Forward Visibility for your business The future in improving design and operations with simulation technology Rienk Bijlsma Rockwell Automation

Forward Visibility for your business Contents About Rockwell Automation Traditional Use of Simulation Technology Recent Software Developments Live Examples Arena Software

Forward Visibility for your business Rockwell Automation Technology Conglomerate since 1902 NYSE: ROK B$ Revenue Leading Automation Provider Hardware: PLC, DCS, Networks, Drives Software: PLC Code, MES, HMI, Simulation

Forward Visibility for your business Rockwell Automation Rockwell Brand Names Allen Bradley Reliance Electric Dodge Rockwell Software –Arena, RS BizWare, RS View, RS Teststand

Forward Visibility for your business Seamless Integration Modelling / Scheduling / Tracking/HM I/Scada Condition Based Maintenance Automation Platforms Automation Components Legacy Devices Computerised Maintenance Management System Smart Devices Control / Advanced Diagnostics e-Procurement Supply Chain Partners The Web Enterprise Systems Supply Chain Management i2 MRO Suppliers ERP RA.com OEM’s Manufacturing BusinessWare

Forward Visibility for your business Simulation Traditional Use Validation/Design of New Systems Improving existing systems Application Areas –Supply Chain, Business Processes, Manufacturing, Transportation/Logistics

Forward Visibility for your business Simulation Traditional Use Simulation Pro’s –What If Analysis –Variability & System Complexity –Communication Possibilities, animation –Flexibility Simulation Con’s –Data Requirements –One Time Effort –No Clear Answers, requires interpretation –Time Consuming, even with experts

Forward Visibility for your business Future Directions Design Automation –Business Driver: Reduce Time to Market Testing of PLC Code Generating PLC Code from Design Objects Share Data across design applications Operational Decision Support –Business Driver: Optimize Manufacturing Interact with HMI & ERP User Interfaces Real Live Data Access Replacing custom code applications

Forward Visibility for your business Recent Developments Common Architecture & Software Tools Common Repository

Forward Visibility for your business Recent Developments Design Operate Maintain FactoryTalk(SP95) Product View Facility View Activity Areas Site, Area, Line, Work Cell Equipment Resources / Sets Labor Resources / Sets Shift Patterns Manufacturing Orders Materials (Make/Buy) Production Lots Segment Data Phase Times Resource Actions Material Actions Constraints Actual Data Process Times Start, Stop Failures Order Details Resources Operators Login, Quality, Comments

Forward Visibility for your business Arena Developments Arena Factory Analyzer (Link with MES) Real Time (OPC Client) –Emulation –PLC Testing ADO (Data Accessibility) Building/Reports/Documenting

Forward Visibility for your business Typical Project Architecture Database Interface

Forward Visibility for your business Live Examples Packaging Line Warehouse Supply Chain

Forward Visibility for your business What have customers done with Arena ? Redesigned assembly line and finished goods storage processes, saved $350,000 in reduced labor costs and increased productivity. Redesigned finished goods handling and storage processes, saved millions by avoiding unnecessary construction of new loading docks. Redesigned distribution system of 14 plants, 6 DC’s, and 25 whse’s, saved $500,000 in reduced transportation costs Increased throughput by 13% to 20% in several different lines, saved $650,000 in reduced labor costs, increased productivity, and reduced wastewater discharge costs.

Forward Visibility for your business What have customers done with Arena ? Redesigned their worldwide supply chain, saved over $20,000,000. Avoided purchasing unnecessary packaging line equipment, saved $850,000. Avoided purchasing unnecessary accumulator conveyors, saved over $500,000 saved over $500,000. Designed problem-free material flow systems in a new engine assembly plant, avoided their worst nightmares. Avoided building a new production facility 23’ too short to meet forecasted production requirements, saved their careers!

Forward Visibility for your business Some References CustomersNetwork Redesign Replenishment Strategy Production Strategy Contingency Planning NoYes No YesNoYesNo Yes

Forward Visibility for your business Chemical Industry CustomersNetwork Redesign Replenishment Strategy Production Strategy Contingency Planning NoYes Answers: Results: Number of Railcars necessary for SC Saved 2.5 M$ in Capital Expenditure Best Rubber Production StrategyImprove Throughput by 35 % Combining Cargo on Chemical VesselsSaving 12 % of Logistical Transportation costs, 2M$ Annually SKU resizing & locations in existing SCSaving 1.6M$ in Supply Chain Cost Other Customers:

Forward Visibility for your business Apparel Industry CustomersNetwork Redesign Replenishment Strategy Production Strategy Contingency Planning Yes No Answers: Results: Direct Order Strategy Planning/Production Lead Time Reduction 55 % Different Collaboration StrategiesFinished Goods Inventory Reduction of 80 % Retailer’s Lead Time Reduction 52 % Order Lead Time Decrease 49 % Other Customers:

Forward Visibility for your business Food &Beverage Industry CustomersNetwork Redesign Replenishment Strategy Production Strategy Contingency Planning Yes No Answers: Results: Direct Order Strategy 20 % Inventory Carrying Cost Savings Lead Time Reduction of 30 % Different Replenishment StrategyMin-Max Best Alternative Other Customers:

Forward Visibility for your business CPG Industry CustomersNetwork Redesign Replenishment Strategy Production Strategy Contingency Planning Yes Answers: Results: 27 alternative scenario’s analyzedThroughput Increase of 70 % Make-to-Order PolicyCost Decrease of 70.2M$ WIP Dropped 66 % Cycle Time Improved by 84 % Potential Customer:

Forward Visibility for your business Electronics Industry CustomersNetwork Redesign Replenishment Strategy Production Strategy Contingency Planning Yes Answers: Results: 5 Different Designs Evaluated39 % Inventory Reduction Covers Repair Strategy, Inventory Strategy16 % Reduction Transport Costs Logistics structure, etc.Direct Ship with ASN best option Overall Savings of 50 M$ Other Customers: