Rockwell Automation Arena Packaging User Manual

Arena®Packaging

USER’S GUIDE

PUBLICATION ARENPK-UM001F-EN-P–November 2007

Supersedes Publication ARENPK-UM001E-EN-P

Contact Rockwell

Customer Support Telephone — 1.440.646.3434 Online Support — http://www.rockwellautomation.com/support/

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Warran ty

This document and any accompanying Rockwell Software products are copyrighted by Rockwell Automation Technologies, Inc. Any reproduction and/or distribution without prior written consent from Rockwell Automation Technologies, Inc. is strictly prohibited. Please refer to the license agreement for details.

Arena, Rockwell Automation, and SIMAN are registered trademarks of Rockwell Automation, Inc.

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All other trademarks are the property of their respective holders and are hereby acknowledged.

This product is warranted in accordance with the product license. The product’s performance may be affected by system configuration, the application being performed, operator control, maintenance and other related factors. Rockwell Automation is not responsible for these intervening factors. The instructions in this document do not cover all the details or variations in the equipment, procedure, or process described, nor do they provide directions for meeting every possible contingency during installation, operation, or maintenance. This product’s implementation may vary among users.

This document is current as of the time of release of the product; however, the accompanying software may have changed since the release. Rockwell Automation, Inc. reserves the right to change any information contained in this document or the software at anytime without prior notice. It is your responsibility to obtain the most current information available from Rockwell when installing or using this product.

Version: 12.00.00 (CPR9) Modified: October 8, 2007 10:39 am

1 • Welcome to the Arena Packaging Template 1

What is the Arena Packaging template?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intended audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Where can I go for help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Reference the user’s guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Explore our examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Get help. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Use the HSMARTs library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Access the Arena Symbol Factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Get phone support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Get Web support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Get training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Get consulting services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 • General Concepts 5

Template overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Template framework and modeling methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

•

Step 1 Step 2 Step 3 Step 4 Step 5

Place and connect equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

•

Define equipment behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

•

Run the model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

•

View automatic statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

•

Experiment with complex strategies. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 • The Packaging Panel 21

Panel modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Actions module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Conveyor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Conveyor Link (CLink) module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Label module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Machine module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Machine Link (MLink) module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Merge module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Operator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Operator Group module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operator Schedule module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

iii

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

Palletizer module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Product module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Production Plans module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Simulate module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Split module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Storage module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Switch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Tank module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Common module dialogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Actions dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Animation dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Controls dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Costs dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Loss dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Operators dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Production and Changeovers dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Reliability dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Run Options dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Scheduled Stops dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Sensors dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4 • Statistics 47

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Selecting the statistics to report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Statistic descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Machine statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Conveyor statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Palletizer statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Storage statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Operator statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Operator Group statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5 • Variables 67

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Organization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Assigning and referencing Arena Packaging template variables . . . . . . . . . . . . . 67

Updating Arena Packaging template variables. . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Assigning and referencing variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Assigning values to variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

CONTENTS

Referencing variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

References in Arena and SIMAN template modules . . . . . . . . . . . . . . . . . . . . . . 71

References in Arena Packaging template modules. . . . . . . . . . . . . . . . . . . . . . . . 72

Updating variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Updating variables for animation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Updating variables at a specific time—The Update action . . . . . . . . . . . . . . . . . 73

Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Conveyor variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Conveyor Link variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Machine variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Palletizer variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Storage variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Switch variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Tank variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Valve variable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

A • Equipment Reliability and Loss 85

Defining reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Using expected uptime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Using reliability over a time span. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Using individual failure streams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Questions and answers about reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Defining loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Event-based loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Production-based loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Questions and answers about loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

• • • • •

B • Placing Animation 99

The Animation dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

State or Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Blocked/Starved symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Product picture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Variables or statistics table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Questions and answers about animation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Index 103

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

Welcome to the Arena Packaging Template

What is the Arena Packaging template?

Arena Packaging is a simulation system developed by Rockwell Automation for the performance analysis of high-speed, high-volume manufacturing systems.

