Supply Chain RE Design

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The future in improving design and operations
with simulation technology
Rienk Bijlsma Rockwell Automation
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Contents

• About Rockwell Automation
• Traditional Use of Simulation Technology
• Recent Software Developments
• Live Examples
• Arena Software

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Rockwell Automation

• Technology Conglomerate since 1902
• NYSE ROK
• 4.500 B Revenue
• Leading Automation Provider
• Hardware PLC, DCS, Networks, Drives
• Software PLC Code, MES, HMI, Simulation

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Rockwell Automation

• Rockwell Brand Names
• Allen Bradley
• Reliance Electric
• Dodge
• Rockwell Software
• Arena, RS BizWare, RS View, RS Teststand

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Seamless Integration
Manufacturing BusinessWare
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Simulation Traditional Use

• Validation/Design of New Systems
• Improving existing systems
• Application Areas
• Supply Chain, Business Processes, Manufacturing,
  Transportation/Logistics

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Simulation Traditional Use

• Simulation Pros
• What If Analysis
• Variability System Complexity
• Communication Possibilities, animation
• Flexibility
• Simulation Cons
• Data Requirements
• One Time Effort
• No Clear Answers, requires interpretation
• Time Consuming, even with experts

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Future Directions

• Design Automation
• Business Driver Reduce Time to Market
• Testing of PLC Code
• Generating PLC Code from Design Objects
• Share Data across design applications
• Operational Decision Support
• Business Driver Optimize Manufacturing
• Interact with HMI ERP User Interfaces
• Real Live Data Access
• Replacing custom code applications

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Recent Developments
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Recent Developments
Actual Data
Process Times Start, Stop Failures Order Details
Resources Operators Login, Quality, Comments
Product View
Facility View
Activity Areas Site, Area, Line, Work
Cell Equipment Resources / Sets Labor Resources /
Sets Shift Patterns
Manufacturing Orders Materials (Make/Buy) Producti
on Lots Segment Data Phase Times Resource
Actions Material Actions Constraints
Factory Talk (SP95)
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Arena Developments

• Arena Factory Analyzer (Link with MES)
• Real Time (OPC Client)
• Emulation
• PLC Testing
• ADO (Data Accessibility)
• Building/Reports/Documenting

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Typical Project Architecture
Interface
Database
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Live Examples

• Packaging Line
• Warehouse
• Supply Chain

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What have customers done with Arena?
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What have customers done with Arena?
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Some References
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Chemical Industry

• Answers Results
• Number of Railcars necessary for SC Saved 2.5
  M in Capital Expenditure
• Best Rubber Production Strategy Improve
  Throughput by 35
• Combining Cargo on Chemical Vessels Saving 12
  of Logistical Transportation costs, 2M
  Annually
• SKU resizing locations in existing SC Saving
  1.6M in Supply Chain Cost
• Other Customers

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Apparel Industry

• Answers Results
• Direct Order Strategy Planning/Production Lead
  Time Reduction 55
• Different Collaboration Strategies Finished
  Goods Inventory Reduction of 80
• Retailers Lead Time Reduction 52
• Order Lead Time Decrease 49
• Other Customers

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Food Beverage Industry

• Answers Results
• Direct Order Strategy 20 Inventory Carrying
  Cost Savings
• Lead Time Reduction of 30
• Different Replenishment Strategy Min-Max Best
  Alternative
• Other Customers

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CPG Industry

• Answers Results
• 27 alternative scenarios analyzed Throughput
  Increase of 70
• Make-to-Order Policy Cost Decrease of 70.2M
• WIP Dropped 66
• Cycle Time Improved by 84
• Potential Customer

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Electronics Industry

• Answers Results
• 5 Different Designs Evaluated 39 Inventory
  Reduction
• Covers Repair Strategy, Inventory Strategy 16
  Reduction Transport Costs
• Logistics structure, etc. Direct Ship with ASN
  best option
• Overall Savings of 50 M
• Other Customers