to perform dictates the kind of data you need to gather. The table of analysis tasks accomplished with Factory tools reviews typical analysis tasks, their associated data inputs, and the outputs created by FactoryFLOW. The flow data you need to perform an analysis, particularly part routing information, may come from other information systems, often through a report from an existing company production database to a file that can be read into a Microsoft Excel spreadsheet, then imported to FactoryFLOW. FactoryFLOW stores all data in a single database file, which is named with a.flo filename extension. 5. Produce an AutoCAD plant layout drawing FactoryFLOW uses an AutoCAD drawing of the facility or analysis area to compute travel distances. Depending on the type of analyses you want to perform, the drawing also provides information that FactoryFLOW uses to size aisles, pack containers in storage areas, document manufacturing cells, and generate operator walk paths. Here are basic requirements for the drawing that FactoryFLOW uses: The drawing scale must be 1:1 so that correct distances can be extracted. Note: FactoryFLOW uses either imperial or metric linear units. When using imperial units, the base unit is an inch. When using metric units, the base unit is a millimeter. The drawing must be detailed enough that you can identify the location for each activity point included in the analysis data. Activity point locations should be accurate, as should the location of aisles and any obstacles that affect travel paths. In general, existing AutoCAD drawings of facilities can be used. Drawings created with FactoryCAD are particularly well-suited to use with FactoryFLOW, and the functionality in FactoryCAD is required for some advanced FactoryFLOW analyses. You can also import and translate drawings from another CAD system, as well as scan in paper drawings, although both of these options have limitations. EAI Factory technical support staff can provide more guidance and information. FactoryFLOW Training Manual v.1.2 9

10 6. Produce reports and diagrams for analysis Given input data and a layout drawing, FactoryFLOW calculates distances, costs, intensity (frequency of path use), and material handling activities, and then diagrams the material flow. FactoryFLOW generates three types of material flow paths: Euclidian paths are straight-line flows between activity points. Euclidian flow diagrams quickly illustrate flow intensities among activity points. Rectilinear paths are two-segment flows between activity points whose segments are parallel to the X and Y axes. Rectilinear flow diagrams provide a quick approximation of actual distances Actual paths are the shortest route (based on distance or travel time for the material handling device) along an aisle network connecting activity points. Actual path flow diagrams provide the most accurate distance and time calculations, and can serve as the basis for computing aisle congestion. All flows that have the same routing (from activity point, to activity point, and material handling device) use the same flow path. FactoryFLOW can add arrows to show direction of flow. As flows are identified, FactoryFLOW performs the distance, cost, and path use calculations. The results for each flow path are summed, and each flow line s width is adjusted to reflect the intensity (frequency of path use) of material handling along the path. When actual paths have been calculated and drawn, FactoryFLOW can then calculate and diagram aisle congestion. 10 FactoryFLOW Training Manual v.1.2

11 You can use additional FactoryFLOW diagrams, charts, and reports to find areas of possible improvement or comparison. You can change activity locations, edit paths, or change any of the input data and immediately calculate the impact of the change. You can compare alternate layouts and/or material handling systems, and you can use FactoryFLOW output to help document and justify recommendations for changes to production layout or material handling. FactoryFLOW Training Manual v

12 Understanding the FactoryFLOW data structure To perform calculations and generate output, FactoryFLOW combines a layout drawing with a database of production and facility information. A FactoryFLOW database file contains all textual data for an analysis project, both input data and calculation results. The project file is named with a.flo filename extension. While the.flo database file format is compatible with Microsoft Access, FactoryFLOW does not require any external database application. You can enter data into the.flo database through several means: Migrate data files from an earlier release of FactoryFLOW Import data from an appropriately structured Excel workbook Enter data using the FactoryFLOW graphical data editor Input data for FactoryFLOW analyses can be categorized into the following types: This data category Company-standard data Facility-specific data Applies to this type of data Data that must be the same in FactoryFLOW projects, or studies, that will be compared with each other, including Activity equations Activity templates Container types Containers Activity point types Global activity assignment matrix Studies for a given facility include the same activity points and material handling equipment. Analysis projects are normally limited to only one facility per.flo file. Study-specific data Study-specific data mainly comprise part routings for the analysis areas or assemblies being studied. Routing data for multiple products, assemblies or other part groupings can be contained in a single.flo file, and can be selectively included in analysis calculations. 12 FactoryFLOW Training Manual v.1.2

13 FactoryFLOW Equations FactoryFLOW utilizes the following equations to calculate distance, cost, time and material handling utilization: The number of trips for a move: (Prod Vol)(Part Qty)(Part Usage)(Flow %) # trips = (Parts/Cont)(Cont/Trip) The total distance for a move: The total time for a move: Total Dist = (# of trips)(trip Dist) Total Time Total Dist = + (Time det. by Load Temp.) Speed of Device + (Time det. by Unload Temp.) + (Time det. by MH Temp.) The total cost for a move: Total Cost + (Labor/hr) = (Fixed Cost) + (F/P/M Cost/hr) Total Time 60 Min Total Time 60 Min The material handling device utilization: Utilizatio n = Total Busy Minutes Total Available Minutes FactoryFLOW Training Manual v

14 Exercise in mechanics of FactoryFLOW In order to effectively and correctly apply FactoryFLOW to a material handling project and analyze the resulting data, it is essential to understand how the program manipulates the input data to calculate the costs, distance, and time requirements for a project. The following example illustrates the mechanics of FactoryFLOW: Example: The following data is available for a single material handling trip in the ACME manufacturing/assembly plant: The plant produces 4000 widgets per week Each widget requires 4 parts (part number ) to produce a single final product. A lift truck (F142) lifts a load (2 racks/pallets, each containing 20 parts) of part number at location A and transports it 800 ft to location B. This is the only material handling trip recorded. At location B, two pallets/racks are set down and two empty pallets/racks are picked up. The forklift then returns to location A. It takes the lift truck 1.5 minutes to load the pallets/racks, and 1.5 minutes to unload the pallets/racks The average speed of the lift truck is 300 ft/min From the IE department the following information was obtained: Available time for each lift truck driver, after subtracting lunch, breaks and allowances from an 8 hour shift is 6.5 hours per shift ACME works 2 shifts each day, 5 days per week for 50 weeks a year The EFFECTIVE labor cost per hour worked is $31 ($25 x 8hrs / 6.5hrs) The EFFECTIVE hourly fuel, power and maintenance cost per lift truck is $10 The life of a lift truck is 5 years at an original cost of $100,000 (depreciation is linear in fixed increments) 14 FactoryFLOW Training Manual v.1.2

