SDP-STUDENT DEVELOPMENT PROGRAM

INDUSTRY 4.0 AND ITS APPLICATION IN MANUFACTURING INDUSTRIES

Organized by

Tamil Nadu smart and Advanced

Manufacturing Centre
 UNIT – 1
INTRODUCTION TO PLANT SIMULATION
Industry 4.0 is the Digital transformation of manufacturing/production and
related industries and value creation processes.

Industry 4.0 is the realization of

the digital transformation of

• The field
• Delivering real-time decision
making
• Enhanced productivity
• Flexibility
• Agility.
INDUSTRY 4.0 ADVANCED TECHNOLOGY
INDUSTRY 4.0 ADVANCED TECHNOLOGY
 CYBERSECURITY
 AUGMENTED REALITY
 BIG DATA AND AI ANALYTICS
 AUTONOMOUS ROBOTS
 ADDITIVE MANUFACTURING (3D-PRINTING)
 SIMULATION
 SYSTEM INTEGRATION
 CLOUD COMPUTING
 INTERNET OF THINGS (IoT)
APPLICATION OF INDUSTRY 4.0
 Smart Manufacturing
 Internet of Things (IoT)
 Big Data Analytics
 Artificial Intelligence (AI)
 Cyber-Physical Systems (CPS)
 Augmented Reality (AR) and Virtual Reality (VR)
 Autonomous Vehicles
 Additive Manufacturing (3D Printing)
 Cloud Computing
 Block-chain Technology
 Energy Management
 Healthcare Innovations
ADVANTAGES OF INDUSTRY 4.0
 Increased Efficiency
 Cost Reduction
 Enhanced Productivity
 Improved Quality
 Data-Driven Decision Making
 Customization and Personalization
 Supply Chain Optimization
 Remote Monitoring and Maintenance
 Workforce Safety
 Sustainability
 Innovation and Agility
SMART MANUFACTURING

PLANT SIMULATION- LAYOUT DESIGN

Plant Simulation software

TECNOMATIX PLANT SIMULATION

`

SOFTWARE
Software and Hardware Required

• Software : Tecnomatix Simulation

• Specification Required for Hardware

● Processor - CPU. Core i3 2.7 Ghz.
● Memory RAM. 8 GBB or More.
● Hard Disk. 500 GB SATA
● Graphic Card. 2 GB RAM (NVIDIA GeForce)
OVERVIEW OF TECNOMATIX :

• Organization of Work Centers in the Production Facility

• Modeling a Process Flow in Manufacturing of Support Housings for Gas Turbines

• Use of visualization, in support of Decision Making , through display of charts, for

understanding impact of change to Process Parameters
What’s Process Flow ?
 What is Simulation?

• Simulation is the imitation of a physical thing or process.

• It represents key characteristics and behavior of a system.
 Uses of Simulation
To plan a new facility:
• Determine and optimize the times and the throughput
• Determine the dimensioning
• Determine the limits of performance
• Investigate the influence of failures
• Determine manpower requirements
• Gain knowledge about the behavior of the facility
• Determine suitable control strategies
• Evaluate different alternatives
Simulation can:
Increase the profitability of the facility
Increase
• Resource utilization
• Utilization of the facility
Determine
• Optimal buffer sizes
• Number of transporters and AGVs
• Number of the workpiece carriers
• Production schedules and sequences
Decrease
• Throughput times
• Required resources
• Storage requirements
Other
• Validate the process design in the planning process
• Identify bottlenecks
• Reduce WIP (work-in-progress)
• Evaluate capital investments or changes in processes
• Optimize control strategies
• Avoid planning errors
• Protect investments
Benefits :
• Improved productivity of existing facilities
• Reduced investment in planning of new facilities
• Reduced inventory and throughput time
• Optimized system dimensions, including buffer sizes
• Lowered investment risks through early proof of concept
• Maximized use of manufacturing resources
Simulating and analyzing system performance

Plant Simulation models are

used to optimize throughput, relieve
bottlenecks and minimize work-in-
progress. The simulation models take
into consideration internal and
external supply chains, production.
 What’s meant by Cycle Time ?
• Cycle time refers to the average time taken to complete a single unit. The Lead
Time refers to the length of time it takes from the date of receipt of an order to
the date of delivery.

