SIMULATION STUDY OF MULTILANE SELECTIVITY BANK IN AUTOMOTIVE INDUSTRY

This study deals with a very common problem encountered in many automotive industries. Automotive companies try to level the production of different models over time based on the demands for these models in the market. In order to achieve this, they introduce a leveled stream of cars in the beginning of the production line. But because of many reasons this leveled stream gets disturbed in its course. In order to re-level the stream, buffers are used between the shops. One such buffer is called as selectivity bank and it sits between paint shop and assembly shop. This buffer receives a disturbed sequence from the paint shop. The thesis tries to develop different algorithms that can be used to discharge cars from this buffer in order to achieve better leveling in the presence of rework and assembly constraints. These algorithms continuously try to steer the system from an undesirable state to a more desirable state by keeping track of current conditions in the plant. A simulation model is developed, which gives a platform for comparing relative performance of these logics under different conditions. The simulation tool is also helpful in designing optimum size of this buffer that will result in desired leveling performance

Design and operational control of an AGV system

In this paper we first deal with the design and operational control of Automated Guided Vehicle (AGV) systems, starting from the literature on these topics. Three main issues emerge: track layout, the number of AGVs required and operational transportation control. An hierarchical queueing network approach to determine the number of AGVs is decribed. Also basic concepts are presented for the transportation control of both a job-shop and a flow-shop. Next we report on the results of a case study, in which track layout and transportation control are the main issues. Finally we suggest some topics for further research

Komponenttien luokittelu ja parhaat käytännöt tuotantosimulaation mallinnuksessa

Production simulation software plays a major role in validation, optimization and illustration of production systems. Operation of production simulation is generally based on components and their interaction. Components typically represent factory floor devices, but in addition, there can be components to provide visualization, statistics, control or other input to simulation. The demand for having high-quality, easy-to-use and compatible components emphasizes the importance of component modelling. The objectives of this thesis were to develop component classes based on industrial devices, to standardize component modelling solutions and best practices in component modelling. Other objectives were to identify and analyse future prospects of production simulation. This focuses on the concept of digital twin, which could be described as reflective real-time simulation model from the physical system. In addition, focus is also set on formal modelling languages. The outcome of this thesis presents component classes and best practices in component modelling. In component classification, the focus was set to development of generic components, which can be controlled with signal-based logic. This enables components from the software to be externally controlled. In addition, automatic model creation tool wizard, is implemented to instantly generate components based on the defined component classes. Best practices were based on the selected modelling fields that are most relevant for general use. In the development of best practices, interviewing method was utilized to receive input from simulation experts.Tuotantosimulaatio on tärkeässä osassa tuotantojärjestelmien validoinnissa, optimoinnissa ja visualisoinnissa. Tuotantosimulaation toiminta perustuu yleisesti komponentteihin ja niiden väliseen vuorovaikutukseen. Komponentit esittävät tyypillisesti tehtaasta löytyviä laitteita ja esineitä, mutta komponentteja voidaan käyttää myös visualisointiin, statistiikan keräämiseen, järjestelmän ohjaukseen tai muuhun tarpeeseen simuloinnissa. Tämän diplomityön tavoitteita oli kehittää komponenttiluokkia teollisuudesta valittujen laitteiden perusteella, mikä mahdollistaa mallinnusratkaisujen standardoinnin. Sen lisäksi tavoitteena oli kehittää parhaat käytännöt komponenttimallinnukseen. Muita tavoitteita oli tunnistaa ja analysoida tulevaisuuden näkymiä tuotantosimulaatiolle. Tämä keskittyi pääosin digitaaliseen kaksoseen, jota voidaan kuvata reaaliaikaisesti peilautuvaksi simulaatiomalliksi todellisesta järjestelmästä. Tämän lisäksi työssä keskityttiin formaaleihin mallinnuskieliin. Diplomityön lopputulos esittää kehitetyt komponenttiluokat ja parhaat käytännöt komponenttimallinnuksessa. Komponenttien luokittelussa keskityttiin kehittämään geneerisiä komponentteja, joita voidaan ohjata signaalipohjaisilla komennoilla. Tämä mahdollistaa komponentin ohjaamisen myös simulointiohjelman ulkopuolelta. Tämän lisäksi automaattista komponenttien luomistyökalua käytettiin luokiteltujen komponenttien luomisessa. Parhaat käytännöt komponenttimallinnuksessa pohjautuivat mallinnuksen oleellisimpiin osa-alueisiin tavanomaisissa mallinnustilanteissa. Parhaiden käytäntöjen kehityksessä haastateltiin simulointiammattilaisia, joiden mielipiteistä muodostettiin perusta käytäntöjen kehitykselle