15 Complete the Input Data 1. Effectiveness of the material handling device 2. Available time per week (in minutes) 3. Investment cost per week Calculate 1. Quantity of parts required for one week s production 2. Number of trips required per week to move parts from A to B 3. The actual distance traveled for each cycle (from A to B and back to A) 4. The total distance traveled in one week 5. The total time required to complete each cycle (remember to include load/unload times) 6. The total time required to move a week s production from A to B and return the empties to A 7. The utilization of the material handling device 8. The weekly cost of running the lift truck FactoryFLOW Training Manual v

16 Basic FactoryFLOW Exercises This section contains several exercises created for the student to gain an understanding of the user interface of FactoryFLOW, as well as the steps required to complete a FactoryFLOW study. In the first exercise we create a study from scratch. We will model a small facility that assembles a chair for a product. GOAL: The goal of this study is to gain familiarity with the FactoryFLOW application and user interface. Users can also experience how data is entered and manipulated within the editor. Starting FactoryFLOW Step 1- Start AutoCAD and open the Chair Assembly drawing (Chair Assembly.dwg) located in the class directory specified by the instructor. Step 2- Select FactoryFLOW from the Factory menu. The menu choices should change to include a FactoryFLOW pull-down. Step 3- Select the FactoryFLOW Editor from the FactoryFLOW pull-down. This starts the FactoryFLOW application. The program asks for a.flo file to open. Instead of selecting an existing.flo file, type chair.flo in the file name field and select Open. Since a new file name was selected, FactoryFLOW creates a new file based on a default standard database named FactoryFLOW.flo. This file is found in the program folder within the folder where the Factory programs were installed. NOTE: Since FactoryFLOW uses a live database for storing its information; any changes that are made in the FactoryFLOW editor are automatically changed in the database. As a result, it is imperative for the user to save an alternative.flo file using the Save Project As feature on the File menu if he or she wishes to keep the original project undisturbed. Observe the general layout of the FactoryFLOW editor. On the left hand side is the Assembly Hierarchy window. It contains the Product and Part Structure (under the Assembly Data heading), Activity Point information (under the Activity Points heading), and Material Handling information (under the Material Handling Equipment heading). On the right hand side of the editor is the data window. Depending on what is selected in the tree structure, the corresponding data appears in the window. 16 FactoryFLOW Training Manual v.1.2

17 Assembly hierarchy Data window Setting up the Product Structure The chair has the following parts and assemblies: 1 seat 1 back consisting of: 1 back rail 3 back spokes 4 legs consisting of: 1 leg spindle each 1 foot hardware each 4 cross braces Step 1 - Right click the Assembly Data heading in the tree structure. Choose New from the pop-up menu, then choose Assembly in the fly-out. Name the new assembly Chair. Right click (or double click) on the Chair assembly and look over the properties. Enter 400 / day for the Volume FactoryFLOW Training Manual v

18 Step 2 - Right click on Chair. Choose New, then Part. Enter the name of the first part as Seat. Step 3 - Continue this process for the rest of the parts. For the subassemblies, select New Assembly instead of New Part. For example, choose a new subassembly named Leg Assy. In Leg Assy, add two new parts: Leg Spindle and Foot Hardware. Step 4 - Once the product structure has been entered, part quantities per product must be input. Either double-click on the part and assembly names, or right-click and choose Properties to bring up the properties of that item. By default, all part quantities are set to one. For the parts and assemblies that need to be modified, change the part quantity field to the correct number (example: part quantity field for cross braces should be four) NOTE: For the Part Quantity in a subassembly, input the number of subassemblies that are needed to make the product. For the parts that make up a subassembly, enter the number of parts needed to make the subassembly, not the product. 18 FactoryFLOW Training Manual v.1.2

19 Specifying Material Handling Devices Step 1 - Right click Material Handling Devices in the Assembly Hierarchy. Choose New Material Handling Device from the pop-up menu. Fill out the dialog box with the information displayed below: Select OK when finished. Step 2 - Use the same method to create the next material handling devices with the following information: FactoryFLOW Training Manual v

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21 Creating Routes for the parts and assemblies Receiving Dock Cross braces Seat Leg Spindles Foot hardware Back rail Back spokes Fork (200/load) Fork (100/load) Fork (200/load) Fork (400/load) Fork (100/load) Fork (200/load) Central Store Central Store Cross braces Seat Handcart (50/load) Handcart (25/load) Leg Spindles Foot hardware Handcart (20/load) Handcart (100/load) Station 1 Leg Assy Handcart (20/load) Station 3 Chair Base Hand (2/load) Back rail Back spokes Handcart (10/load) Handcart (20/load) Station 2 Back Assy Hand (2/load) Station 4 Chair Assy Fork (20/load) Ship Dock As can be seen from the above diagram, all of the parts are taken from a receiving dock to central storage and from there to the assembly stations. The following steps guide us through entering the data into the FactoryFLOW project. Step 1 Add an activity point. a. Click the back rail part in the back subassembly. The right side of the window changes to display the flow diagram for the back rail. b. Right-click an empty space in the Flow Diagram pane and select Add activity Point from the shortcut menu. c. Type Rec Dock for the name of the activity point and then choose OK. d. A dialog box pops up stating that this point does not exist, and asking if you want to create one. Choose OK. e. In the new dialog box, select the activity type dock. FactoryFLOW Training Manual v

