Simulation for inbound and outbound logistics

Project

Buffer dimmensioning, conveyor adjustments, portal operations.

Solution

Simulation model created with Simio. Daily operational data loaded into the model. All machines adjusted to the current orders.

Features

Animated portals restacking boxes on pallets, a logistics of full and empty pallets, use of experiments for buffers dimmensioning.

Simulation of a complete production site

Project

Optimization of machine work time for current production orders.

Solution

Simulation model created with Simio. Daily operational data loaded into the model. Compares scenarios in experiments and datailed dashboards.

Features

Parallel comparison of various scenarios with the use of interactive dashboards, i.e. order delays.

Simulation of a commissioning center

Project

Identify bottlenecks in a commissioning center.

Solution

Simulation model created with Simio for planning daily operations in the center. The number of employees and forklifts can be determined in advance to fit the current picking load.

Features

Animation objects from SketchUp, sorting of picking list, using experiments to calculate the number of resources needed.

Dynamic dimensioning of a warehouse system

Project

Construction verification and dimensioning of a warehouse.

Solution

Simulation model created with Simio. Flexible customization of all the objects in the layout. Testing the final warehouse before its construction begins.

Features

Playing with warehouse size depending on the pallet input quantities, viewing utilization/stock in a number of charts.

Simulation of a ASRS

Project

Dimensioning with the number of rows and levels, testing the warehouse loading or unloading strategy.

Solution

Simulation model created with Simio. Daily stocks and planning orders of arrivals and deliveries are an input to the model.

Features

Flexible ASRS framework allows to build the warehouse with the required number of shelves and rows. Accurate movements in the aisle. Using a dynamic rule to find the best shelf for a pallet.

Simulation of AGVs in manufakturing lines

Project

Determining the optimal usage and number of AGVs to supply assembly lines for an investment decision.

Solution

Simulation model created with Simio. The number of AGVs and its speed is analyzed using Simio Experiments.

Features

Animation objects from SketchUp, automatic assignment of an AGV to a task. AGVs deliver a full box then pick an empty box and then drive to the loading area.

In- and Output movements of ASRS with AGVs

Project

Determining the number, speed and movements of AGVs for a scalable warehouse with ASRS.

Solution

Simulation model created with Simio. Using the SimulateFirst framework to model the warehouse with ASRS. Flexible AGV network allow for exact control of the AGVs.

Features

Driving an AGV in and out of the loading/unloading bay. Repacking stations retrieve and send pallets back to the warehouse.

Controlling the material supply with AGV

Project

Simulation of AGV movements to ensure continuous material supply for all the work areas.

Solution

Simulation model created with Visual Components. AGVs with CAD and logic resemble closely the Omron mobile robots.

Features

Logic of the AGVs by Omron integrated, recording of routes per AGV, allocation of containers from utility station to the work areas.

Daily planning of a complete batch production

Project

Data-driven simulation of machining stations for automotive small parts. Alternative occupancy of facilities, assembly lines, production with pallets and buffers.

Solution

3D-simulation model with Simio. Analyses of buffers, congestion, waiting time, utilization of resources.

Features

Initialization from current data, alternative work cells for a task, using flows to represent parts, interactive analyses.

Cycle time analyses and robot simulation

Project

Simulation of an automated production line with multiple product variants with different processing time in order to realize cycle time optimization and increase utilization.

Solution

A robot simulation model in Simio. Quick analyses reveal possible delays in the cycle due to improper parts sequence.

Features

Robot simulation in Simio, turn tables, cycle time for each work cell, data based sequence of stations.

Production planning, lot size of 1

Project

Planning and simulation of a production system with the lot size of 1. Another user application maintains daily production data. Simio imports these and sends the results back to the app.

Solution

Development of a user application in .NET and Access, storing the data in the central SQL Server.

Features

Simio binds to SQL Server, Simio works together with a user app, production with lot size of one.

Consulting with a simulation model

Project

Convince decision makers of the quality of the proposed automation system. The flexible model allows for an interactive customization even during a meeting.

Solution

A fast model with experiments that simulates, visualizes and analyses the production flow within a few seconds.