The initial design of the Packaging template was developed by Ouroumoff Diffusion (a consulting firm headquartered in Lyon, France) during a consulting engagement with Pechiney CRV to analyze canning lines. The core algorithms of the product involved vital input from the engineering staff at Pechiney. The final design of the Packaging template then involved significant input by staff at Rockwell Automation as well as Michigan State University’s School of Packaging.

Intended audience

The Arena Packaging template is designed for manufacturing or business process consultants and analysts and industrial or systems engineers. It is typically deployed as an enterprise business analysis and productivity tool.

We assume that you are familiar with the basic concepts and terms used in these types of systems. You are interested in improving business or manufacturing productivity and are responsible for evaluating and predicting the impact of proposed strategic and tactical changes to help improve performance. A familiarity with computers and the Microsoft Windows in simulation is also helpful.

operating system is assumed. A familiarity with the concepts and terms used

1 • Welcome

Where can I go for help?

Our commitment to your success starts with the suite of learning aids and assistance we provide for Arena. Whether you’re new to simulation or a seasoned veteran putting a new tool to use, you’ll quickly feel at home with Arena Packaging.

Reference the user’s guides

The documentation set includes this manual, Arena Packaging Template User’s Guide, which cover the product basics as well as the Arena User’s Guide, which covers the standard product modules and offers an easy, “click-by-click” tutorial, and the Variables Guide, a separate reference booklet providing complete descriptions of Arena variables found in the Arena product templates.

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

OCUMENT CONVENTIONS

Throughout the guides, a number of style conventions are used to help identify material. New terms and concepts may be emphasized by use of italics or bold; file menu paths are in bold with a (>) separating the entries (e.g., go to Help > Arena Help); text you are asked to type is shown in Courier Bold (e.g., in this field, type Work Week), and dialog box and window button names are shown in bold (e.g., click OK).

Explore our examples

Arena is accompanied by a number of sample models that illustrate many of the commonly used approaches for capturing the essence of manufacturing processes. Examples are provided for both job shop and flow shop environments. For a description of and list of Arena’s examples, go to Help > Arena Help. On the Contents tab, choose Model Building Basics, and then select Viewing Arena Example Models.

Get help

Online help is always at your fingertips! Arena incorporates the latest in help features, including What’s This? help that displays a brief description of fields in dialog boxes, context-sensitive help on menu and toolbar buttons, and a help button on each of Arena’s modules. Just refer to the Arena help table of contents and index for a list of all help topics.

Use the HSMARTs library

As you craft models of your own manufacturing processes, use our HSMARTs library to explore how to best use Arena. HSMARTs are a collection of small, self-contained models that illustrate different aspects of modeling in Arena Packaging. We recommend you go through these small files to see how concepts are implemented in actual models. For a list of categories and their related HSMARTS, go to Help > Arena Help. On the Contents tab, choose Template Help > Packaging > Arena Packaging Template > Learning Arena Packaging Template with the HSMART Files.

Access the Arena Symbol Factory

Arena animations can be enhanced using Arena Symbol Factory’s extensive library of over 4,000 symbols. These symbols can be used for entity, resource, transporter or global pictures; or as graphic symbols within a model window. You can copy these symbols directly to the Arena model window, add them to your own libraries (.plb files), or add them to any of the Arena picture library files.

1 • WELCOME TO THE ARENA PACKAGING TEMPLATE

Get phone support

Rockwell Automation’s support team of outstanding professionals provides top-notch technical support—monitoring and tracking your experience with our simulation products to pave the road to your success in understanding and improving your performance.

Rockwell Automation provides full support for the entire Arena family of products. Questions concerning installation, how modules work, the use of the model editor, and the use of the software are handled by technical support.

RENA TECHNICAL SUPPORT INCLUDES

 (for users on active maintenance) a technical support hotline and e-mail address

staffed by full-time, experienced professionals

 help with installation problems or questions related to the software’s requirements  troubleshooting  limited support regarding the interaction of Arena with other programs  support of the Arena Object Model, which is used in Microsoft Visual Basic for

Applications.

