David P. Sly

Simulation data exchange (SDX) implementation and use

Facility layouts of existing or proposed production systems often form the basis of a dynamic simulation study to prove the design concept and to determine if the required throughput (jobs per hour) can be achieved. Traditionally, this requires the simulation engineer to duplicate the CAD drawing in the simulation environment before being able to model it. With sophisticated manufacturing systems such as conveyor networks, material handling systems, automotive plants and powertrain facilities, this job can be very difficult, time consuming and error prone. An application and interface was needed to provide an automated integration of the layout and simulation technologies for manufacturing. This paper discusses SDX (Simulation Data Exchange) and its implementation.

A systematic approach to factory layout and design with FactoryPLAN, FactoryOPT, and FactoryFLOW

Since the finished quality of every layout project depends on a successful combination of products, processes and tools, it is essential to select each of these carefully. A good project will always begin with an analysis of the production volumes of the products with common process sequences and tool requirements in order to create manufacturing families. For each of these families you can select the best manufacturing practices that need to be used and re-engineer the processes and tooling to fit the desired throughput and inventory requirements. Only after you know the desired manufacturing practices to be used for each product family is it appropriate to begin developing layouts around a systematic flow and non-flow evaluation process. This systematic approach to layout design combines with Factory PLAN/OPT and FLOW software tools working in AutoCAD to create the most efficient factory designs in record time.

Before dynamic simulation: systematic layout design from scratch

Excellent production design and planning depends on accurate simulation of a high quality layout. A good layout project will always begin With an analysis of the production volumes of the products with common process sequences and tool requirements in order to create manufacturing families. For each of these families you can select the best manufacturing practices that need to be used and re-engineer the processes and tooling to fit the desired throughput and inventory requirements. Once you know the manufacturing practices to be used for each family, you can begin developing layouts through a systematic flow and non-flow evaluation process. Static flow and relationship analysis software tools FactoryFLOW and FactoryPLAN/OPT lend themselves to a systematic process leading to effective layout design in record time.

Plant design for efficiency using AutoCAD and FactoryFLOW

Designing industrial facilities in AutoCAD is very different from designing the office and laboratory environments typically discussed at AEC-oriented shows and seminars. In factories the cost of moving equipment and automated material handling systems is significant, making their initial placement critical. In addition, factories are designed for the optimal flow of materials, which requires a significant quantitative review and can be very time consuming and difficult to present. This paper discusses the systematic approach to the design of industrial facilities and how this approach can be greatly simplified with the use of such tools as AutoCAD with FactoryFLOW.

Material flow analysis of automotive assembly plants using FactoryFlow

When designing a new assembly plant or retrofitting an existing plant, it is critical to determine where all the materials will be received, stored and used. Variable width and color material flow diagrams created by FactoryFLOW are especially useful for presenting this information. FactoryFLOW automatically finds the shortest route from origin to destination along an aisle network for all materials/parts involved. Once routes are determined. FactoryFLOW draws the routes, outputs travel distances, times, and costs to report files and scales the thickness of flow lines according to the flow intensity of each part. The input data required by FactoryFLOW is the kind of basic from-to information typically already available in a database or spreadsheet. Among other output reports, FactoryFLOW generates detailed reports on manpower requirements by equipment type. FactoryFLOWs from-to chart shows the flow intensities and distances between ail from-to locations analyzed. The distance intensity chart plots each parts move intensity against its travel distance on an X-Y graph. With the help of powerful personal computer systems and user friendly graphical environments, material flow studies of over 10,000 parts within facilities of over 5 million square feet can be accomplished by a novice user in under an hour.

Object-oriented factory layout in AutoCAD

Factory layout and design is traditionally a 2D process involving the creation of 2D CAD drawings for construction and space planning purposes. Moving from 2D drawings to a 3D model of industrial facilities has been a significant challenge, due to the extensive requirements of equipment and manpower. A new object-oriented approach (VisFactory) allows users to create 2D/3D models of their factories with less time and effort than it would normally take to create the current 2D drawings. I discuss the process and benefits of how 3D models of factories can be created effortlessly in AutoCAD and then communicated to simulation packages.

Increasing the power and value of manufacturing simulation via collaboration with other analytical tools (panel session): a panel discussion

The objective of this panel session is to describe how a when manufacturing simulation practitioners should add the value of projects by interfacing simulation analys with other analyses such as optimization, layout/mater flow, scheduling, robotic, and queuing. The panelists w discuss how each analytical tool adds value to the discr event manufacturing simulation, when in the life cycle of project it should be brought in, what are the ma advantages and disadvantages of bringing in the additio tools, managing and selling collaborative analyses proje and training requirements for collaborative analyses.

Research To Application Success Stories: Manufacturing

Successful uses of simulation proliferate throughout manufacturing and the papers presented here illustrate the range of uses suitable for simulation models. The forum format allows participants to exchange success stories of using simulation in a variety of applications.

An enhanced microcomputer program for CNC mathematics with graphics

Abstract Solutions to CNC programming for part and cutter path description require the application of basic trigonometry and geometry. This task can be very tedious and take considerable time. The M.A.T.H. PACK is a micro-computer based program that solves and graphically displays mathematics associated with CNC machining. The program contains numerous enhancements over the original version to permit easy storage and manipulation of data. The original program was presented at the 7th Annual Conference on Computers and Industrial Engineering in March of 1985.

Research to application success stories (panel): manufacturing

Successful uses of simulation proliferate throughout manufacturing and the papers presented here illustrate the range of uses suitable for simulation models. The forum format allows participants to exchange success stories of using simulation in a variety of applications.