22 f. Choose OK in the dialog boxes until the dock point has appeared in the Flow Diagram Window. Step 2 - Repeat Step 1, this time add a point named Central Store that has a type of storage. NOTE: Once activity points appear In the tree structure, it is possible to simply left-click on an activity point and drag it into the FLOW Diagram Window. Step 3 - The next step is to establish a route between the two activity points. Select Add Move Arrow. Select the Rec Dock point, then the Central Store point. In the dialog box, choose Fork1 for the material handling device, with 100 parts per trip and 1 container per trip. NOTE: In this example we will assume the parts per trip field will represent the parts per trip. This is accomplished by having the containers per trip equal to one. Step 4 - Continue to create the rest of the routes shown in the diagram given on the previous page. In version 7.0, the capability has been added to copy entire routes, or portions of routes. Simply draw a window around the activity points and arrows that need to be copied, from the Edit menu select copy, and select paste when you have clicked to the part where the route should be pasted. This is very helpful in creating the routes for all the parts between the Rec Dock and Central Store activity points. Ask the instructor any questions that arise. NOTE: It will be necessary to change the product structure to accommodate the routes in the diagram! If the material flow routes have been entered correctly, an entire process flow diagram can be created. Step 1 - First check for full connectivity. Select Check connectivity from the Flow Diagram menu. A dialog box will pop up stating either that the process diagram is fully connected or that it isn t connected. If it is not fully connected, make changes to the process flows. Step 2 - Select Display Entire Process Flow Diagram from the Flow diagram menu. FactoryFLOW will create a process flow diagram containing all of the individual flows. You can move the nodes to form a more clearly structured diagram. When you select a part name in the tree, flow for the selected part is highlighted. 22 FactoryFLOW Training Manual v.1.2

23 At this point, the basic data has been entered to perform a FactoryFLOW study. Adding Activity Points to a Drawing Now that the Activity points have been defined in the FactoryFLOW database, they need to be inserted into the AutoCAD drawing. Step 1 - From the Activity Points menu, select Add Missing Activity Points to Drawing. In AutoCAD, place the activity points in the correct areas. Performing a Euclidian Calculation Now that the data has been entered, and the activity points exist in the drawing, a Euclidian calculation of material flow can be performed. A Euclidian analysis is a straight-line analysis and does not require an aisle network. Step 1 - From the Data Analysis Menu, select Calculation. Alternatively, there is a toolbar button with the image of a calculator that also starts the Calculate function. Step 2 - In the dialog box, ensure the distance method selected is Euclidian. Specify a path scale factor of Select Create calculation log file. After these values have been selected, choose Calculate. Note: It is possible to stop the calculation process by clicking the stop button in the FactoryFLOW Calculation Progress dialog. When material handling device capacity is too small for the required moves (busy Min. /DAY is greater than Avail. Min. /DAY), the program displays a dialog box for adjusting the number of devices. Adjustments are optional. FactoryFLOW Training Manual v

24 Tip: Equipment utilization calculation results are shown on the Material Handling Utilization page of the FactoryFLOW Calculation Results dialog box. Querying a material flow path It may be necessary to query a material flow path to find information such as the part being moved, the total cost of the move, the total distance of the move, or the total frequency. Step 1 - From the Paths menu, select Query Path, then Query Flow Path. Step 2 - In AutoCAD, select one or more material flow paths, then press enter. Step 3 - Scan the information available in the Query Flow Path dialog box. Deleting Material Flow Paths To remove material flow paths from a drawing, it is necessary to delete them using FactoryFLOW. Step 1 - From the Paths menu, select Flow Path, then Delete Flow Path. In the dialog box, be sure Delete All Paths is selected and click OK. Creating an Aisle Network In order to perform an actual path calculation, an aisle network must first be drawn. Using AutoCAD lines to create an aisle network: Step 1 - In AutoCAD, from the FactoryFLOW menu, select Go to Aisle Network Layer. This will set the current layer to the cimff_actpath layer. This is the default layer FactoryFLOW uses for aisle network lines. Step 2 - Using the AutoCAD line command, draw lines down the center of the aisles. NOTE: Line intersections MUST be connected. This can either be accomplished using object snaps or simply by overlapping the lines. Joining Activity Points to the Aisle Network After the aisle network has been created, the activity points must be joined to that network. This can be done several ways. They can be joined using AutoJoin, or they can be drawn manually using the Manual Join command or using the AutoCAD line command and insertion point snaps. For this example the AutoJoin command will be used. 24 FactoryFLOW Training Manual v.1.2

25 Step 1 - From the Paths menu, select AutoJoin and then AutoJoin Activity Points in Current Drawing. This will look for all the points in the current AutoCAD drawing and automatically join them to the nearest aisle network line. Switch to the AutoCAD drawing and note that all the points have been joined. Performing an Actual Path Calculation Now that an aisle network has been created and the activity points have been joined to it, an actual path calculation can be performed. Step 1 - From the Data Analysis menu, select Flow Calculation. In the dialog box be sure the distance type is set to Actual. Create Calculation log file should be selected, and the path scale factor should be Choose Calculate after verifying the selections. Step 2 - Switch to the AutoCAD drawing and look over the actual path diagram. Note how the material flow lines follow the aisle network. NOTE: If Euclidian lines are drawn during an actual path calculation, the path connecting the from and to activity points is not connected. This may be due to open intersections (lines do not connect or overlap), the aisle lines being on an incorrect layer, or the activity points not being joined to the aisle network. Creating Charts and Reports An actual path analysis is the most accurate description of the material flow in a facility. It is the analysis typically used to create charts and reports available in FactoryFLOW. The following exercise will go through some the charts and reports available. Step 1 - Create a Distance Intensity Chart. a. From the Reports menu, select Create Distance-Intensity Chart. b. In the Distance-Intensity Chart Setting dialog accept the default values and then select the Plot button. c. View the chart in AutoCAD. FactoryFLOW Training Manual v

26 Step 2 - Query a Distance-Intensity Point. From the Reports menu, select Query Distance-Intensity Point. Select one of the points in the chart. Step 3 - Create and review reports such as simple flow results, complete flow results, material handling utilization, Material Handling Activity Template, etc. Browse the information in the reports. Filtering the Material Flow Diagram When an actual path calculation has been performed. The material flow lines all following the same aisles, making it difficult to visually discern where individual flows occur. FactoryFLOW includes a filtering tool for such occasions. Step 1 - From the Paths menu, select Flow Paths, then Filter Flow Path. Step 2 - In the Flow Diagram Filtering dialog box, note the many different ways to filter. These include by Product, Part, Material Handling Equipment, Containers, From and To locations, and frequency. For this example, all the parts traveling from station 2 to station 4 will be filtered to the display. Switch the Activity Point areas to By Name. Then select Station 2 for the from activity area. Select Station 4 for the to activity area. Choose Filter. Step 3 - After noting the results of the filter in the AutoCAD layout, select the Unfilter Flow Path from the Paths Flow Path menu. This will return the diagram to a non-filtered state. Creating a Congestion Diagram FactoryFLOW enables users to depict aisle congestion through the use of a diagram. This tool adds all the individual trips along an aisle segment, then creates a color coded diagram. Step 1 - From the Data Analysis menu, select Aisle congestion analysis. 26 FactoryFLOW Training Manual v.1.2

27 Step 2 - In the Aisle Congestion dialog box, change the color code percentages to 25%, 25%, 25%, and 25%. Enter a scale factor of The last field should change to zero. Select Draw Congestion Paths when finished. Step 3 - When finished looking at the congestion diagram in AutoCAD, select Delete Congestion Path from the Paths Congestion Path menu. NOTE: The prerequisites to performing an Aisle Congestion Analysis include a fully connected aisle network, and that an automatic actual path calculation has been performed. Moving an Activity Point One of the changes that can be analyzed is a change in location of an activity point. In this example the Central Store activity point will be relocated from its current position to a new position. Step 1 - In AutoCAD, erase the aisle network connection to the Central Store activity point. Step 2 - Using the AutoCAD move command, select the Central Store activity point and surrounding area and move it to the new location where Station 1 and Station 2 are. Move Station 1 and Station 2 to the area vacated by central store. The areas may need to be rotated. Since this is a first pass, the exactness of fitting the areas into the existing structure is not important. Step 3 - The activity point must be reconnected to the aisle network. This can be done using the AutoJoin or Manual Join command. If a Manual Join is appropriate, go to the Paths menu, select AutoJoin and then select Manual Join Activity Paths from the fly-out menu. Find the desired activity point and click on it, then select a point on the aisle network and the activity point will be joined to the aisle network. Step 4 - Once the activity point has been re-connected to the aisle network, a new Actual Path calculation can be performed. Select Flow Calculate from the Data Analysis menu. Note the difference in the results. FactoryFLOW Training Manual v

28 Advanced Flow Exercises Review of Basic FactoryFLOW exercises These next fifteen steps are designed to review the basic features of FactoryFLOW and how to perform a basic FactoryFLOW analysis. This same example will then be used to look at some of the advanced features of FactoryFLOW. Step 1 - Open flowdemo.dwg located in the class directory Step 2 - Load the FactoryFLOW application. Open the database flowdemo- 01.flo located in the class directory. Step 3 - Perform a Euclidian calculation. (Data Analysis Calculation) Step 4 - Adjust the path thickness to (Paths Flow Path Adjust Flow Path Thickness) Step 5 - Query a path. (Paths Query Path Query Flow Path) Step 6 - Delete the flow paths. (Paths Flow Path Delete Flow Path) Step 7 - In AutoCAD under the FactoryFLOW menu, select Go to Aisle Network Layer. This will turn the CIMFF_ACTPATH layer on. It was frozen by default in the drawing file. Step 8 - Perform an AutoJoin Activity Points in the Project. (Paths AutoJoin AutoJoin Activity Points in Current Project) Step 9 - Perform an Actual Path calculation (make sure that the calculation log is selected before executing the function. (Data Analysis Calculation) Note: The AutoCAD progress bar is used to indicate the status of the calculation. To see the progress bar do not maximize the FactoryFLOW Editor window. Step 10 - View and discuss the calculation log. Step 11 - Create a Distance-Intensity Diagram. (Reports Create Distance- Intensity Chart) Step 12 - Query a Distance-Intensity Point. (Reports Query Distance-Intensity Point) Step 13 - Generate a Congestion Diagram with a scale factor of 0.01 and an aisle thickness of 12ft. (Data Analysis Aisle Congestion Analysis) Step 14 - Delete the material flow paths. 28 FactoryFLOW Training Manual v.1.2

29 Step 15 - Delete the congestion diagram paths. (Paths Congestion Path Delete Congestion Path) Setting up Company Defaults FactoryFLOW now uses a database to store all the information needed to run a study. Some of this information is repeatable for different Flow studies and can then be stored in a default database. This database can then be used as the starting point for all future flow studies. In the basic example the default database used was called FactoryFLOW.flo. The following exercises will go through the process of adding information that can be contained in this default database. Creating a default FactoryFLOW.flo file 1. Open FactoryFLOW 2. Create a study with the name FactoryFLOW.flo 3. From the Data menu, select Activity Point Types. FactoryFLOW allows users to define their own activity types. Add the following AP types, then delete existing AP types that were already there. Select a color and shape for each type: Activity Type Internal Type Color Shape Loading dock Dock Red Arrow Marshalling Process Magenta Diamond Inspection Process Blue Square Line Feed Assembly Green Circle Empty Storage Store Cyan Triangle Full Storage Store Yellow Triangle 4. Delete all other Activity Points. 5. Select Containers from the Data menu. In the Containers dialog box, delete all but two containers. 6. Add Container and Carton. 7. In the Containers dialog box, set the type and size of Carton to 24x24x12 (type carton) and Container to 96x60x72 (type Rack). Each will have a stack height of From the Options menu, select Settings. FactoryFLOW Training Manual v