If you call the support line (1.440.646.3434), you should be at your computer and be prepared to give the following information:

• • • • •

1 • Welcome

 the product serial number  the product version number  the operating system you are using  the exact wording of any messages that appeared on your screen  a description of what happened and what you were doing when the problem occurred  a description of how you tried to solve the problem.

Get Web support

In addition to phone support, the Rockwell Automation Customer Support Center offers extensive online knowledgebases of tech notes and frequently asked questions for support of non-urgent issues. These databases are updated daily by our support specialists.

To receive regular e-mail messages with links to the latest tech notes, software updates, and firmware updates for the products that are of interest to you or to submit an online support request, go to support.rockwellautomation.com/supportrequests

And be sure to check the Arena User Zone section of our Web site at www.ArenaSimulation.com. The User Zone links to a peer-to-peer forum on Arena topics and has a link to a download page where you can check for possible software updates (patches). If you can’t find the answer you need, contact your local representative or Arena technical support.

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

Get training

Do you need training? Rockwell Automation offers a standard training course comprised of lecture and hands-on workshops designed to introduce you to the fundamental concepts of modeling with Arena.

We also offer customized training courses designed to meet your specific needs. These courses can be held in our offices or yours, and we can accommodate one person or twenty. You design the course that’s right for you! Simply contact our consulting services group to discuss how we can help you achieve success in your simulation efforts.

Get consulting services

Rockwell Automation provides expert consulting and turnkey implementation of the entire Arena product suite. Please call our offices for more information or e-mail ArenaInfo@ra.rockwell.com.

Contact us

We strive to help all of our customers become successful in their manufacturing improvement efforts. Toward this objective, we invite you to contact your local representative or Rockwell Automation at any time that we may be of service to you.

Support E-mail: Arena-Support@ra.rockwell.com

Corporate E-mail: Arena-Info@ra.rockwell.com

Support Phone: 1.440.646.3434

URL: www.ArenaSimulation.com

URL: www.rockwellautomation.com

General Concepts

Template overview

Arena Packaging is one of a family of application solution templates (ASTs) built on the Arena simulation system. It is designed specifically for performing accurate and efficient simulations of high-speed, high-volume manufacturing systems, where the processing rates take place at hundreds, even thousands, of entities per minute. The Packaging template enables users to build and run simulation models of high-speed processing lines quickly and easily, and to analyze the results that these models produce.

To use the Arena Packaging template, you attach the Packaging panel to the Arena development environment. The Packaging panel contains a collection of objects or modules. Each module defines the logic, data, animation, and/or statistics collection for a particular element in a model (e.g., machines, conveyors, operators).

The Packaging panel contains the following modules:

 A Machine module for modeling the physical components of a line where the actual

processing or conversion of units takes place.

 A Conveyor module for modeling the accumulating conveyors between machines

where units are transferred and buffered.

 Machine Link and Conveyor Link modules for linking machines and conveyors

directly together.

 Merge, Split, and Switch modules for modeling transfer points between conveyors

where product flow is split or combined (i.e., flow controls).

2 • General Concepts

 Operator, Operator Group, and Operator Schedule modules for modeling the

availability and organization of labor in the system.

 Palletizer and Storage modules for modeling the physical components of a line where

units are stored on or removed from pallets.

 Val ve and Tank modules for modeling fluid constraints of filling operations.

 Product and Production Plans modules for defining multiple products processed in a

system and their requirements.

 An Actions module for performing actions on a high-speed system (e.g., changing run

speeds of machines, adjusting valves, adding pallets to a storage) using discrete entities and logic.

 A Label module for labeling a particular portion of the model logic, whereby discrete

entities may be sent easily to the label from other locations in the model.

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

 A Simulate module for advanced model options (e.g., units of measure, statistic

collection switches).

Template framework and modeling methodology

Simulation studies are initiated because a decision maker or group of decision makers face a problem and need a solution. You should begin a simulation project by first collecting enough information and data to provide an adequate understanding of both the problem and the system to be studied. Once that step is complete, you are then ready to formulate models.

