1. 1 1 TECNOMATIX eM-Plant-Shop - Training

2. 2 2 Application Objects Modeling, simulation, animation and evaluation of discrete production systems in the manufacturing industry System components ProductionTransportWarehousePurchase

3. 3 3 Overview Production Orders Strategy Entry Queuing Process Sequencing Resource Selection Masterdata Operations Plans Bill of Material Procurement (I/E) Customer Orders Due Date Release Date Production orders Purchase orders Rules for Lot sizes Simulation Results Throughput time Utilization Belated orders Machine settings Production Layout Model settings Input of the Simulation

4. 4 4 Production manager: Operations plans Bill of material Masterdata of entity types Procurement type Customer orders (primary demand) Production orders (derived secondary demand) Purchase orders (derived secondary demand) Work station: Operations Set-Up and Processing time Failure behaviour Buffer capacity Part: Production order (a lot of a certain entity type) Elementary Production System }

5. 5 5 The Assistant as a modeling support tool All system components are registered and the data are check for completeness and consistence. The results of the analyzation and registration are recorded. Please observe the console. The Assistant does not recognize any changes of your model. Therefore it is recommended to start the Assistant whenever you change your model.

6. 6 6 Custom attributes: EntityTypeNo systematic name used for the production control (i.e. ``2100-100´´) EntityType verbal description (i.e.``shaft, 100 mm´´) OperationsPlan Sequence of operations with set-up and processing time (type table) OperationsPlanPos current step of the operations plan (type integer) globDestination work station for the next processing step OrderNo name of the production order (i.e. ``PO-10008´´) quantityLot size of the production order (type integer) billOfMaterial systematic name of all components with quantities (type table) WarehouseTypeverbal description of the storing place (i.e. ``warehouseOfProducts´´) OrderLPos number of the productions order (type integer) The movable element Part

7. 7 7 Modeling a Elementary Production 1.Create an empty Frame by using the Context menu of the folder Models 2.Insert a Production Manager, 3 Stations, the Assistant and Protocol. 3.Start the Assistant to register all stations at the production manager. 4.Define the names (Lathe, Mill, Grinding) of the stations and for each station assign an operation( turn, mill, grind). 5.Start the Assistant again to register all operations.

8. 8 8 6. Define the Master data of the parts in the Production Manager. Necessary data: EntityNo (systematic name ) ProcurementType Inhouse production type ``I´´ Purchase type ``E´´ OperationPlanL Create the subtable and load the prepared file OperationPlan.txt Master data of the parts

9. 9 9 All used operations must be defined in at least one station. The processing time of a lot of this entity type is given by Processing Time of the entity type * Lot Size Base Factor of the entity type * Pace Factor of the station Operations plans as a part of the Master data

10. 10 Customer order as primary demands 6. Insert the customer order under consideration in the Production Manager. Necessary data: EntityNo systematic name of the master data Date of delivery Otherwise Default start date is used. Quantity

11. 11 1.Insert the object Gantt from the folder.Shop.Evaluation. 2.Start the Assistant again to register the Gantt at the stations. 3.Open Gantt and select the stations to be evaluated. 4.Start the simulation again. Visualize the Work Flow by a Gantt Chart

12. 12 1.Define Costs in all stations 2.Insert the object Analyser from the folder 3..Shop. Evaluation. 4.Start the Assistant to register the Analyzer 5.Start the Simulation again. 6.Look at some results Analysis by the Analyzer

13. 13 Evaluations with the Analyzer

14. 14 Analysis by the Station Protocol All Lots processed on a stations are recorded: Production order Entity type Start and End time for Set-up. Start and End time for the Processing.

15. 15 Rules for Lot Sizing Open the Master data in the Production manager. Create a subtable for the View of Scheduling Insert ``FL´´ for Fixed Lot size. Further prepared rules: UL: all required parts together form one lot (unique lot size) SL: each required amount of parts forms one lot (single lot)

16. 16 Generation of the Production orders The lots are calculated in the Reset phase. Calculated start time Look at the Table of all Productions orders. of the production order A portion of the Production order list of the Production manager: Instance of a single lot the Fixed Lot size rule has generated 4 lots the size of which is at most 20. All rules never produce more as necessary. A Lot size rule gets a table of requirements of a certain Entity type. The table is sorted according to delivery date. If a warehouse system is contained in the model the stock at start of the Entity type is considered.

17. 17 Generation of the Production orders Plan the Inhouse production time for the used entity types (1 h, 2 h, 24 h). Inhouse production time is the expected time needed for the production of the entity type. It is a planning time for the termination the production orders and is not derivable from the Operations plans of the entity type. Set different Inhouse production time and compare the belated production orders recorded in the Analyser. The Master data are changed if desired.

18. 18 Shifts for Work stations All shift plan as trigger objects are contained in the frame ShiftPlans of the Production manager. The assignment of the stations to the shift plans is done by the corresponding Pop-up menu of the station dialog. The button Shift Plan in the station dialog opens the dialog of the chosen trigger object. All trigger objects and the list of assigned station can be opened by the dialog of the production manager. Note: This will be replaced by the new shift object in the next version.

19. 19 Composed parts have a Bill of material which is defined in the Master data of the Entity type. The evaluation of the Bill of material needs a Warehouse system consisting of Warehouse manager and at least one Warehouse. 1. Duplicate the model frame for a elementary production by using the context menu of the frame (See the beginning of chapter 1) 2. Insert a further work station Assembly performing the operation ``assembly´´. 3. Insert a Warehouse manager and one Warehouse. 4. Suppose that the transmission consists of 3 shaft 4 gearwheel 1 housing Open the master data list in the production manager and create the sub table for the Bill of material for the Entity type 100-1. Load the prepared text file BOM.txt in this sub table. Modeling a Production of composed part

20. 20 The new Entity types and the Bill of material 5. Copy the needed Entity types and its description from the Bill of material into the corresponding portion of the Master data list. 6. Copy the operations plan of type 100-1 to another types. 7. Load the file assembly.txt into the sub table for the operations plan of Entity type 100-1. 8. Start the Assistant. 9. Start the Simulation. 10. Since all lots of the new Entity types are belated you must plan the Inhouse production time in the Production manager.

21. 21 Termination of Production orders 100-1 Transmission 200-2 gearwheel 4 pieces 200-1 shaft 3 pieces 200-3 housing 1 piece Due date Release date Inhouse production time Due date Release date Inhouse production time The Release Date of a composed part is the Due Date of all components of the Bill of Material. Due Date Inhouse production time = Release Date.

22. 22 Availability check for the Start of Processing Reserve the Stock Register Stock Outage Stock Outage Waiting Lots Available stockReserved stock Warehousing a Lot Reduce the stock outage Enlarge the available stock Start the Processing of the Lot Reduce the Reserved stock Register Circulating stock Inventory Control and Availability checks Warehouse

23. 23 Order scheduling Transmission 1300-100 transmission 1000 kp shaft 2100-100 shaft 100 mm shaft 2100-200 shaft 200 mm housing 7100-000 transmission housing gearwheel 2100-100 gearwheel 50 tooth 2 1 4 1 Round bar 7300-060 round bar, 60 mm Round bar 7300-060 round bar, 60 mm 100 mm 200 mm Inhouse Production Time Purchased part 20.03. 24.02. 16.02. 17.02. 24.02. 17.02. Planned release date Planned due date 7 Tage inhouse production time 14.03.