30 9. Under Time Setting, set the time unit for both Material handling and Production to DAY. 10. Exit FactoryFLOW Editor. 11. The file that was just created will become your new default file for all FactoryFLOW studies. Go to the \\CIMF\PROGRAM directory and rename the existing FactoryFLOW.flo file to FactoryFLOW-old1.flo. 12. Copy the file you created above ( FactoryFLOW.flo ) to the \\CIMF\PROGRAM directory. 13. When you have completed the training you will have to set up your own company standard FactoryFLOW.flo file. Creating Default Time Templates When FactoryFLOW calculates the time to move a container of parts from one location to the next, the total travel time is calculated in three steps: 1. Time to load the container determined by the Load Template. 2. Time to move to the drop location determined by the distance and speed of the material handling device. 3. Time to unload the container determined by the Unload Template. Load and unload templates for a specific trip can be defined in 3 ways: GLOBAL MATRIX: Use a specific template based on: The type of action (load or unload) of a specific container type that is delivered by a specific Material handling device to a specific Activity Point location For example: If a carton of parts is unloaded with a Fork Lift at a Line Feed location then use the Fork unload 123 Template. MATERIAL HANDLING DEFAULT: Specify a specific load and unload template for a material handling device and use these templates whenever a material handling move is made by the device. LOCAL ACTIVITY: For any specific move, overwrite either of the options mentioned above with a specific load or unload time. 30 FactoryFLOW Training Manual v.1.2

31 Setting up the order of selecting templates 1. Open the FactoryFLOW.flo file created above. 2. From the Options menu select Settings and select the Activity Assignment Priority tab. 3. For both the load and unload, alter the order of the priority so that it is Local Activity first, then Global Matrix, and finally Material Handling Default. Setting up time equations We are now going to create a number of time equations that will be used in our activity templates. All times are in MINUTES. Look at the following table: (Highlighted items should already be present.) Name a b c x- variable y- variable Frequency Get off Fork: 0.3 Per Trip Get on Fork 0.5 Per Trip Load Activity 1 Per Trip Unload Activity 1.2 Per Trip Tugger Load 0.2 Per Trip Tugger Unload 0.3 Per Trip Sign paper work 1 Per Trip Cut open container 0.05 Per Container Unwrap part 0.02 Per Part Maneuver Fork Lift Walk Trip Feet Walked Walk Container Feet Walked 0.3 Per Trip Per Trip Per Container Each item in the preceding table represents a specific time element. The total time of each element is defined by an equation of the format ax+by+c. For example, if we look at the Walk - Container equation we can model it as: Time = 0.01 (Feet Walked) Do this once per container FactoryFLOW Training Manual v

32 So, if 5 containers move a total of 30 feet each, the total time generated by this equation will be: TIME = (0.01* ) *5 = 1.6 min To set up the equations listed above: 1. From Data select Activity Equations. 2. Select Create a new activity equation. 3. In the Equation Wizard, name the new equation Walk - Container. 4. Add the optional description Walk time per container delivered. 5. Choose to Set up an equation with variables. 6. In the first variable description enter Feet Walked. 7. Set the value of the coefficient a to Do not create a second variable. 9. Enter a constant of This activity is performed once per container. 12. Now enter the remaining equations listed above. 32 FactoryFLOW Training Manual v.1.2

33 Setting up templates Now that we have defined the different equations that define the material handling tasks we need to create specific material handling templates. The templates that we are going to create are listed below: Template Name Activity X Y Get Cont at Dock Maneuver Fork Get off Fork Walk Trip 30 Sign paper Work Walk Trip 30 Get on Fork Load Activity Set Cont at Line Maneuver Fork Unload Activity Get off Fork Walk Container 10 Cut open Container Unwrap part Walk Container 10 Get on Fork Fork Load Load Activity Fork Unload Unload Activity Tugger Load Tugger Load Tugger Unload Tugger Unload To set up the actual templates do the following: 1. From Data select Activity Templates. 2. Select Add new Activity template and enter Get Cont at Dock. Note: Data and text fields for templates allow up to 255 characters. 3. From the Available Activities select the appropriate elements as listed in the table above. FactoryFLOW Training Manual v

34 4. Repeat the process for each template in the table. 5. Close the template dialog box. Note: To summarize templates and activity equations used in a study, you can create an Activity Template report from the Standard Reports menu. Setting up the Global Matrix Now that we have defined our templates we can specify when they apply. This is done in the GLOBAL MATRIX. Activity Point Type Container Type Material Handling Type Load/ Unload Template Loading Dock Carton Lift Truck Load Get Cont at Dock Line Feed Carton Lift Truck Unload Set Cont at Line 1. From the Data menu select Global Matrix. 2. Enter the information listed in the table above. Summary If we load a unit load of cartons with a Fork Lift at a Loading Dock the Get Cont at dock template will be applied. If we do any other type of loading with a fork lift the Fork Lift s default load template will be applied (to set up the default load template, see the Material Handling Section in the Data Import section of this tutorial), unless a Local activity is specified for the move. The order in which FactoryFLOW looks for the load/unload template is determined by the Activity Assignment Priority settings. To use the templates in all future studies The templates are saved in the.flo file. To use a.flo file, including its templates, as the default for new studies, you can replace the current default file. 1. Exit FactoryFLOW Editor. 2. In a file browser go to the Factory \PROGRAM folder and rename the existing FactoryFLOW.flo file to FactoryFLOW-old2.flo. 3. Copy the file you created above ( FactoryFLOW.flo ) to the Factory PROGRAM folder. Important: Make backup copies of the original and any new.flo files you use as default for new studies. As an alternative to automatically basing new studies on FactoryFLOW.flo, you can open any project file and save it with a new name. 34 FactoryFLOW Training Manual v.1.2

