Integration possibilities of software tools used in design of manufacturing systems

INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS 42 INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS P. Vik Technická uni e si a Libe ci Fakul a s ojní, Ka ed a ý obních sys émů S uden ská 2, 461 17 Libe ec 1, Czech Republic [email p o ec ed] L. Dias, G. Pe ei a Uni e sidade do Minho Depa amen o de P odução e Sis emas Campus de Gual a , 4710 – 057, B aga, Po ugal [email p o ec ed], [email p o ec ed] Abs ac Nowadays he e is a g ea p essu e on p oduc ion sys ems design o be done in a sho ime and mo e e ec i ely. Mo eo e , i mus suppo he sys ems’ lexibili y, modula i y and obus ness. Fo hese pu poses se e al so wa e ools ha e been used– mainly o p ojec analysis, design and alida ion. Ne e heless, hese ools ha e been used wi h a low in eg a ion le el, including he absence o da a cohe ence. This pape deals wi h p oduc ion sys ems’ design, ac ually conce ning he in eg a ion o pa icula so wa e ools in o a uni ied sys em. This wo k iden i ies di e en ools, desc ibing hei unc ions and p inciples o in eg a ion. I also add esses he way his in eg a ion enabled he au oma ic gene a ion o simula ion p og ams. Fu he mo e, i inally discusses ways o making his in eg a ion con ibu ing o he au oma ic gene a ion o di e en pa e ns o p ojec layou s. 1. In oduc ion The p oduc ion sys em’s design is a p ocess o managing echnical and o ganiza ion a ian s in o de o con igu e sys em elemen s wi h ega d o he op imal usage o all sou ces (i.e. ma e ial, ene gy, a eas), p oduc i e and nonp oduc i e acili ies (p oduc ion machines, handling and checking acili ies) and wo ke s. These a ian s deal wi h spa ial layou and also wi h dynamic ime changes. Gene ally i is possible o di ide he used so wa e ools in o ou g oups:  Da abases – analysis o s a es, da a s o age, da a mining  CAD sys ems – g aphic designs, e i ica ion o spa ial layou a ian s  Disc e e compu e simula ion sys ems - e i ica ion o a ian s wi h ime changes  Visual sys ems – 2D, 3D anima ion o i ual eali y o be e unde s anding o sugges ed p inciples INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS 43 On he basis o expe iences om se e al p ojec s and analysis o he cu en s a e , he ollowing disad an ages and limi a ions in using so wa e ools ha e been ound:  Absence o da a- low be ween p og ams  Exis ence o se e al independen da a-sou ces  Absence o eedbacks which a e necessa y o egis e ing o changes sugges ed du ing he design p ocess  Managing o p ojec a ian s Manual p ojec da a-connec ion causes slowdowns in he p ocess o designing, duplica ing wo k o e en being a sou ce o mis akes. We know abou he exis ence o sys ems called “Digi al ac o ies” ha in ol e hemen ioned ools in one common solu ion. The pa icula ools a e connec ed by in o ma ion lows. The big disad an ages a e a huge p ice o hese so wa e packages, ocused mainly on mass p oduc ion (au omo i e indus y) in la ge-sized ac o ies, and also hei excessi e complica ion. The p oo o complica ion could be he exis ence o only wo sys ems o digi al ac o ies - Tecnoma ix and Delmia. The e is s ill no any simila solu ion o small and middle-sized ac o ies wi h a e y easy con olling and wi h unc ions ocused on hese kinds o ac o ies and p oduc ion p oblems. Fig. 1: Compa ing o he cu en and new app oaches o so wa e in e connec ion Fo hese easons a compac sys em has been elabo a ed on. I is o connec pa icula sys ems oge he , and o simpli y and s eamline designing o p oduc ion sys ems. One o he main aims is o co e he wide ange o p oblems and asks sol ed du ing designing – such as:  Dimensioning o s o ages and bu e s, es ablishmen o s o age limi a ion  Op imal usage o sou ces  Bo leneck analysis INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS 44  Design o handling and supplying sys em (AGV, milk- un sys em, con eyo , manual handling e c.)  P oblema ics o long- e m designing (changes in p oduc mix and olume), change o cos s o o he pa ame e s  Sugges ion o de ailed layou and eal cons ain s (cu en acili ies, walls, pilla s, e gonomics, e c.)  Re-layou p oblema ic (mo e o en han g een- ield designing) In he igu e 1 he e is a compa ison be ween he mos equen ly used p inciple o oday (on he le side) and a new app oach wi h he ela i e in e connec ion (on he igh side). 