data based model generation gas turbines and turbo...
TRANSCRIPT
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
© Siemens AG 2015 All rights reserved.
2015-06-16Page 1
Data Based Model GenerationGas Turbines and Turbo CompressorsPavel Gocev and Andreas Sowinski
© Siemens AG 2015 All rights reserved.
2015-06-16Page 2
GAS TURBINESGAS TURBINES
LOADLOAD
SIMBOMSIMBOM
PROCESSESPROCESSES
ORDERS/JOBSORDERS/JOBSFACTORY/
SIMULATIONFACTORY/
SIMULATIONRESULTS
KPIRESULTS
KPI
BLADES &VANES
BLADES &VANES
ROTORROTOR
STATOR/CASINGSTATOR/CASING
ASSEMBLYASSEMBLYDISCSDISCS
TURBO COMPRESSORSTURBO COMPRESSORS
IMPELLERIMPELLER ROTORROTOR
STATOR/CASINGSTATOR/CASING
ASSEMBLYASSEMBLYPACKAGE/TESTING
PACKAGE/TESTING
WHEELSWHEELS
ROUTINGSROUTINGS
DIFFERENT PRODUCTS - SIMILAR CONFIGURATIONSDifferent Value Streams channeled in one Modeling and Simulation Workflow
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
© Siemens AG 2015 All rights reserved.
2015-06-16Page 3
• Multiple sites, areas andproduction lines
• Many models and modules developedby several simulation experts
• Modeling of dynamic andcomplex behaviors
• Dispersed and different structures ofavailable data and information
• Different logic descriptions
DRIVERS AND CHALLENGESReduction of Modeling Effort through an Unified Approach
DRIVERS AS MOTIVATIONDRIVERS AS MOTIVATION
• Reduction of modeling effort andshortening of the modeling time
• Reusable modules andmodel structures
• Universal solution fordifferent parties
• Upgradable andadaptable model
• Improved communicationthrough standardization
CHALLENGES TO RESPOND ONCHALLENGES TO RESPOND ON
… DEFINE… DEFINE
© Siemens AG 2015 All rights reserved.
2015-06-16Page 4
Simulation ModelPlant Simulation
LoadRoutingsBill of MaterialsProcessesResourcesShift PlanFailuresMTBF, MTTRAvailabilities
Lead TimeYieldOn Time Delivery (OTD)UtilizationWork In Progress (WIP)Fill RateQueue TimeWait to batchWait to match
3
6
9
12
2.700 4.716 6.732 8.748 10.764
Umlaufbestand
Work Orders and Routings GeneratorResources and Layout Generator
WIP-InterfaceAlternative Resources
Alternative Technology ChainsContext-sensitive selection of alternatives
Dynamic decision of batch-buildingEvent-driven process execution
InputData Base
ResultsKPI Cockpit
ONE MODELING AND SIMULATION ARCHITECTURESimulation Model is Connected to the Factory Data Base
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
© Siemens AG 2015 All rights reserved.
2015-06-16Page 5
Close-to-RealityStochastic DrivenTime-based KPI’s
Rapid Scenario ValidationStatements on Time Periods
Adjustable Detail LevelArbitrary Extendable
GTRotor
Unsteady LoadMake or Buy Decision
Layout ConstraintsVariable Process TimesUtilization vs. Lead TimeCrossing Material Flow
Variety of Scenarios
IMPLEMENTATIONSIMPLEMENTATIONSCHALLENGESCHALLENGES BENEFITSBENEFITS
GTCasing
GTCombustion
PLANT SIMULATIONPLANT SIMULATIONDATA AND KNOWLEDGEDATA AND KNOWLEDGE RESULTSRESULTS
DIGITAL FACTORY SIMULATION COMMUNITY (DFSC) IN FOUNDATIONDIGITAL FACTORY SIMULATION COMMUNITY (DFSC) IN FOUNDATION
TCSRotor
TCSCasing
GTB&V
SIMULATION AS A RESPONSE TO OPERATIONAL CHALLENGESSimulation as a Central Element of Digital Factory is Already in Implementation
© Siemens AG 2015 All rights reserved.
2015-06-16Page 6
RULESINTERDEPENDENCIES
DISPOSITIONCONTROLS
PRIORITIZATIONREWORK
OUTSOURCINGBATCHING
PLANT SIMULATIONPLANT SIMULATION
SALESSALES
ORDERSPARAMETERS
LOADLOAD
END-PRODUCTS(GT OR TCS)
SHOP-FLOORSHOP-FLOOR
WORK-IN-PROGRESS(WIP)
SIMBOMSIMBOM
SIM-RELEVANTCOMPONENTS
ORDERS/JOBSORDERS/JOBSCOMPONENTOPERATIONRESOURCES
PROCESS TIME
META-ROUTINGMETA-ROUTINGPROCESS
COMPONENTSRESOURCESPARAMTERS
RESOURCESRESOURCESWORK CENTERS
SHIFT MODELLOCATIONFAILUERS
LOAD-LISTLOAD-LIST
COMPONENTPARAMTERESDUE DATES
FROM DATA AND INFORMATION TO SIMULATION MODEL
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
© Siemens AG 2015 All rights reserved.