35 Importing Data You can import data to a FactoryFLOW project file from a properly formatted Excel multi-sheet workbook that can contain all the input data required for a study except the layout drawing, or only a set of selected data. You can import up to eight categories of input data from an Excel workbook that includes properly formatted data in the following worksheets: Worksheet name Assembly Tree Routing Units MH Equipment Activity Points Act Point Types Containers Tugger Routes Data Contained in worksheet Information about how parts are organized by products and assemblies. Routing information for all moves. Units for various parts of the analysis. Material handling equipment definitions. Activity points data. Activity point type definitions. Container definitions. Tugger route definitions. You can also export study data from FactoryFLOW to an Excel workbook. Having the data in a workbook provides you an additional environment for examining and manipulating the input data. Importing a partial workbook 1. Open the Excel file Flow-Demo-partial.xls (look at the format). 2. Start AutoCAD. 3. Load layout: FlowDemo.dwg. 4. Launch FactoryFLOW. 5. Open the FactoryFLOW Editor. 6. Start a new flow project and in the dialog box specify a name of a new project as FlowDemo-02.flo. 7. File import Excel workbook select Flow-Demo-partial.xls. FactoryFLOW Training Manual v

36 NOTE: In order to successfully import Excel spreadsheet data, Microsoft Excel must be loaded on the computer. 8. Select the Truck under Assembly data and then right-click, select Properties and specify the production volume as 1500/day. 9. Select the first part in the first product and then look at the flow diagram pane. The shapes of the locations are all defaulted to the first Activity Point type that is of internal type process. The black arrows indicate full containers. Red arrows indicate empty. Look at editable fields in the table section of the route editor. 10. Select Activity Points in the left tree structure. 11. For each activity point select the appropriate type. (for example, dock = loading dock, estore = empty storage) 12. Return to assembly data and look at the different part flow diagrams. Importing a complete workbook 1. Open the Excel file Flow-Demo-full.xls (look at the format). 2. Open a new project the FactoryFLOW Editor. 3. Start a new flow project and in the dialog box specify a name of a new project as FlowDemo-02.flo. 4. File import Excel workbook select Flow-Demo-full.xls. Leave all worksheet options checked on. 5. Observe the imported data and tree structure. 36 FactoryFLOW Training Manual v.1.2

37 Calculating Tugger material handling 1. Select the material handling item from the tree. 2. Select Tugger1 and observe that the device type is set as tugger (this means that the device runs a fixed route at a predefined frequency and delivers multiple parts per round trip). 3. Click the button labeled Show Parts Delivered by this device. 4. Click the Tugger Route button found in Tugger1 s dialog, or choose the Tugger Routes command from the Data menu. 5. In the Tugger Route dialog box, define all of the routes (closed loop routes) that a specific tugger will complete and specify the frequency of each route. 6. Delete any existing routes by highlighting the route name in blue and selecting the Delete Route button. FactoryFLOW Training Manual v

38 7. Select Add Route and add a route called Route_1. Make sure that the checkbox next to the route name is selected to include this route in the next calculation. 8. Specify the number of times that this route will be completed per day (set frequency to 16 trips per day) (If your time unit displayed is not day then change it in Options Settings.) 9. In the available AP list, all AP in the database are listed. All of the AP with red icons must be visited by the tugger. Now select a route and be sure to include all the Activity Points that have to be included. Once a route has been created, it can be renamed or copied for use in alternative routes. 10. Perform a FLOW calculation and observe the path of travel for the newly created tugger route. 11. Return to the Tugger Routes dialog and go to the Show Delivery Time portion of the dialog. Select Actual in The Distance Type and then select the Show Delivery Time button. This will calculate the delivery time to deliver all of the parts for this tugger route. This feature can be used to do preliminary validation of tugger routes. Note: In order to produce valid results, a FLOW calculation should always be performed before running this function. Tugger Optimization FactoryFLOW allows for the automatic generation of tugger routes based on the shortest travel distance between points on the tugger path. The following example demonstrates: 1. If not open, then open FlowDemo.dwg and FlowDemo-01.flo. 2. Save as FlowDemo-tug.dwg. 3. The first thing that we want to do is see what the existing tugger travel would look like. Do a Euclidian calculation and set the scale factor to Set the Arrow scale factory to 1, and select At end of Path under the Arrow Types. 4. View the created FactoryFLOW Diagram in AutoCAD. 5. Go to Path, Flow Path and select the Filter Flow Path. Under the options available view only the Tugger material handling equipment. 6. Go to Path, Query Path and choose Query Tugger Route. Select the displayed tugger route path and observe the reported information. 38 FactoryFLOW Training Manual v.1.2

39 7. After viewing the filtered flow diagram and related report, select the Unfilter Flow Path option under the Path, Flow Path menu. 8. Go to the Tugger Routes menu, choose the Euclidian distance type and select the Show Delivery Time button. Observe the reported distances and times. 9. Go to the Data Analysis menu and select Tugger Utilization graph. 10. From the tugger list select Tugger1 and select Route_1. In the cycle text fields select all cycles from Click the Show Tugger Utilization Graph button. 11. Note the color coding and query a specific cycle, e.g. cycle 129. View the Delivery Time per Cycle, Activity Points Visited per Cycle, and Containers Handled per Cycle, and Container Deficit per Cycle graphs. 12. Change the delivery frequency of this device from 16 to 8 and look at the effect of the lower frequency on the tugger s utilization. 13. Click on the Container Deficit per Cycle tab and observe the change. 14. Click on the Utilization Report and Exception Report buttons and observe the reports. 15. Select Path, Flow Path, and then Delete Path. Optimization of the tugger route 1. Under the material handling equipment select Tugger1. 2. Select Tugger route and deselect all existing tugger routes and click OK. 3. Select Data Analysis and then select Tugger route Optimization. 4. Under the tugger name select Tugger1 and select the store as Store1. Choose to create only one route and base it on Euclidian travel distances. There are three delivery time constraints that can be applied to an optimized tugger route: Minimize travel time only - Finds the route design that minimizes travel time Minimize maximum delivery time over all routes* - Finds the route design that minimizes the maximum delivery time among the set of routes Minimize maximum total delivery time for required deliveries over all routes considering available time and frequency* - Finds the route design FactoryFLOW Training Manual v

