Applications of Value Stream Mapping for Discrete Event

SimulationJon Fournier

CCAT12/14/2009

Slide 2

© 2009 Connecticut Center for Advanced Technology Inc.  All rights reserved.

Connecticut Center for Advanced Technology, Inc.

A unique economic development organization that combines expertise in cutting-edge technology with specialized centers of excellence in manufacturing, education, training, energy and entrepreneurialism.

Who we are…

What we do…Promote partnerships between industry, academia and government to create a new collaborative framework for addressing 21st-century economic challenges.

Value Stream Mapping Software

eVSM™ Software selected by CCAT• Software developed by Gumshoe KI• Based on Microsoft Visio• Supports Visual Basic for Applications (VBA) Macro

Development• VSM Data linked directly to Excel Spreadsheet

eVSM Supports Lean

• Spaghetti Diagram for defining part travel paths on layout

• Background Excel Data (includes Automatic Calculation and roll-up of part travel distances)

Why Discrete Event Factory Modeling?

•Validate Process Flow (to Meet Throughput and Cost)•Validate the Design of Complex Material Handling Systems•Optimize Space Utilization•Mitigate Cost and Risk•Maximize Equipment Utilization•Reduce or Allocate Labor•Reduce Inventory•Minimize Work In Process (WIP)•Validate Production Scheduling•Verify Capacity Planning•Determine Failure Planning•Justify Capital Equipment•Raise Efficiency•Enhanced Communication•Support Winning Proposals

Systems Integration, Process Flow Validation, Visualization

Initial Factory Modeling Software Selected

DELMIA QUEST • Easy to Use Interface Mechanism• Supports two scripting languages

– Simulation Control Language (SCL)• Model run-time logics• Macro-scripting language

– Batch Control Language (BCL)• Create/Modify elements within the model

CCAT Link of eVSM to QUEST

CCAT has developed eVSM Macro enhancements to rapidly build Discrete Event Factory models directly from the data

– Exports processes in shape of VSM– Exports machines as laid out in Spaghetti Chart– Exports DXF layout underneath machines in QUEST

Electronic assembly modeling project

• Received processes in eVSM format• Built initial importer for eVSM data• Evaluated number of workstations, operators,

and inspectors required to meet projected production rates

Machining cell evaluation

• Used spread sheet interface to import process data• Evaluated number of stations, people, to meet

projected production rates• Evaluated proposed cell layout• Identified bottleneck for machining time reduction

Machining Cell Evaluation

• Turbine Blade Manufacturing Cell• Generated electronic Value Stream Map using eVSMTM

• Used eVSM to Generate QUEST model of system• “What If” scenarios were tested in the model

“CCAT has provided access to tools that have helped us better understand how to make our value stream lean.  Using their value stream mapping and factory modeling software, we were able to run “what if” scenarios on our future state.  Our team was able to see the impact of batch sizes, buffer stock and asset utilization in a virtual environment before implementation.  This has given us the validation we needed to move forward on our shared resource value stream. I highly recommend any manufacturing company to tap into the CCAT’s state of the art offerings.”

~Continuous Improvement Manager for client

Large Fuel Cell Manufacturing

• Imported flow of parts from eVSM• Manually modified element locations• Manually added material handling system

Machining Value Stream Analysis

• Received data in eVSM format• Modified map with simulation data• Built spaghetti chart for machine locations• Completely automated build (using BCL script)

Machining Bottleneck Identification

• Received basic VSM• Evaluated future state recommendations

– Evaluated adding shifts to machine feeding bottleneck

– Evaluated splitting processes to different machines• Total modeling and initial analysis time : 4 hrs

Machining Cell Analysis• Populated Excel

spreadsheet with routings– In eVSM->QUEST

format• Built BCL Macro for finishing build

• In Excel• Built Outlook macro to exercise model

based on emailed schedule file• Returns Excel stat report

Electro-Mechanical Assembly

• Built VSM combined with spaghetti chart based on process flows

• Integrated secondary feeding model• Built using CMSD & QUEST

The CMSD Information Model defines a data specification for efficient exchange of manufacturing data in a manufacturing simulation environment. The specification provides a neutral data format for integrating manufacturing application and simulation.