2015-06-16Page 7
RESOURCES AND LAYOUTAutomated generation of resources and layout is based data in one simple table
Layout TableLayout Table Visualization of real layoutVisualization of real layout Deep Dive: Machine AreaDeep Dive: Machine Area
Simple table to describe the resources
(=Machine Area)
x-y-Coordinates
x-y-Size
Rotation angle
Color
Layout of Machine Areas (red rectangles)
is created based on the x-y-coordinates
automatically (SimTalk-Method)
No direct connectors between areas as
there are no simple flows in a job-shop
Machine Area = [Frame]
Within each Machine Area each resource
is represented by a Queue for incoming
goods (Qin) the Resource itself (Res) and
a Queue for outgoing goods (Qout)
Qin / Qout = [PlaceBuffer]
Res = [SingleProc]
Machine-Area A
© Siemens AG 2015 All rights reserved.
2015-06-16Page 8
WORK ORDERS AND ROUTINGSEach job is moved from Machine Area to the next Machine Area according to the particular Routing
Jobs
/Par
ts
Processing Steps
SUBTABLEContains information regarding…
Main Processing Resource
Possible alternative resources if main resource is busy
Times (Setup and Processing)
Batching rules if necessary
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
© Siemens AG 2015 All rights reserved.
2015-06-16Page 9
TRANSPORT ALTERNATIVE RESOURCES ASSEMBLY BATCHING
CONTROL LOGICBasic model is extended by a number of modules to improve the accuracy of the simulation results
BASIC-MODEL
Machine-Area A Machine-Area B
+ + +
Machine Area A
BMachine Area B
y
Distance = x + y
Ax Res A
Res B
Res C
WorkOrder
?
?
? Workstation
+
© Siemens AG 2015 All rights reserved.
2015-06-16Page 10
PRIORITIZATION AND DISPATCHINGTwo levels of prioritization of jobs within the model
Jobs waiting in front of a resourceto be processed(e.g. FIFO, Due Date, Slack Quotient)
Jobs waiting to bedispatched into the system(e.g. via ConWIP-Logic)
StationA
StationB
StationC
Micro
Macro - Dispatching
Micro
Production System
Micro
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
© Siemens AG 2015 All rights reserved.
2015-06-16Page 11
LOADThree types of possible load can be simulated
Work-In-Process
Upcoming Orders
Arbitrary Load
Projects that are currently being processed
WIP does not necessarily start with Step 1
New orders according to sales forecast
Processing starts always with Step 1
Projects that are not based on “real” orders
Used for scenario-modellingWIP
Upcoming
Arbitrary
Today= Start of Simulation
Time
Load
© Siemens AG 2015 All rights reserved.
2015-06-16Page 12
ANALYSIS OF SIMULATION RESULTSTimestamps guarantee that the processing of every single part can be traced
Batching
TBin
Queue 1 Processing Queue 2 Transport
TQ1in TPin TQ2in TTin TTout
Time spent within Machine Area
*Quality Control / Rework / Scrap neglected
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
© Siemens AG 2015 All rights reserved.
2015-06-16Page 13
RULESINTERDEPENDENCIES
DISPOSITIONCONTROLS
PRIORITIZATIONREWORK
OUTSOURCINGBATCHING
PLANT SIMULATIONPLANT SIMULATION
SCENARIOSSCENARIOS
EXPERIMENTSEXPERIMENTS
RESULTSRESULTS
JOB-SCHEDULEJOB-SCHEDULE
EVALUATIONEVALUATION ACTIONSACTIONS
SIMULATION FOR CONTINUOUS IMPROVEMENTScenario-based Experiments Validate the Actions to be Taken
© Siemens AG 2015 All rights reserved.
2015-06-16Page 14
• Modeling and Simulation Architecture forcomplex and dynamic value streams
• Lean and easy model generationthrough standardized structures
• Scalable from macro to micro level• Extendable and adaptable for arbitrary
products, processes and resource
SUMMARY AND NEXT STEPS
SUMMARYSUMMARY
• Further standardization andharmonization of the structures
• Module for flexible scenarios thatconsider personnel qualifications
• Module for integration of timingbehaviors of different resources
• Detailed monitoring and reportingof the resource status
• Integration of costs and energy aspects
NEXT STEPSNEXT STEPS
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
© Siemens AG 2015 All rights reserved.
2015-06-16Page 15
Pavel GocevPG GT LGT LT BLN
Huttenstr. 1210553 Berlin
Phone: +49 30 3461 1424Mobile: +49 172 6343 397
BE INVENTIVE – USE PLANT SIMULATION
siemens.com
Andreas SowinskiPG CP TCS DBG MF
Wolfgang-Reuter-Platz 447053 Duisburg
Phone: +49 203 605 2918