For Example :
Operation : Turning
Cycle Time : 60 Secs/Component
: 60 Components/hr
: 500 Components/8 hrs / Shift
: 1500 Components / Day/3 Shifts
If the Cycle Time of Component can be found by 45 Secs means , we can easily
calculate the cycle time by the use of Tecnomatix Simulation Per
hr/Day/Month/Year Instantly.
 What’s Lead Time ??

• In manufacturing, lead time often represents the time it takes to create a

product and deliver it to a consumer. Lead time is calculated by adding any
combination of the number of days to procure materials, manufacture
goods, and deliver finished products.
Lead Time
Optimization of Tecnomatix Simulation
 TECNOMATIX PLANT SIMULTION

TOPICS -TECNOMATIX
 Tecnomatix Window license issues  Assembly Station
troubleshooting.  Pick And Place Robot
 Tecnomatix Plant Simulation  Store
software setting  Buffer
 How to create new model  Sorter
 Basic plant simulation workflow  Conveyor
 Class library  Angular Converter
 Material Flow Objects  Connector
 Source  Event Controller
 Drain  Practical on Tecnomatix plant
 Station Simulation
Tecnomatix Window Graphics
Tecnomatix Window Graphics
Tecnomatix Plant Simulation Software Setting
Open
preferences

Click
file

Fix the graphical

Open new area
model

Open the
software
PREFERENCES SETTINGS
 • Tecnomatix Window license issues
troubleshooting

File / preferences /
license / License file /
Student
CREATE NEW MODEL
 TECNOMATIX
Plant Simulation
Tecnomatix
concepts
Problem and target BASIC PLANT SIMULATION WORKFLOW

Analyse problem

Required data

Create a model

Analyse a model

Evaluate the results

Improvements
CLASS LIBRARY :

 The Class Library shows

the built-in objects in a
hierarchical view grouped
in folders and sub-folders.

 By default, the Class

Library contains a folder
for Material Flow
Objects, for Resource
Objects, for Information
Flow Objects, for Mobile
Objects, for Display and
User Interface Objects,
for Models, and for Tools.
Material Flow Objects

Tecnomatix Plant Simulation provides these

objects for simulating the flow of materials
through a plant:
SOURCE:

• The Source for producing the parts that

move through your model. It usually represents the
receiving department of your plant or the main
machine producing the parts.

• Drag and click the icon from the

material flow.
DRAIN:

• The Drain for removing the parts from the plant

after they have been processed. It usually represents
the shipping department of your plant.

• Drag and click the icon from the

material flow
STATION:

• The Station for processing parts on a single

processing station. You’ll use it for modeling most of
your machines.

• Drag and click the icon from the

material flow
ASSEMBLY STATION:

• The Assembly Station for adding

mounting parts to a main part, for example
doors to a car body.

• Drag and click the icon from the

material flow
PICK AND PLACE ROBOT:

• The Pick and Place Robot for picking up

a part at one station and placing it onto another
station.

• Drag and click the icon from the

material flow
STORE:

• The Store for storing parts

• Drag and click the icon from the material

flow
BUFFER :

• The Buffer for temporarily holding a large

number of parts.

• Drag and click the icon from the material

flow
SORTER :

• The Sorter for sorting parts

according to different sort criteria.

• Drag and click the icon from the material flow

CONVEYOR :

• The Conveyor for modeling a conveyor

system.

• Drag and click the icon from the

material flow
ANGULAR CONVEYOR :

• The Angular Converter for changing

the conveying direction of the mobile objects.

• Drag and click the

icon from the material flow
CONNECTOR :

• The Connector for establishing material

flow connections between objects along which the
parts move.

• Drag and click the

icon from the material flow
EVENT CONTROLLER :

• The Event Controller for

coordinating and synchronizing the events
taking place during a simulation run.

• The event controller as been have

as the default in the workspace