Features

Quick and interactive analyses of KPIs, use of experiments.

Virtual commissioning of a controller

Project

Early validation of a control system under load. The simulation model receives requests and replies from the controller, then sends back the status messages after every production step.

Solution

A model built in Simio plus an AddOn in .NET allows for continuous communication with the Controller over TCP/IP.

Features

Simio runs in real time; the AddOn receives messages from the controller and passes them on the running model.

Simulation of a complete plant

Project

A flexible modeling solution for a complete plant with orders, resources, employees, warehouses, means of transport (also AGV or AMHS).

Solution

Developed yet prior to Simio in Enterprise Dynamics to create a digital twin of a production and logistics system.

Features

Data based model design in ED, highly parametrized modeling with good animation.

Incerase pick rate and throughput

Project

Simulation model with delta robots picking biscuits. Coordination of the picking task between the robots.

Solution

Simulation model created with Visual Components. With dynamic algorithms it was possible to achieve a higher pick rate and reduce the number of needed robots.

Features

Delta robots pass messages between each other to let know which biscuit is going to be picked by which robot.

Robot simulation with SCARA, Delta and 6-arm

Project

Simulate the way different robot types work with each other and coordinate them.

Solution

Simulation model created with Visual Components. The functions of the robots become clearly visible.

Features

More than 1000 predefined robots such as Kuka, ABB, Stäubli, Fanuc, Motoman, Kawassaki can be integrated; Exported as 3D PDF.

Optimized operation plans verified with simulation

Project

We combine mathematical process optimization with 3D simulation. The process flow, which is calculated almost optimally but with little room for deviations, is tested dynamically for different disturbances in a simulation model. This allows to answer valid "what if?" questions and update the optimization algorithms and production plans before they are passed to the real systems.

The picture shows an automatic system with handling robots that move products one after another. It was important to maintain short time tolerances at each station on one side and to increase the number of parts in processing on another side.

Traffic planing in Freiburg

Project

Some specific junctions in Freiburg causes long waiting time. The cycle time of the traffic lights and alternative routes for redirection need to be analyzed.

Solution

A model of the traffic network with relevant traffic. Numbers of vehicles and cycle times added.

Features

Control of cycle times possible, traffic lights visible, Dashboards for valuation integrated, effects on waiting time fast and at any time available.

Stop operation in the railway network

Project

Determine the cycle time of trains that an optimal utilization occurs depending on demand. Scenarios with higher number of trains, shorter cycle time and safe stop operation.

Solution

Rail network created according to layout. Trains equipped with seats and standing places. Number of trains and distances to operate with are flexible.

Features

Turn arounds, no collision, keeping distance between trains at any time.

Coordination of AGVs in manufacturing line

Project

Simulate movements of AGVs guideways. no double order reservation, AGVs deliver and pick boxes in time.

Solution

Simulation model created with Simio. The number of AGVs and its speed is analyzed using Simio Experiments. No lack of boxes, no waste of time or movements.

Features

Animation objects from SketchUp, automatic assignment of an AGV to a task, AGVs deliver a full box then pick an empty box and then drive to the loading area, waiting time included.

Simulation of work cells with multiple robots

Project

Detecting errors, deadlocks and collisions in the automated system as well as inefficient processes at an early stage and testing improvements

Solution

Robot simulation with Visual Components, incl offline programming of multiple robots, collision testing.

Features

Offline programming of the robots, checking the robot sequence for collisions, tact time reduction.

Balancing the production flow

Project

A digital twin of the assembly area at a car manufacturer for a continuous improvement of the production flow and increase in throughput as early as possible to save costs.

Solution

Digital twin in Simio, with data imports for product requirements, routing, WIP and production plan, analyzes of KPIs.

Features

Relational data structure, update of the model at the start, output results shown as Gantt and dashboards.

Complete assembly with ASRS and robotics

Project

Simulation of numerous machining stations, ASRS; employees, buffers and robots to illustrate the process steps and the project environment.

Solution

3D simulation model created with Visual Components. Analysis of danger zones, congestion and collisions.

Features

Detailed simulation of multiple robot brands in one system (see also robot simulation).