virtual plant design with arena® simulation

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PUBLIC

Virtual Plant Design with Arena® SimulationIs It Part of Your Competitive Advantage?


Agenda

Driving Competitive Advantage

Demonstration

Why Arena®

Simulation Overview

Introduction


Agenda


Demonstration

Why Arena®

Simulation Overview

Introduction

www.rockwellautomation.com


PUBLIC

Pallet Stretch WrappingCase Study:


Case Study: Pallet Stretch Wrapping

Soft Drink Pallet Wrapping Machines

Plant Layout:

Case packer line

5 Palletizer Lines feeding 2 Stretch Wrappers

Challenge:

Increased load pushing pallet wrapping machines to limits


Case Study: Pallet Stretch Wrapping

Questions:

Can the two existing Stretch Wrappers keep up with increased load?

Is an additional stretch wrapping machine required?

What directional feeding rules will ensure that palletizer lines don’t

back up?

What directional feeding rules will maintain smooth, continuous

operations?


Case Study: Addressing the Challenge

Built a simulation model of the process using Arena simulation software

Identified variability/uncertainty around key process parameters

Package types

Pallet creation times

Pallet wrapping times

Forklift speeds

Stretch wrapper failure/downtime modes and frequencies

Run simulation scenarios to test alternate designs

Revised Feeding Rules

Addition of 3rd stretch wrapper


Case Study: Visualizing the Operation


Variability Considerations (Input)

Time to create pallet (TRI dist) Min Mode Max

Time to wrap pallet ("stop to start")in minutes W

yard

Dela

y

923C

Dela

y

320 D

ela

y

923A

Dela

y

FS

800 D

ela

y

Wyard 90 137 165 Muller 808 46 44

923C - 12 Packs 102 196 235 Muller 606 44 44 44 41

320 - 6 Packs 133 784 940

923A - Cube 79 157 188 3 0

FS800 240 343 411

East West

Choose the package coming off the Wyard Forklift Speed in ft/min 250 250

9 70% % eff Stretchwrapper Failure Modes

mean time betw een failure (minutes) Uptime Downtime Uptime Downtime

Muller 808 - West 112 8 235 5

Choose the package coming off the FS800 Muller 606 - East 232 8 235 5

1 70% % eff

What is your can line efficiency 75% % eff

East West Switch at M12 (1=West, 2=East, 3=Auto)

Break Film Change


Case Study: Arena® Simulation Results

Developed New Palletizer Feeding Rules to Eliminate Backlogs

Line 1: Feed Left Only

Line 2: Feed Left or Right

Lines 3,4 & 5 Feed Right Only

3rd Stretch Wrapper Not Required:

$150K Capex avoidance

Reduced long-term system maintenance costs



PUBLIC

Primary Steelmaking OperationsCase Study:


Case Study: Primary Steelmaking Operations

ArcelorMittal Dofasco Steel - Hamilton, ON

Shipping 4.5M net tons of flat carbon steel annually

One of ArcelorMittal’s best performing sites

Primary Steelmaking Operations

Linear process (5 main process steps)

Eleven (11) different steel grades

Entire system constrained by slowest element in the process

SIP Capital Improvement Project to Improve Production


Case Study: The Challenges

Challenges:

1. Uncertain if current system can meet/exceed yearly production goals

2. Expecting increase in demand

3. Four (4) alternative shop configurations proposed

Assumption:

Current steel making process is capable of achieving yearly production goal (3.1M Tons) by making incremental improvements to sub-systems

Full Analysis of Steelmaking Operations

Understand True Throughput Capacity

Identify & Eliminate Bottlenecks

Quantify Impact of Changes to the System


Case Study: Goals

Questions:

What is constraining the output potential of the operation today?

Will incremental sub-process changes deliver the required productivity

increase?

Or are major capital equipment investment required?

What is the most sustainable solution?


Case Study: Addressing the Challenge

Define the system

Iron Making & Desulph, Steelmaking (KOBM), Ladle Metallurgy Facility (LMF), Vacuum Degassing (VD), Casting

87 unique system processes/activities

Identified variability/uncertainty around key process parameters (100+)

Steel Grades

Production Schedule

Hot Metal parameters, Steel Making parameters, LMF parameters, Casting parameters

Maintenance, Failures, and Downtime frequencies

Verification & Validation

Ran model with historical data

Compared model run results to the actual production data

Simulation results were within 1% of actuals for the calendar year


Case Study: Visualizing the Operation


Case Study: Arena® Simulation Results

Output / Key Performance Indicators (KPI)

Total Casting Overall and by Product

Number of Ladles Cast Overall and by Day

Casting Cycle Time

Caster Shutdowns

Specific Queue Times (Determine Bottlenecks)

Hot Metal Production Delivered to Steel Making & Coffining

For each KPI, Arena provided: Average, Minimum, and Maximum with Confidence Interval


Case Study: Results Continued…

More Realistic View of the “As Is” System Identified 20 Key Areas Constraining Output of Current System and Impact of Each (narrowed from 100+)

Past methods overstated potential results

Better Understanding of Relationships Between Sub-Processes

Quantified Impact of Changes to Sub-Processes

Confidently Predict True Throughput Capacity of Current State

Determined Which “To Be” System Would Provide Greatest Benefit Justify Capex Before Spending

Operational Decision Making Tool


Agenda


Demonstration

Why Arena®

Simulation Overview

Introduction


Is Simulation Right For Me?

1. Variability or uncertainty impacting the process

2. Constraints or limitations on resources (people or equipment)

3. Some degree of system interaction or complexity

Arena provides value to an organization when they are faced with at least one of these challenges:


What is Discrete Event Simulation?


Global Applicability

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ervi

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ervi

ces


Why Simulation?


Agenda


Demonstration

Why Arena®

Simulation Overview

Introduction


Arena® Models All Business Processes


Advantages of Simulation

Compare alternative designs

Incorporate system variability

Include system interactions

Observe complex systems over time

Animation communicates ideas

Understand bottlenecks

Low risk/high return

Enhance Competitive Advantage

Excel

Simulation


Agenda


Demonstration

Why Arena®

Simulation Overview

Introduction


Benefits for SIs & OEMs

Validation of system design

Incorporate variability, uncertainty and constraints into design

Quantitative comparison of alternatives

Demonstrate design to customers

Optimize/enhance equipment performance

Value-add service/expertise to customers

Extension of simulation models to real-time applications


Support from Rockwell Automation

Training courses

Bi-monthly courses in Austin, TX

On-site, customized courses

Technical Support

M-F, 9-5 (Eastern Time)

Phone or E-mail

Consulting Services

Project assistance

Turn-key projects


Need Additional Information?

Sales:

Steve Blatney

[email protected]

+1 (724) 741-4044

Technical Support:

[email protected]

+1 (440) 646-6789

www.ArenaSimulation.com

mailto:[email protected]

mailto:[email protected]

http://www.arenasimulation.com/


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PUBLIC

Primary Steelmaking OperationsCase Study:

virtual plant design with arena® simulation

Software