This section introduces a five-step modeling methodology for developing those simulation models in Arena Packaging. The steps of the methodology are illustrated in the following diagram.

Place & Connect

Equipment

Define Equipment

Behavior

Run

the

Model

View Automatic

Statistics

Experiment with

Complex Strategies

Step 1 • Place and connect equipment

First, flowchart on paper the step-by-step sequence of your line as raw goods are converted into finished product. For example, you might construct flowcharts of the machines, conveyors, palletizers, merges, splits, etc., in your line similar to the flowchart below.

(De)Palletizer

Processing Step

Conveyor

Tank

Inspection

2 • GENERAL CONCEPTS

Once you have flowcharted your process, duplicate that flowchart in Arena by graphically placing and connecting appropriate modules from the Packaging panel into an Arena model window. To select a module, you simply drag and drop an icon in the panel onto the workspace region where you want the module to be placed.

• • • • •

2 • General Concepts

HSMARTs are a collection of small models that illustrate modeling techniques. To learn combinations of Packaging modules that are appropriate for specific situations, it is useful to refer to the HSMART examples for Step 1.

 Step 1 • Place and Connect Equipment

 Processing

 HSMART01: Basic Processing Operation  HSMART02: Basic Processing Operation Using a Non-accumulating

Conveyor

 HSMART03: Assembly Operation  HSMART04: Packing Operation  HSMART05: Filling Operation  HSMART06: Inspection Operation  HSMART07: Linking Two Machines  HSMART08: Modeling a Supply Constraint for an Operation  HSMART09: Modeling a Machine as Two or More Separate Components

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

 Conveyors and Flow Control

 HSMART10: Accumulating Conveyors  HSMART11: Linking Two Accumulating Conveyors  HSMART12: Splitting Conveyor Flow by Count  HSMART13: Merging Conveyor Flow  HSMART14: Modeling a Surge Area or Table  HSMART15: Modeling a Secondary Line  HSMART16: Modeling Rework

 Tanks and Valves

 HSMART17: Simple Tank and Valve  HSMART18: Tank Farm

 Fronts (Sources) and Ends (Sinks) of Lines

 HSMART19: Using Palletizers to End a Line  HSMART20: Using Depalletizers to Begin a Line  HSMART21: Storage Example Using Palletizer/Depalletizer

Step 2 • Define equipment behavior

The next step is to specify the basic run parameters (e.g., run speeds), characteristics (e.g., reliability, loss), and dimensions (e.g., length, width, capacity) for each individual element in the line. For example, you might have collected and organized data about the equipment in your line as follows.

Processing Elements:

Element Name

Nom. Run Speed (units/min) Unit Loss

Reliability for a Week

Cleaner 500 .01% .97

Filler 650 .01% .99

Inspector 500 1.0% .98

Depalletizer 600 .01% .99

2 • GENERAL CONCEPTS

Conveyor Elements:

Conveyor Name

Nom. Ve lo ci t y (ft/min)

Length (ft)

Width (ft)

Unit Density

(units/ft

Unit

)

Loss

Reliability for a Week

Conveyor 1 100 200 3 10 .01% .995

Conveyor 2 90 100 2 10 .01% .995

Conveyor 3 90 100 2 10 .01% .995

Conveyor 4 100 150 2 10 .01% .995

Conveyor 5 95 50 3 10 .01% .995

In Arena Packaging, you define equipment parameters such as those listed above by double-clicking on modules and filling in the descriptive information in the module dialogs. For example, the main dialog box of the Conveyor module is shown below.

• • • • •

2 • General Concepts

1. Double-click on a module.

2. Fill in the basic run parameters.

3. Define loss and reliability, if possible.

4. Define basic animation and/or desired statistics for module.

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

All module dialogs are self-contained and designed with terminology for high-volume applications. The graphical “point-and-click” interface allows you to develop models of sophisticated systems without writing any code. You just answer the questions in the dialog boxes.