2. Desc ibing o he new app oach On he basis o possibili ies and gi en equi emen s a sys em was sugges ed. The e a e h ee p og ams in eg a ed, conc e ely MS Access (da abase), Wi ness Simula ion ool (disc e e simula ion ool) and Au oCAD (CAD sys em o d awing o layou s). These p og ams we e chosen o hei usage expansion in his a ea o designing. In he diag am 2 he e is showed he o e all in eg a ion wi h in o ma ion lows and snapsho s om pa icula p og ams. Fig 2: O e all in eg a ion In p u da a MS Access Au oCAD Va ian s Op imal disposi ion o acili ies sol ed by ma e ial low Disposi ion o acili ies in luenced by eal cons ain s Analyses (Dynamic op imiza ion) Lib a y o CAD objec s Wi ness VR 3D anima ion and VR Real p ocesses a en e p ise SAP, Excel, MySQL da abase Im p lemen a ion Wi ness INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS 45 2.1. In e connec ion Fo in eg a ion and con olling o p og ams, Visual Basic o Applica ion (VBA) was chosen like a p og amming language. The main easons a e:  i s in ol emen in almos all p oduc s o Mic oso , Au oCAD and many o he s (one common language simpli ies he in eg a ion)  easy language syn axes and using (especially in e ac i e de elopmen en e ainmen and isual ools)  easy es ablishing connec ion o da abases (e.g. wi h help o OLE DB Mic oso Je )  suppo o OLE Au oma ion (Objec Linking and Embedding) se es o con olling o o he p og ams and using o hei objec s  DDE (Dynamic Da a Exchange) o da a exchange be ween applica ions. 2.2. The de ailed desc ip ion o pa icula ools unc ion Da abase sys em A common da abase (MS Access) se es as he sou ce and deposi o p ojec da a (i.e. also o inpu s and ou pu s da a om simula ion and CAD) and i builds a basic in e connec ion elemen . This da abase includes VBA mac os o au oma ic gene a ion simula ion o elemen s and hei p ope ies wi h minimum use in e en ion. In he igu e 3 he ela ional da abase wi h i s s uc u e and VBA mac os is displayed. The needed da a o simula ion model a e:  The de ini ion o ope a ion (inpu s and ou pu s pa s, size ba ches, assembly in o ma ion, p ocess imes e c.,  P oduc ion sequences o pa s (i.e. hei ou ing hough p oduc ion acili ies),  Kinds o c a es and anspo ed quan i y,  P oduc i e and nonp oduc i e acili ies (machines and handling equipmen ) and hei p ope ies (se up imes, anspo speeds),  Scheduling o p oduc ion,  Wo ke s and hei p ope ies. The da abase con ains also VBA mac os o au oma ic loading o CAD objec s in o Au oCAD, also wi h a minimum in e en ion. The e is also some undamen al analysis (mainly PQ analysis). An emphasis is placed on easy da a en y and change – such as a p oduc ion plan o olumes (in au omo i e indus y i is conce ned mainly wi h he p oduc aceli s, expansion o new p oduc ion launches). I is possible o make some expe imen s and es sys em wi h hese da a and sea ch consequences in o he designed sys em o o make a es o unce ain y in luences and de e mina e he obus ness and lexibili y o he sys em. INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS 46 Fig. 3: Snapsho s om he ela ional da abase and VBA mac os Simula ion sys em The gene a ed simula ion model consis s o he elemen s men ioned be o e and some o he elemen s such as lis s (ope a ion, acili ies, pa s e c.), module o p ojec da abase es ablishmen and o he modules in ol ing SQL que ies o loading da a. These modules eed simula ion elemen s by da a, and also au oma ically con igu e and upda e hem. I is possible o con igu e model on basis o he ac ual da a om he da abase (model’s ini ializa ion a he beginning o he simula ion un). So he use s change only da a in he da abase in use - iendly o ms o manage he simula ion model. A e gene a ing and con igu a ion o he model, a phase o simula ion uns and expe imen a ion ollows. The ob ained da a a e eco ded back o he da abase. Ou pu da a a e mainly s ochas ic ma e ial lows, a e age and maximal occupa ion o bu e s ( his in o ma ion is used in he design o layou in CAD), usages o sou ces (machines, ope a o s and handling sys em), bo leneck places, h oughpu o sys em e c. In he igu e 4 he e is a show o gene a ed simula ion model in un. I shows he ac ual occupa ion o bu e s (queues), usages o acili ies (pie g aphs), and some o he in o ma ion (lis o acili