WSC 2001 Final Abstracts

Panel Session: The Future of Simulation
Jerry Banks (Professor Emeritus, Georgia Institute of Technology), Farhad Azadivar (University of Massachusetts Dartmouth), David Ferrin (Accenture), John W. Fowler (Arizona State University), Daniel W. Halpin (Purdue University), Averill M. Law (Averill M. Law & Associates), Mani Manivannan (Vector SCM) and William S. Murphy (Defense Information Systems Agency)

Abstract:
Panelists representing seven areas of application give their views on the future of simulation. There is some consistency, but not a lot. Optimization, the web, training, supply chain management, graphics, and real time simulation received two mentions each. However, depending on how the counting is performed, there are another six areas with a single mention.

Using Emulation to Reduce Commissioning Costs on a High Speed Bottling Line
Geoff Mueller (E2M, Inc.)

Abstract:
E²M/Polytron builds high speed filling and packaging systems for Fortune 100 companies. In the last year we have developed a process to improve the quality of these systems that uses the new emulation technology in Brooks Automation’s AutoMod simulation tool. The method, called PolySim, enables us to functionally test control logic on a simulated 3D model of a system prior to startup. Our first application was on a new line for Gerber Baby Food. The project had been done without the use of the new technology and there were some on-going controls problems with the high speed label application area a month after startup. Using our PolySim method enabled us to isolate and fix these controls problems in two weeks without interfering with production. With the problem fixed, Gerber saw an 11% increase in line efficiency.

Emulation: Debug It in the Lab – Not on the Floor
Cindy Schiess (Design Systems, Inc.)

Abstract:
Emulation is a very powerful tool for testing and debugging control code/logic in an office environment rather than on the plant floor. Through the use of emulation, the actual control logic is connected to a simulation model that imitates the actual machine/conveyance hardware. The emulation software also has the ability to mimic the operator stations. Logic problems can be found and corrected in the office with field time reduced to only verifying physical, site specific, installation issues. Time, money, aggravation, lost production, employees (from burnout), and potentially marriages can be saved through the use of emulation.

Future of Simulation Optimization
Justin Boesel (The MITRE Corporation), Royce O. Bowden, Jr. (Mississippi State University), Fred Glover (University of Colorado), James P. Kelly (OptTek Systems, Inc) and Erik Westwig (Palisade Corporation)

Abstract:
The combination of simulation and optimization, essentially unheard of in practice a decade ago, is much more accessible today, thanks in large part to the development of commercial optimization software designed for use with existing simulation packages. Despite this growth, untapped applications abound. This panel, which includes developers of simulation-optimization packages, will discuss this untapped potential, barriers to broader applicability, and approaches for overcoming these barriers. This paper starts off with a brief introduction by the panel's organizer, followed by position statements from the panelists.

Integrating Capacity Simulation into Process Planning
Vaughan Hetem (DaimlerChrysler)

Abstract:
Process planning in the automotive industry is referred to as advance manufacturing engineering, because it is done in advance of production — before the facilities are created. When developing these processes, simulation is typically done by service groups, not the process planner, resulting in communication errors and unnecessary iterations. Software applications are now becoming available that not only simulate the production throughput objective of process planning, but other planning considerations such as process capability, material flow, ergonomics, and interferences. The impact of these simulation tools is put into perspective when considering the powertrain manufacturing engineering environment: process development time in years, cycle time accuracy in seconds, cost of the facility in hundreds of millions, and expected duration of the process in years. That is, a single expensive opportunity to implement a long term investment, with verification done by “simulation” experts not intimately involved with the process. The future of simulation for me seems obvious!

Simulation Data Exchange (SDX) Implementation and Use
Dave Sly and Shreekanth Moorthy (UGS)

Abstract:
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.

The Expanding Role of Simulation in Future Manufacturing
Charles McLean and Swee Leong (National Institute of Standards and Technology)

Abstract:
Simulation technology holds tremendous promise for reducing costs, improving quality, and shortening the time-to- market for manufactured goods. Unfortunately, this technology still remains largely underutilized by industry today. This paper suggests benefits to industry resulting from the widespread, pervasive implementation of manufacturing simulation technology. Potential simulation impact areas are closely intertwined with strategic manufacturing. Yet, a number of factors currently inhibit the deployment of simulation technology in industry today. The development of new simulation interface standards could help increase the deployment of simulation technology. Interface standards could improve the accessibility of this technology by helping to reduce the expenses associated with acquisition and deployment, minimize model development time and costs, and provide new types of simulation functionality that are not available today.

Seamless Integration of Layout and Simulation
Karsten Mecklenburg (General Motors)

Abstract:
This document talks about the usage of Simulation Data Exchange (SDX) (Moorthy 1999) in order to enable a consistent digital model of automotive factories. The scope of the digital model is to plan and analyze the factory by using different software packages. Thus the model doesn’t exist in only one application. Therefore the consistency in terms of geometry and process data needs to be guaranteed with external support. Whereas any redundant information storage and rework of existing data has to be avoided. SDX is a promising approach to accomplish this interface management.