It is also easy to define basic animation and statistics for a module. Arena Packaging allows you to generate animation and statistics (e.g., production summary, costing, or state statistics) for modules automatically by clicking on the Animation and Statistics check boxes. Animation is placed upon exiting the dialog box. It can then be enhanced by using symbols from Arena’s picture libraries, Arena Symbol Factory, or from other graphics files such as Clip Art or AutoCAD

To learn more about defining basic behavior for the Arena Packaging template’s modules, refer to the module descriptions in Chapter 3 or the HSMART examples listed below.

 Step 2 • Define Equipment Behavior

 HSMART22: Defining Event-Based Loss  HSMART23: Defining Production-Based Loss  HSMART24: Modeling Reliability Using Expected Uptime  HSMART25: Modeling Reliability Using Reliability  HSMART26: Modeling Reliability Using Multiple Failure Streams

Step 3 • Run the model

At this stage, while you’re probably not ready to reach significant conclusions yet with your model, you do have a complete tool that you can now build on as your project progresses. It is a good idea to run this first model to verify that your basic logic is working correctly. Animation is a great tool for verifying model logic. You can also gain valuable insight on further detail to add and future strategies with which to experiment.

In Arena Packaging, to run a model, you must first place a Simulate module. This module defines which categories of Packaging module statistics will be collected as well as additional information such as units of measure. Before starting a simulation run, you will want to specify the simulation project parameters, such as the number of replications, the run length, and base time units. This is done by choosing the

File

Arena’s parameters. Then use the

menu. This opens the Run Setup dialog box. Enter the replication and project

command (

Run

menu) to start the simulation run.

Run > Setup

menu option from

3. Watch Arena Packaging track variables such as input and output rates, throughputs, states, conveyor accumulations, etc.

4. Place additional animation constructs (e.g., plots) to animate system variables.

2. Click the Go button on the Run toolbar to start the simulation.

1. Place the Simulate module and specify advanced options. Enter replication parameters in Arena’s Run > Setup menu.

• • • • •

2 • GENERAL CONCEPTS

2 • General Concepts

When a simulation run begins, Arena Packaging first processes the data and logic of the system as defined by the modules in the model. Special-purpose variables called Arena Packaging variables are automatically created for each module. These variables are dynamic quantities that describe the state of the system. Examples of Arena Packaging template variables include equipment states, run speeds, input and output rates, throughputs, conveyor accumulation levels, tank levels, etc. A more detailed discussion and list of the Arena Packaging template variables can be found in Chapter 5 of this user’s guide.

The model of the system is then input into a simulation engine specifically designed for simulating high-speed, high-volume flow. This engine utilizes two distinct technologies: SIMAN and an algorithmic kernel. The SIMAN portion of the engine manages discrete system events such as equipment failures, changeovers, and stops, as well as system resources such as operators. SIMAN is the core language of the Arena development environment and has been designed, developed, and successfully used since 1982 to conduct discrete-event simulations.

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

Packaging Edition

Model

Animation

SIMAN Engine

Algorithmic Engine

Statistics

The algorithmic portion of the Arena Packaging

template

’s engine manages the complex logic and statistics associated with high-speed, high-volume flow. Specifically designed for simulating high-speed processes, it allows Arena Packaging to simulate the performance of a high-volume system accurately and efficiently without using entities to represent individual units or batches of units.

As the simulation begins, unit flow starts at the front of lines and moves downstream. The simulation then automatically tracks, updates, and collects statistics on the Arena Packaging variables for the length of the simulation run. Numeric values, plots, and levels of Arena Packaging template variables can be viewed during the simulation using Arena’s animation constructs.

For more information, refer to the HSMART examples for Step 3.

 Step 3 • Run the Model

 HSMART28: Updating Arena Packaging Template Variables Automatically  HSMART29: Animating Arena Packaging Template Variables  HSMART31: Custom Pictures for Conveyor Animation

2 • GENERAL CONCEPTS

Step 4 • View automatic statistics

A primary objective of most simulation studies is to generate statistics about a system’s performance so that you can make the “right” decisions.

When an Arena Packaging template model (i.e., .doe file) is run, the simulation results are stored in a Microsoft Access database (.mdb) file by the same name (e.g., the simulation results for CandyLine.doe are stored in CandyLine.mdb).