Komponenttien luokittelu ja parhaat käytännöt tuotantosimulaation mallinnuksessa

Production simulation software plays a major role in validation, optimization and illustration of production systems. Operation of production simulation is generally based on components and their interaction. Components typically represent factory floor devices, but in addition, there can be components to provide visualization, statistics, control or other input to simulation. The demand for having high-quality, easy-to-use and compatible components emphasizes the importance of component modelling. The objectives of this thesis were to develop component classes based on industrial devices, to standardize component modelling solutions and best practices in component modelling. Other objectives were to identify and analyse future prospects of production simulation. This focuses on the concept of digital twin, which could be described as reflective real-time simulation model from the physical system. In addition, focus is also set on formal modelling languages. The outcome of this thesis presents component classes and best practices in component modelling. In component classification, the focus was set to development of generic components, which can be controlled with signal-based logic. This enables components from the software to be externally controlled. In addition, automatic model creation tool wizard, is implemented to instantly generate components based on the defined component classes. Best practices were based on the selected modelling fields that are most relevant for general use. In the development of best practices, interviewing method was utilized to receive input from simulation experts.Tuotantosimulaatio on tärkeässä osassa tuotantojärjestelmien validoinnissa, optimoinnissa ja visualisoinnissa. Tuotantosimulaation toiminta perustuu yleisesti komponentteihin ja niiden väliseen vuorovaikutukseen. Komponentit esittävät tyypillisesti tehtaasta löytyviä laitteita ja esineitä, mutta komponentteja voidaan käyttää myös visualisointiin, statistiikan keräämiseen, järjestelmän ohjaukseen tai muuhun tarpeeseen simuloinnissa. Tämän diplomityön tavoitteita oli kehittää komponenttiluokkia teollisuudesta valittujen laitteiden perusteella, mikä mahdollistaa mallinnusratkaisujen standardoinnin. Sen lisäksi tavoitteena oli kehittää parhaat käytännöt komponenttimallinnukseen. Muita tavoitteita oli tunnistaa ja analysoida tulevaisuuden näkymiä tuotantosimulaatiolle. Tämä keskittyi pääosin digitaaliseen kaksoseen, jota voidaan kuvata reaaliaikaisesti peilautuvaksi simulaatiomalliksi todellisesta järjestelmästä. Tämän lisäksi työssä keskityttiin formaaleihin mallinnuskieliin. Diplomityön lopputulos esittää kehitetyt komponenttiluokat ja parhaat käytännöt komponenttimallinnuksessa. Komponenttien luokittelussa keskityttiin kehittämään geneerisiä komponentteja, joita voidaan ohjata signaalipohjaisilla komennoilla. Tämä mahdollistaa komponentin ohjaamisen myös simulointiohjelman ulkopuolelta. Tämän lisäksi automaattista komponenttien luomistyökalua käytettiin luokiteltujen komponenttien luomisessa. Parhaat käytännöt komponenttimallinnuksessa pohjautuivat mallinnuksen oleellisimpiin osa-alueisiin tavanomaisissa mallinnustilanteissa. Parhaiden käytäntöjen kehityksessä haastateltiin simulointiammattilaisia, joiden mielipiteistä muodostettiin perusta käytäntöjen kehitykselle

The Seedling Sanctuary: Automated Cold Frame for Gardner Elementary

The purpose of this report is to provide the details of the Seedling Sanctuary, a mechanical engineering senior design project. The project in question is an automated cold frame designed specifically for Gardner Academy, a local elementary school in San Jose. A cold frame is a miniature greenhouse that opens like a chest and is made from clear plastic. Automated ventilation and watering systems create a microclimate within this greenhouse structure to create the ideal growing conditions for seeds. The main purposes of the cold frame are to lengthen the growing season, be maintenance free, and enhance garden education. From testing, the project goals were verified to have been achieved through several performance metrics. First, the system’s ability to lengthen the growing season is dependent on germinating seedlings that can be planted earlier in the season. The automated system maintained the seedlings at the proper soil moisture levels to grow. The system also implemented passive temperature control systems to maintain the plants in ideal conditions. With the ventilation and thermal mass, the system is able to be cooler at the hottest times of day and warmer at night than unprotected plants. The system has also successfully automated the care of the seedlings, achieving our goal of being maintenance free. Finally, the enhancement of garden education was incorporated through community engagement with the design and building of the cold frame, as well as the Bluetooth application which will be used in the school curriculum

A Simulation-Based Analysis of the Impact of In-Sourcing a Major Process Element on the Coast Guard HH-601 Depot Maintenance Process

Leaders at the United States Coast Guard\u27s Aircraft Repair and Service Center (ARSC) in Elizabeth City, North Carolina recently formalized their planning and analysis functions by adding a dedicated branch to their command structure. The Planning and Analysis Branch intends to apply computer modeling and simulation to study the impact of process changes to the various Programmed Depot Maintenance (PDM) lines. This research considers the applicability of this type of modeling and simulation, using ARENA to study the current HH-6OJ PDM process. The contribution of this research is a methodology specific to ARSC needs, an analysis of methodology based on a discrete event simulation model of PDM lines, and a specific case study demonstrating the methodologies. The response variable of interest is average PDM process time as a function of either in-sourcing or out-sourcing labor for a major process step. The research includes development and evaluation of a macro-level process model using ARENA 5.0

A hybrid CFGTSA based approach for scheduling problem: a case study of an automobile industry

In the global competitive world swift, reliable and cost effective production subject to uncertain situations, through an appropriate management of the available resources, has turned out to be the necessity for surviving in the market. This inspired the development of the more efficient and robust methods to counteract the existing complexities prevailing in the market. The present paper proposes a hybrid CFGTSA algorithm inheriting the salient features of GA, TS, SA, and chaotic theory to solve the complex scheduling problems commonly faced by most of the manufacturing industries. The proposed CFGTSA algorithm has been tested on a scheduling problem of an automobile industry, and its efficacy has been shown by comparing the results with GA, SA, TS, GTS, and hybrid TSA algorithms

SimLack: simulation-based optimization and scheduling of generic powder coating lines

https://www.asim2018.de/Powder coating and paint-spray lines are often complex production plants because of many dynamical dependencies, limited buffer space and sequence dependent changeover times. We have developed a generic simulation and optimization platform that enables the engineers to design more performant and energy efficient facilities and the production planners to increase productivity through simulation-based optimization. The simulation environment builds on a generic modelling library that captures all variations of such facilities. Execuable models are generated automatically from annotated CAD layouts. As a result, the system smoothly integrates with the engineering process. Once the facility is in use, the fully specified virtual plant is used for simulation-based scheduling, employing a combination of a generic priority-based heuristic and a variant of simulated annealing. We discuss how these two aspects of the system render it an important innovation for the painting line industry and show first results from the scheduling system