ies, pa s, and ope a ion). This model is jus o a demons a i e show, i is a simula ion o unpacking pa s om anspo c a es and hei assembly. Fig. 4: Show o simula ion model INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS 47 CAD sys em I is mainly used o displaying acili ies in layou and hei sys em se lemen , i.e. inding he bes loca ion o each acili y in layou . Fo ha he e a e VBA mac os enabling o ind he bes (ideal) posi ions acco ding o a iangula algo i hm based on he alues o ma e ial lows. The de ailed layou is in luenced by se e al ac o s and limi a ions (cu en p oduc ion acili ies o building cons ain s). G aphic objec s (d awing o acili ies o simpli ying compensa ion) a e au oma ically pu om lib a ies in o he layou . The e a e displayed ma e ial lows – de e minis ic o s ochas ic (ob ained by simula ion, and in ol ing s ochas ic in luences). The gene a ed lows a e de ined like a di ec wo-poin line, wi hou espec o he eal de o ma ion caused by eal cons ain s (e.g. building). Fo displaying eal ma e ial lows, i is necessa y o change hese lines in o poly-lines (a line de ined by se e al poin s), and o modi y hei shapes wi h espec o he eal cons ain s. The de ini ion poin s o poly-lines a e eco ded in o he da abase. In he igu e 5 he e is a simple show o layou wi h ma e ial lows (ideal and eal) o pa icula pa s. Fo compa ing o p ojec a ian s based on ma e ial lows, i is possible o coun a sum o ma e ial lows ( eal leng h mul iplied by i s wid h), and o e alua e hem by hese numbe s. Flows could ha e a ious uni s ( anspo ed weigh a e some ime o equency o anspo mo emen ). I is also possible o display lows acco ding o a ious pa ame e s – lows o speci ic pa s, lows o one kind o anspo o lows o one kind o c a e (e.g. palle s). The e a e used da a, such as bu e sizes i.e. necessa y a eas o s o ages. I could help o design shel es and o he logis ic elemen s. Ou pu da a eco ded in o he p ojec da abase a e coo dina es o acili ies, eal ma e ial lows (coo dina es o de ini ion poin s) and also changes aised du ing he layou design – e.g. changes o palle s numbe ob ained by simula ion (o iginal ask) - i is necessa y o educe i because o lack o space ( indings du ing layou design). In his case, he e a ises a ques ion how his limi a ion in luences he designed p oduc ion sys em. Fig. 5: Snapsho s o layou in Au oCAD wi h ma e ial lows (ideal and eal) INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS 48 O he p ope ies o in eg a ion: One o he ad an ages esul ing om his app oach is a possibili y o wo ways o designing manu ac u ing sys ems, namely:  Design o layou , hen i s e i ica ion by compu e simula ion  Design a simula ion model, hen design a layou  (O possibili y o combina ion wo k in bo h sys ems al e na ely) Gene ally, o minimiza ion o handling cos s i is be e o use he way s a ing in CAD, and hen o con inue by a compu e simula ion. In he case ha he main aims a e p ocesses and hei imp o ing ( h oughpu , bo leneck places, ba ch sizes, usage o handling sys em e c.), i is be e o s a by a compu e simula ion and o con inue wi h he layou design in he CAD sys em. 3. Conclusion The desc ibed solu ion in eg a es so wa e ools used in p oduc ion sys ems’ design in o a unique sys em whe e all ools a e connec ed by a da abase. The gene al aim o his wo k was o imp o e he p ocess o p oduc ion sys ems’ design, emo ing edundan ac i i ies and eplacing “manual” wo k by some au oma ic design phases. I in eg a es s a ic and dynamic layou op imiza ion, inc easing he ac o y compe i i eness while helping he design o lexible and obus p oduc ion sys ems. Ano he bene i om his wo k is he in elligible illus a ion, e.g. ende ing o ma e ial lows, 2D anima ion o p ocesses wi hin he simula ion ool o he possibili y o c ea e i ual eali y en e ainmen wi h Wi ness Vi ual Reali y Toolbox. The mos p oblema ic issues o his app oach a e da a-uni ica ion be ween companies and p ojec da abases, in ol ing eal cons ain s in o layou de ini ions and some es ic ion as a as au oma ic gene a ion o simula ion models is conce ned (models a e gene a ed jus o sol ing speci ic and common asks). Fu u e wo k will be ocused on using his in eg a ion o sol ing eal p oduc ion p oblems, imp o ing and adding some unc ions – such as sol ing ou ing p oblems, inding he bes ou es o anspo ehicles (e.g. milk- un sys ems) o c ea ing a ool o designing s o age sys ems. INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS 49 Li e a u e [1] ALEISA E., LIN L.: Fo e ec i e acili ies planning: layou op imiza ion hen simula ion, o ice e sa? , In P oceedings o he Win e Simula ion Con e ence, 2005, s. 1381-1385 [2] BENJAAFAR, S., HERAGU, S. S., IRANI S.: Nex gene a ion Fac o y layou s: Resea ch challenges and ecen p og ess, In e ace 2002. [3] FRANCIS R.L., McGINNIS L.F., WHITE J.A.: Facili y Layou and Loca ion: An Analy ical App oach, 2nd edi ion, P en ice-Hall, Englewood Cli s, NJ, USA, 1992. 