Arena Packaging then utilizes Crystal Reports database. The Category Overview report displays information for system resources defined using the Packaging template modules, such as machines, palletizers, conveyors, storages, etc. It also displays information for system resources defined using the Arena template modules.

Each major section of the report pertains to a type of system resource (e.g., machines, conveyors, palletizers, storages). Within these sections, statistics are listed by module and grouped into categories. The categories are Description, Unit Summary, Activity Counter, Total Time, Cost, Performance, Usage, and Other.

to display the statistics stored in the report

• • • • •

2 • General Concepts

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

Module statistics are not generated by default. Instead, Arena Packaging allows you to choose which statistics you want to collect, write to the report database, and see in Crystal Reports. You specify that a module’s statistics are included in the reports by selecting the Statistics option in the module dialog box.

Check Statistics to report statistics for a module.

It is also easy to turn off statistics for all modules of a particular type (e.g., turn off statistics for all conveyors, or all machines). Within the Simulate module, there are check boxes for collecting statistics on Machines, Conveyors, Palletizers, Operators, Operator Groups, and Storages. When one of those prompts is checked, statistics will be reported for all modules of that type that have their individual module-level statistics check box selected. When one of those prompts is not checked, no modules of that type will have statistics reported, regardless of whether the individual module-level statistics are selected.

2 • GENERAL CONCEPTS

Turn on/off statistics for all modules of a particular type in the Simulate module.

• • • • •

2 • General Concepts

Refer to the HSMART examples for Step 4 for more information.

 Step 4 • View Automatic Statistics

 HSMART30: Generating Cost Statistics

Step 5 • Experiment with complex strategies

In the first four steps of the methodology, you built a base model of your system’s process; defined basic equipment behavior such as run speeds, loss, and reliability; and performed an initial simulation run.

Once that base model and study are completed, you can utilize additional features in Arena Packaging to experiment with more complex strategies and issues in your line. For discussion purposes, these strategies and feature sets have been divided into five main topics.

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

The five topics are introduced briefly below.

 Products, production plans, and changeovers

By default, the Arena Packaging template’s algorithms simulate the flow of a “generic” or single product type through the system. Optionally, you can model the flow of multiple product types and thus incorporate product-related issues such as changeovers, set-up times, product-dependent run speeds, etc.

The Product and Production Plans modules are available for defining multiple products processed in a system and their requirements. The Production and Changeovers option in Machine and Palletizer modules is where you assign changeover times or production plan data to those elements.

The Switch module can be used to split unit flow based on product type.

 Scheduled stops

Arena Packaging has options for defining scheduled downtimes or maintenance for machines, conveyors, and palletizers in the system. Scheduled stops are considered to be planned downtimes and thus are reported and tracked separately from the failures that occur due to equipment reliability. Unlike failures, scheduled stops are also not factored into utilization.

2 • GENERAL CONCEPTS

The Scheduled Stops option in Machine, Palletizer, and Conveyor modules is where you define scheduled downtimes for those elements.

 Dynamic line control

• • • • •

2 • General Concepts

Dynamic line control is often necessary for regulating or directing particular situations and events in a system. It can be a critical factor of a line’s design, impacting system utilization and performance.

The Arena Packaging template has options for placing controls and sensors on equipment such that the details of your functional control system can be incorporated into the model logic. A control is a function that monitors system status for one or more conditions. When a condition is true, one or more actions can be taken (e.g., change the speed factor of a machine). Sensors are devices that can be placed anywhere along the lengths of conveyors and tanks to monitor accumulation levels of units or fluids. When a sensor is either covered or uncovered, it is triggered and one or more actions can be taken.

The Controls option in Machine, Palletizer, and Conveyor modules is where you define controls for those elements. The Sensors option in Conveyor and Tank modules is where you define sensors for those elements.

The Actions module is also available for performing actions on the system using discrete entities and logic rather than controls or sensors.

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

Define controls for equipment in the Controls dialog box.

Place sensors on conveyors or tanks in the Sensors dialog box.

