Introduction to Plant Simulation

Exercise 2

IWF Betriebliche Simulation von Produktionsanlagen Dr. Peter Acél 1

Agenda

• Basics of Plant Simulation

• Handin and working on exercise 2
• Some tips

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Important Objects in Plant Simulation

• PlaceBuffer
• ParallelStation
• Conveyor
• Worker
• Workplace
• Footpath
• Workerpool
• Broker

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PlaceBuffer

• Processing time = minimum time Default setting:

1 minute
that a MU remains in the
PlaceBuffer.

Processing time 1 min.

Processing time 20 sec.

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PlaceBuffer Accumulating: if the output is blocked, the MUs
can change their relative distance
Accumulating deactivated
t

t+1

t+2

Output blocked
t+..
Accumulating activated
t
t+1
t+2
…until Buffer is full
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ParallelStation

The ParallelStation has several

workstations on which the
incoming mobile units (MUs) are
processed. Its characteristics
are the same as those of a
single station with multiple
workstations. = 4 Stations
Number of stations:
X dimension * Y dimension

The attribute start processing when full determines whether the parallel
station only starts processing the parts when all stations are loaded with one
part each. This is the default setting.

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Conveyor
Conveyor systems of all types can be
modelled with the conveyor line.
The conveyor transports the MU
along its entire length at a constant
speed.

In contrast to the other material flow

objects, Plant Simulation uses the
length that you have entered during
the simulation.

The length of the conveyor line and

the sum of the lengths of the MUs on
it determine how many MUs can be
on the conveyor line
Length/Speed

YouTube video from Siemens: https://www.youtube.com/watch?v=JXovFobXTIE

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Time Settings (Station)

• The processing time is the

time, which the MU remains on
the material flow object to be
processed. It is the interval
between set-up and the time
the material flow object moves
it on to its successor.

• The set-up time is the time it takes to set the object up for processing
a different type of MU. An identical name designates that parts are of
the same type

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Time Settings (Station)
• The recovery time is the time
which is required to set a station
into a defined state before it can
start processing the next part. The
recovery time is, for example,
useful to model materials handling
equipment, such as a robot, which
requires a certain time to insert
work pieces into or remove them
from processing stations.

• The cycle time is the time during which the second gate at the entrance
of a material flow object opens and closes cyclically, regardless of MUs
entering the object. The cycle time is useful to model chain conveyors
with a fixed chain interval that only transport materials when a free hook
is available.

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Resource type und product statistics

• Selecting the resource type is used to collect the

desired product statistics
• Classification of the expenses according to
production, transport, storage.
• Default setting is usually sufficient
• Display of the product statistics via the drain

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Important Elements(1)

Worker
• Has, among other things, the properties
capacity, speed and efficiency (percentage that
affects the processing time).
WorkerPool
• Create and group workers
• Corresponds to lounge in a factory
Footpath
• Way where workers can walk

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Important Elements(2)
Workplace
• Worker's place of activity, which can be
assigned to a station

Broker
• Mediates between service supply and
service demand
• Arranges the workers to the individual work
stations

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Central Service Switching: The Broker

• Central personnel deployment management

• Negotiation between supply and demand of
services

Broker
Central service switchboard

Importer Exporter or WorkerPool

Service request Provide services

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Worker modeling

• Workers work at fixed workstations

• Workstations are assigned to machines
• Workers are defined in the worker pool
• After the request, the worker moves on the
(shortest) footpath to
the workstation
• The broker as central
personnel control unit
manages all workers

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Activate importer (e.g. Station)
Importer tab

Activate

Default: Standard Broker set

service

Inheritance disabled (to

change services)

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Connect workstation with importer

Default: Standard
service

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Create worker

Movement type:
- beaming (no footpath
needed)
- footpath (movement
through footpaths)

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Useful videos

Video with the explanation of the workers in YouTube

(by Siemens):
https://www.youtube.com/watch?v=81y3WXMs0dk&t
Other videos:
https://www.youtube.com/watch?v=xRH0W7PheU8

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Agenda

• Basics of Plant Simulation

• Handin and working on exercise 2
• Some tips

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Exercise 2: Tasks distribution

Each group works on its own problem

Procedure:
1. Check the task (advice: timely)
2. Distribute the Central‘s zones among the groups
3. Work on the exercise

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Exercise 2: Tips and important points

Objectives must be unambiguous.

Demarcation: describe what is taken into account and what

is not. Where are the boundaries of the system?

Do not design abstract model with Plant Simulation building

blocks.

Keep it simple
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Agenda

• Basics of Plant Simulation

• Handin and working on exercise 2
• Some tips

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Typical errors when using simulation

Models that are too Strategy „100%"

complex often lead to • High time requirement
ineffectiveness • Increased effort in the
initial phase
• Reduced workload for
routine tasks
• Low demand on the
qualification of the
processor
Poor, inaccurate
modeling leads to no
Strategy „20%"
insights
• No findings
• Planning phase too short
• Lack of goal orientation
• Lack of employee
qualification
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Sensible approach for simulation projects

Strategy "80%"
• Clear goals!
• Clear delimitation of the
system boundaries
• Clear definition of the level of
detail
• Less effort in the initial phase
• Adaptability for task-oriented
simulation use
• Qualification (know-how) of
the processor required

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