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Ap il 2008, ISBN 978–80-7318-663-0 [11] WU Y., APPLETON E.: The op imiza ion o block layou and aisle s uc u e by a gene ic algo i hm, Compu e s and Indus ial Enginee ing, 41, no4, 371–387, 2002 [12] ZELINKA A., KRÁL M.: P ojek o ání ý obních sys émů, P aha: ČVUT, 1995, ISBN 80–01- 013302-2 [13] Bu eš M., Ul ych Z.,Leede E.:Digi ální ab ika – so wa o é p oduk y p o oblas dii ální ab iky, In Mopp – Modelo ání a op imalizace podniko ý p ocesů, Plzeň 8.-9. 2. 2007 ISBN 978–80–7043–535-9 [14] Vila inho P., Guima aes R.: A Facili y Layou Design Suppo Sys em, In es igacao Ope acional 23, 2003, p. 145–161, ISSN 0874–5161 Do učeno edakci: 10. 4. 2009 Recenzo áno: 16. 6. 2009 Sch áleno k publiko ání: 23. 6. 2009 INTEGRATION POSSIBILITIES OF SOFTWARE TOOLS USED IN DESIGN OF MANUFACTURING SYSTEMS 50 INTEGRATIONSMÖGLICHKEITEN VON SOFTWARE-WERKZEUGEN FÜR DEN ENTWURF VON FERTIGUNGSSYSTEMEN Gegenwä ig bes eh g oße D uck bei de schnellen und übe legenen E zeugung on P ojek en on P oduk ionssys emen. Ve schiedene So wa e-We kzeuge we den ü diese Zwecke haup sächlich zu Analyse, Planung und Kon olle on P ojek en genu z . Diese Hil smi el we den gewöhnlich gesonde ode mi minimalem ela i em Da enzusammenhal genu z . Diese Au sa z konzen ie sich allgemein au die Thema ik des En wu s on P oduk ionssys emen, konk e au die In eg a ion einzelne So wa e-We kzeuge in ein gemeinsames Sys em. Besch ieben we den mannig al ige Hil smi el und ih e Funk ionen, In eg a ionsp inzipien sowie ande e Möglichkei en, die on diese In eg a ion ausgehen, zum Beispiel au oma isches E zeugen lau ähige Simula ionsmodelle. Die In eg a ion lie e auch die E zeugung on S ellungen ü Anlagen in de P ojek skizze. MOŻLIWOŚCI INTEGRACJI NARZĘDZI SOFTWAROWYCH STOSOWANYCH W PROJEKTOWANIU SYSTEMÓW PRODUKCYJNYCH Obecnie duży nacisk kładziony jes na szybkie i wysokiej jakości p ojek owanie sys emów p odukcji. W ym celu s osowane są óżne na zędzia so wa owe służące do ich analizy, p ojek owania i we y ikacji. Jednak w większości p zypadków na zędzia e s osowane są samodzielnie i p zy niskim poziomie in eg acji danych. Manualne łączenie danych p ojek owych wydłuża p oces p ojek owania, powoduje powielanie czynności i s anowi ź ódło pows awania błędów. Tema yka a ykułu związana jes z p ojek owaniem sys emów p odukcyjnych, a w szczególności do yczy połączenia poszczególnych na zędzi so wa owych w jeden sys em. W p acy opisano poszczególne na zędzia i ich unkcje, zasady ich łączenia o az wynikające z niego możliwości. Należy do nich p zykładowo gene owanie modeli symulacyjnych z bazy danych, gene owanie pozycji u ządzenia w ozmieszczeniu (layou ) p odukcji o az ich op y malnego umiejscowienia wobec siebie w zależności od p zepływów ma e iałowych. MOŽNOSTI PROPOJENÍ SYSTÉMŮ POUŽÍVANÝCH V PROJEKTOVÁNÍ VÝROBNÍCH SYSTÉMŮ V současné době je kladen elký lak na ychlou a k ali ní o bu ná hů p ojek ů ý obních sys émů. P o y o účely se použí á ůzných so wa o ých pomůcek p o analýzu, ná h a o ěření ěch o p ojek ů. Ty o pomůcky se ale ě šinou použí ají samos a ně nebo s minimální zájemnou da o ou p o ázanos í. Ruční spojo ání p ojek o ých da ede ke zpomalení p ocesu na ho ání, duplikační činnos i, případně je i zd ojem chyb. Článek se obecně zabý á éma ikou na ho ání ý obních p ojek ů, konk é ně in eg ací jedno li ých so wa o ých pomůcek do jednoho sys ému. Jsou zde popsány jedno li é nás oje a jejich unkce, p incipy in eg ace a další možnos i plynoucí z oho o p opojení jako např. gene o ání simulačních modelů z da abáze, gene o ání pozic zařízení do ý obního layou u a jejich op imálního zájemného uspořádání podle ma e iálo ých oků.