 Labor

The availability and training of personnel connected to a high-speed line can be critical to the line’s success. It can have a direct effect on issues such as utilization, machine maintenance, and output.

Arena Packaging provides the Operator, Operator Group, and Operator Schedule modules for modeling the availability and organization of labor in the system. You can assign operators to failure repairs, scheduled stops, and/or changeover activities in the equipment modules.

2 • GENERAL CONCEPTS

 Discrete entity creation and logic

The Arena Packaging template supports the modeling of discrete or “low-speed” logic in your system. There are several options for creating entities at discrete times during high-speed simulations, such as when a sensor or control is activated, or when a palletizer completes a pallet.

• • • • •

2 • General Concepts

The Actions module can also be used to perform actions on the high-speed system (e.g., changing run speeds of machines, opening or closing valves, adding pallets to a storage, etc.) using discrete entities and logic. Therefore, this module facilitates the integration of discrete logic built with constructs from the general-purpose Arena template.

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

Refer to the HSMART examples for Step 5 for illustrations.

 Step 5 • Experiment with Complex Strategies

 Operators

 HSMART32: Modeling Operators and Operator Groups  HSMART33: Modeling Operator Schedules

 Control Logic

 HSMART34: Adjusting Equipment Speeds Using Controls  HSMART35: Adjusting Equipment Speeds Using Conveyor Sensors  HSMART36: Adjusting Equipment Speeds Using the Actions Module  HSMART37: Writing Detailed Data to Files Using Controls  HSMART38: Writing Detailed Data to Files Using Sensors  HSMART39: Opening and Closing Valves Using Tank Sensors

 Products and Changeovers

 HSMART40: Using Products and Production Plans (Plan-based Equipment

Changeover)

 HSMART41: Modeling Equipment Changeovers (Product-based Equipment

Changeover)

 HSMART42: Defining Loss for Changeovers  HSMART43: Product Flow Controls Using the Switch Module  HSMART44: Adjusting Equipment Speeds Based on Product Type  HSMART45: Adjusting Container Volumes at a Filler Based on Product Type

 Scheduled Stops

 HSMART46: Modeling Scheduled Stops  HSMART47: Defining Loss for Scheduled Stops

 Integrating with the Arena Template

 HSMART48: Creating Discrete Entities  HSMART49: Referencing Arena Packaging Template Variables in Arena

Modules

 HSMART50: Modeling the Delivery of Raw Material to an Arena Packaging

Template Line

 HSMART51: Modeling Discrete Deliveries of Fluid to a Tank

The Packaging Panel

Panel modules

This chapter contains a detailed description of each of the Packaging panel modules, including prompt descriptions and remarks on module usage.

Actions module

ESCRIPTION

The Actions module is useful for modeling discrete entity logic that alters the status of the system, but which is not directly dependent upon equipment sensors or controls. When an entity enters this module, it performs the set of actions defined in the Actions repeat group. The Actions module is similar to the Actions dialog box found in the Controls and Sensors dialog boxes of Machines, Conveyors, and Palletizers. There is no time delay associated with this module.

EMARKS

The Actions dialog boxes found in the Controls and Sensors dialog boxes of Machines, Conveyors, and Palletizers allow you to alter system status when controls and/or sensors are activated. The Actions module provides similar functionality as those Actions dialog boxes in the equipment modules. It provides additional system control by allowing you to initiate actions using discrete entities.

The Arena Packaging Packaging modules. These special-purpose variables are automatically defined and assigned values over the course of a simulation by the Arena Packaging engine. They reference both dynamic and static information of a modeled system (e.g., equipment run speeds, input and output rates, conveyor accumulation levels, throughput quantities, storage and tank levels, etc.).