40 that minimizes the maximum total delivery time among the set of routes* = Delivery time must not exceed user specified limit 5. Choose the Minimize travel time only option and perform the optimization by selecting the Optimize button. 6. When the optimization has finished, return to the tugger information and view the newly created tugger route. Look at the naming convention of the route. The default frequency is set equal to Change the frequency to 16 and check the route to be included in the next calculation. Select OK. 8. Do a Euclidian calculation and view the FactoryFLOW diagram. 9. Go to Path, Flow Path, and select the Filter Flow Path. Under the options available view only the Tugger material handling equipment. 10. After viewing the filtered flow diagram select Unfliter Flow Path under the Path, Flow Path menu. 11. Select Path, Flow Path, and then Delete Path. Route simplification When we are dealing with large data sets it is often helpful to look at optimizing the route by using grouping. The only problem is that it is very tedious to set up the data in the correct fashion. We may also want to simplify a route (look only at Dock -to -Line flow and ignore all other types of material flow) for the purpose of calculating material handling metrics. Without Grouping 1. Open FlowDemo.dwg. 2. Open FlowDemo-01.flo or FlowDemo-Tug.flo. 3. From Data Analysis select Route simplification. 4. Specify a new name flowdemo-simplify.flo. 5. Simplify the route to show only loading dock to line feed material flow. Note: Do not create any groups 6. Use the most efficient material handling device that is used in any movement to get parts from the dock to line feed (the one that moves the greatest number of parts per trip from Dock to Full Store) 40 FactoryFLOW Training Manual v.1.2

41 7. Look at some of the routings that changed. With Grouping Grouping 1. Reopen FlowDemo-01.flo or FlowDemo-Tug.flo. 2. From Data analysis select Route simplification. 3. Specify a new name flowdemo-grouping.flo. 4. Simplify the route to show only loading dock to line feed material flow. 5. Create a group that includes all Docks we will do a grouping analysis to select the best dock for each part. 6. Use the most efficient material handling device that is used in any movement to get parts from the dock to line feed (the one that moves the greatest number of parts per trip from Dock to Full Store) 7. Look at some of the routings that changed. Note that all Docks have now been renamed to the group name loading Dock RS. 8. Select Activity Points and Groups. The group loading Dock RS has been created that contains all the original Docks. 1. Under Data Analysis, select Grouping Analysis. 2. Select Grouping. 3. Specify a new name FlowDemo-Assigned.flo. 4. Select the Calculate function and do a Euclidian path calculation. 5. Select Path, Flow Path, and then Delete Path. Container Packing Another function included with FactoryFLOW is container packing. This routine allows a user to specify the containers that will be stored at an activity point, then have FactoryFLOW automatically place the containers either in floor storage areas, or on FactoryCAD rack objects. In order for the packing routine to function correctly, there is setup required both in the.flo file and the drawing. The following steps describe the requirements for the.flo and drawing files, then lead you through a packing exercise. FactoryFLOW Training Manual v

42 FLO Data Setup 1. Make sure the FlowDemo.dwg is open. Ensure that you are in Plan view. 2. Open FlowDemo-01.flo The first requirements for container packing are that both container types and containers have been given for the study. Earlier in the manual, these exercises were described. In FlowDemo-01.flo, these have already been given. 3. From the Data menu, select Container Types. Note the types described. Select OK. Next, from the data menu, select Containers. Note the specific containers defined with their dimensions. How does FactoryFLOW know which containers are located at a certain Activity Point? The answer is located in the flow diagram. 4. Highlight the part number AB Look at the flow diagram. Doubleclick on the arrow between Dock3 and Store1. Note that the container used for this move is a carton. The number of cartons containing part AB that can be stored at Store1 is 400. Both of these fields must be populated for the Container Packing routine to automatically place containers. 5. The final piece of information needed is what type of storage, either floor or shelf, is used to store the part. Double-click (or right mouse click and choose properties) on the Store1 activity point and note the dialog box. 42 FactoryFLOW Training Manual v.1.2

43 The dialog box is stating that for part AB stored at the Activity Point named Store1, shelf storage will be used. This means in order for these parts to be packed, FactoryCAD racks will need to exist. In summary, the database items required for the Container Packing routine are: defined container types, defined containers, the number of containers stored at a destination for a part, and the type of storage used for the part. Drawing Setup There are also requirements that need to be met in the drawing file. These include having the storage activity point connected to a station boundary object. Within the station boundary, both floor storage objects and FactoryCAD rack objects can be inserted. In the drawing zoom into the Store1 area. Note that the Store1 activity point symbol is attached to a station object via a FactoryCAD connector. Also notice that within the station object we have 3 floor storage objects and 2 rack objects. These objects represent actual space in Store1 that is available for packing. Later in this exercise, this area will be erased and reconstructed for practice. FactoryFLOW Training Manual v

44 Container Packing Exercise Once the.flo and drawing files have been created and the pertinent information entered, FactoryFLOW can automatically place containers. 1. From the Data analysis menu, select Container Packing. The Packing Wizard dialog appears. Select Standard Packing and then select the Next button. 44 FactoryFLOW Training Manual v.1.2

45 2. In the storage locations list select ONLY Store1. Select the View Containers for Selected Locations to see a list of containers to pack in this location. After viewing the containers, select the Next button again. 3. In the Packing Options, set the Shelf Clearance to 1 and then select the Next button. (dialog not shown in this step) 4. Select Container Type from the Available Sort Fields and then select the > button to move it over to Selected Sort Fields. Accept the Ascending in the Sort Field Properties and then press the Next Button. FactoryFLOW Training Manual v