• Enable data exchange between manufacturing simulation systems, other software applications, and databases

• Support the construction of manufacturing simulators• Support testing and evaluation of manufacturing software• Support manufacturing software application interoperability.

Core manufacturing Simulation Data (CMSD) Goal

Major Data Categories

• Organization• Calendar• Schedule• Work • Process plan • Operation definition• Resource• Skill definition• Setup definition

• Part• Bill-of-Materials• Inventory• Maintenance plan• Revision• Probability distribution• Reference

Simulationapplication A

Process model

Databaseextract

documents

Simulationapplication A

Process model

ARENA

CMSD

Simulationapplication B

Process model

Visualization ToolsAdobe Flex (AIR)

SilverlightJavaFX

ERP storage

MES storage

Inventorystorage

Layout Filestorage

RFID Tracking SystemstorageBoeing

test data set

A CMSD Pilot Implementation

CMSD Balloting Process - Status

• Simulation Interoperability Standards Organization (SISO) has given approval to CMSD Product Development Group to proceed to formal balloting process. SISO Balloted Products Development and Support Process (BPDSP) SISO-

ADM-003-2008.SISO Policies and Procedures SISO-ADM-002-2008.http://www.sisostds.org/index.php?tg=articles&idx=More&article=38&topics=18

• Standard for Core Manufacturing Simulation Data (CMSD) Specification,• SISO-STD-008-2009 (Draft 11 May 09).pdf is available•  

http://www.sisostds.org/index.php?tg=fileman&idx=list&id=49&gr=Y&path=Specifications

Volvo / NIST / Chalmers University CollaborationVolvo Paint Shop Operation

Modeling and simulation using CMSD for interoperability

CMSD Implementation for Truck Manufacturing – 2007

CMSD Implementation for Truck Manufacturing, By: John Marcus Johansson

CMSD Implementation forTruck Manufacturing

A 777 Hypothetical Case

Asset /Vehicle / EquipmentManagement

**** **

***** ***

Sample Automatic IdentificationTechnologies (AIT)

ProductionSystem

Data

Logistics

LinearBarcode

2DBarcode

MemoryButtons

RFIDPassive

RFIDActive

A Hypothetical Case Simulation

• Develop a front end for manufacturing engineer to perform what-if scenarios and iterations of simulation and analysis

CCAT CMSD Roadmap

CMSD API• Application Programming Interface (API)

– Holds classes for:• Part types• Resources• Processes• Process Plans

– Reads/writes CMSD XML files• Abstracts away the complexity of reading/writing of

CMSD XML files– Programmer can quickly generate CMSD interfaces

without XML programming

CMSDAPI

Packages Supported• eVSM

– Generates CMSD data from VSM– Generate VSM’s from CMSD data

• QUEST– Generates QUEST models from CMSD– Generates CMSD data from QUEST mdl file

• Excel – Read/Write PFA format• FlexSim – Builds model• Arena – Builds model

CMSD & eVSM

• Able to export VSM to CMSD

• Able to import CMSD back into eVSM• Maintains process and

assembly sequences

CCAT eVSM Utilities CMSD Integration

• Exports Excel data to CMSD

• Exports eVSM data to CMSD

• Exports CMSD to QUEST

CMSD Authoring Tool

• Stand-alone application• Create/Edit:

– Resources– Processes– Part Types– Process Plans

• Import/Export various data– QUEST, Arena, Excel, Etc…

CCAT CMSD GUI• Windows executable• Drag and drop files

– Select input files– Drag and drop from

Windows Explorer• GUI only shows

CMSD packages you have installed

Demo

Closing

• CCAT is seeking test projects with Air Force supply chain companies– Discrete Event Simulation projects– CMSD software applications

Questions?

Jon FournierApplications Engineer, CCAT

www.ccat.us jfournier@ccat.usdelmiaquest.blogspot.com

222 Pitkin Street, Suite 106East Hartford, CT 06108