Use the Update HiSpeedSim Variables action to make sure that all packaging-related variables reflect the current state before using them. This is especially useful if you will be making decisions based on variable values, writing them, or using them in calculations. Note that the action is named “Update HiSpeedSim Variables” rather than “Update Packaging Variables” to maintain compatibility with models built in earlier versions of the software.

template

provides a set of Packaging variables for several of the

3 • Packaging Panel

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

Conveyor module

ESCRIPTION

This module defines the accumulating conveyor elements that move product through the system. Accumulating conveyors allow products to move on the conveyor even if products at the end of the conveyor are stopped. They are typically used as buffers to level out line fluctuations caused by machine stoppages, failures, differences in run speeds, etc. The following figure shows some basic terminology and attributes for accumulating conveyors.

Upstream

Module

Accumulating Conveyor

Velocity (F eet or Meters/ Min

Input Rate (Units/Min)

Traveling Units

Capacity (Units) = (Length) * (Width) * (Unit Density) Nominal Run Speed (Units/Min) = (Velocity) * (Width) * (Unit Density)

Length (Feet or Meters)

Width (Feet or Meters)

Output Rate

(Units/Min)

Accumulated Units

of Specified Density

Downstream

Module

Products enter the conveyor from the upstream module and travel along the conveyor’s length. If the Output Rate off of the conveyor is less than the Input Rate onto the conveyor, then products accumulate in front of the downstream module.

You can also specify optional characteristics for conveyors such as sensors, controls, loss, reliability, and scheduled stops.

EMARKS

Refer to the Sensors, Controls, Loss, Reliability, Scheduled Stops, Costs, and Animation dialog boxes for more information on these options.

Accumulating conveyors are always initially active with a speed factor of 1 at the beginning of a simulation run.

A conveyor’s run parameters may be specified in either metric or English units of measure, depending on what is selected for Units of Measure in the Simulate module. See the “Simulate module” on page 36 for further information.

Conveyor modules may not be linked directly to other Conveyor modules. The Conveyor Link module must be used to model adjoining conveyors.

3 • THE PACKAGING PANEL

To model non-accumulating conveyors, use a Machine module of type Conveyor Machine.

The Split and Merge modules may be used to model splitting product flow across multiple conveyors or merging the product flow of multiple conveyors onto a single conveyor.

The Switch module may be used to direct flow off a single inbound conveyor onto one of two possible outbound conveyors (i.e., flow goes “left” or “right”).

Conveyor Link (CLink) module

ESCRIPTION

The Conveyor Link module is used to connect two Conveyor modules directly.

EMARKS

You may open or close a conveyor link using the Actions dialog box to permit or prohibit material from passing between conveyors.

• • • • •

Label module

ESCRIPTION

The Label module may be used to identify a particular portion of the model logic, whereby discrete entities may be sent easily to the label from other locations in the model.

The name of a label module can be referenced in a “Send to Label” field (e.g., in a Sensor dialog box) to send discrete entities to this module. Upon arriving to the Label module, each entity will immediately proceed to the next module that is graphically connected to the Label module’s exit point.

Machine module

ESCRIPTION

The Machine module defines the processing elements of the system. Four general types of machines are available for modeling purposes. These types are Basic Machines, Assembly Machines, Filling Machines, and Conveyor Machines (standard or single-file). Each is detailed below.

3 • Packaging Panel

ARENA PACKAGING TEMPLATE USER’S GUIDE

• • • • •

 Basic Machines for standard processing. Examples include labeling, inspecting, and

packaging operations that do not involve multiple inbound lines. The nominal run speed of the machine is defined in terms of cycles/min and units/cycle. Basic machines do not have capacity; the process is instantaneous and capacity is 0.

Inbound Line Outbound Line

 Assembly Machines for merging input from two or more inbound lines (non-fluid).

Examples include capping and packaging operations. The nominal run speed of the machine is defined in terms of cycles/min and assemblies/cycle. In addition to the run speed of the assembly operation, output rates from the inbound lines are dependent on the units/assembly required from each line.

A single inbound line can also be defined for an assembly machine to model a batching operation (e.g., shrink-wrapping inbound units). Assembly machines do not have capacity; the process is instantaneous and capacity is 0.

Basic Machine

Nominal Run Speed

Cycles/Minute

Units/Cycle

Assembly Machine

Nominal Run Speed

Cycles/Minute

Inbound Line Outbound Line

Units/Assembly

Assemblies/Cycle

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