46 5. Select by Height in the Available Sort Fields and then select the > button to move it over to Selected Sort Fields. Accept the Pack racks horizontally, then vertically in the Rack Options and the Ascending in the Sort Field Properties. Select the Next Button again. 6. FactoryFLOW indicates that all of necessary information has been gathered and the packing process can be performed. Select the Next button and FactoryCAD will automatically pack the area selected. 7. Once FactoryFLOW has finished packing, the following dialog box appears. Select each button and view the corresponding report. 46 FactoryFLOW Training Manual v.1.2

47 8. Return to the AutoCAD drawing. 9. Change view to SE isometric view zoom into the storage area and hide. This can be accomplished several different ways: From the AutoCAD Standard Toolbar, pull down a series of icons, which start with Named View. Towards the bottom of the series of icons, there are several isometric views, including SE Isometric. Alternatively, from the AutoCAD View menu, select 3D views, then SE Isometric. This provides the user with a 3D view of the packed area. 10. Zoom in on the Store1 area and note how the floor storage and shelf storage areas are filled with containers. To erase the containers, select the rack or storage area using a left mouse click (grips appears on the object, showing that it has been selected) right click and a menu appears. Select the Factory fly-out menu, then erase containers. FactoryFLOW Training Manual v

48 Assembly line Packing Next an assembly line area will be packed. 1. Verify that the drawing FlowDemo.dwg has been opened and that you are in Plan view. 2. Verify that FlowDemo-01.flo is opened 3. From the Data analysis menu, select Container Packing. Follow the steps for Container Packing above. However, in step #2 in the prior procedure, in the Select Activity Points to Pack list select ONLY Line3R and Line3L. 4. Select View containers for selected locations This provides the user with a list of the parts and containers that will be packed in the storage area highlighted. 5. Continue on going through each dialog box in the Packing Wizard as outlined in the Container Packing routine outlined above. 6. Once the containers have been packed, return to the AutoCAD drawing. Zoom in on the Line3L and Line3R stations and also view the area in a 3D view. 7. From the Data Analysis toolbar, select Container Packing again. 8. Select the Reconcile Packing on the dialog box and then select the Next button. 48 FactoryFLOW Training Manual v.1.2

49 Next, select Line3R in the Packing Reconciliation list and the select the Finish Button. The following dialog box appears. This function will look at the containers packed in the drawing, and compare that with the containers listed in the database. For example, if there is not enough shelf space, some containers may not be packed in the drawing. In this case, the containers for part AB , only 2 of the 5 containers could be packed. 9. Highlight one of the line item for this part with fewer containers in the drawing than in the database and select the Manual Packing function. 10. You will be brought back to the drawing and be prompted to insert the containers in the drawing. 11. Once you have inserted the containers in the drawing, the Packing Reconciliation dialog box gets updated automatically. FactoryFLOW Training Manual v

50 12. Change view to SE isometric view zoom into the storage area. Reconstruction of the Store1 area 1. Zoom into the Store1 area. Make sure all of the containers have been deleted from the floor storage areas and racks. 2. Erase the Station_1 area. It is the large green border around the entire area. Note the connection between the station and the activity point has been opened. 3. Next, erase the 3 floor storage areas. They are the green borders with solid and dashed linetypes. Also erase the rack objects after saving the 50 FactoryFLOW Training Manual v.1.2

51 existing racks parameters in a parameter set so the parameters can be used when the new racks are inserted. 4. Finally, remove the connector from the activity point: a. Select the connector. b. Right-click and on the shortcut menu point to Factory and then select Remove Connector. Now we are left with an activity point. First a station boundary will need to be created. 5. Switch to FactoryCAD by selecting FactoryCAD from the Factory Menu in AutoCAD. Several toolbars may appear. All of these can be closed if desired. One toolbar will be needed, however. Right click in an open spot in a toolbar area. A shortcut menu appears. Point to Cimfcad and then select IMHS. 6. From the IMHS toolbar, select the station object. Draw the Station boundary, following the gray lines around the border. 7. Next, draw in the three floor storage areas using Storage Area button from the IMHS toolbar. There are not exact dimensions for these. In order to know that the floor storage areas, which are contained in the station area, are assigned to the activity point, a connection must be made. 8. Add a connector to both the station area border and the activity point. a. Select the station area border. b. Right-click and then from the Factory shortcuts select Add a Connector. c. Select a point on the left-hand side of the border to place the connector. d. To specify a direction, pull the cursor towards the activity point. 9. Next, add a connector to the activity point. For direction, pull the cursor towards the other connector on the station area border. 10. Finally, close the connection between the border and activity point. FactoryFLOW Training Manual v

52 e. Select either connector and then right-click and from the Factory shortcuts select Close Connection. f. Select the other connector and then choose No Move. 11. To verify that everything works, re-pack the Store1 area using the Container Packing routine. Locating Objects in the Factory Layout Since the 7.0 release of FactoryFLOW, the user can locate Smart FactoryFLOW and FactoryCAD Objects in the AutoCAD layout drawing. This function can be found in the AutoCAD menu of the FactoryFLOW editor. To locate a FactoryFLOW Object in the layout, select the Locate FactoryFLOW Object from the AutoCAD menu. A dialog box appears, in which you can select a FactoryFLOW object from the object tree or specify a container to locate in the layout. 52 FactoryFLOW Training Manual v.1.2

53 Cell Analysis The Cell Analysis routine enables a user to re-arrange a matrix of assemblies/parts and activities according to whether or not the parts visit similar activity points. It provides the user with a method for determining which activity points could be grouped together for cellular manufacturing. It does not change the layout, nor does it change any production information. In this example, we will use a drawing and data set that contains some similar machining areas and several parts. The cell analysis routine will be used to aid in identifying possible manufacturing cells. To begin the cell analysis: 1. Open the drawing named Cell.dwg. Start FactoryFLOW and open the Cell.flo file. Perform a Calculation in order to activate the Cell Analysis function. 2. From the Data Analysis menu, select Cell Analysis. Note the look of the matrix. A list of activity points is displayed across the top, while a list of parts is displayed down the left-hand side. FactoryFLOW Training Manual v