3DEXPERIENCE DELMIA Factory Simulation
Digital Manufacturing Virtual Factory e-Kanban JIT
User will now be able to simulate Just-in-time (JIT) manufacturing and track production. With e-Kanban, we represent a pull system, which means that production is based on customer demand rather than the standard push practice of producing goods and pushing them to the market.
By using e-Kanban function user can validate the production schedule virtually by simulating the entire system in FFS, ensure that the customer demand will be met and then use this production schedule in actual production. If the customer demand is not met, user can modify the production schedule and re-run the simulation, unless he gets the desired production output.
The below Image shows a typical e-Kanban layout.
We have various steps to follow in order to setup a e-Kanban system, which will be explained in a series of videos.
The first step is to import the levelling board into Factory Simulation using the import command. A levelling board is a schedule to withdraw parts from Warehouse, prepared based on customer demand\\forecast. We can validate this levelling board by importing and simulating the levelled board in Factory Simulation Application.
To facilitate users, warnings and alerts registered for missing parts during withdrawal. Please note that each withdrawal defined in Levelling board will have a start and end time.
During simulation warning is displayed if the part is not available at the start time of withdrawal. A warning is also displayed if the part is not withdrawn by the end time of withdrawal.
We also register these alerts in Kanban XML and Resources specific HTML.
The next step is to produce\\manufacture Parts Just-in-time (JIT) using e-Kanban. Here we are demonstrating a simple case of Producing parts as soon the finished Parts are withdrawn from warehouse by a customer.
The steps to define a simple production loop using e-Kanban are
Step 1) Define production card for each Finished Part
Step 2) Set all the attributes of Production card like "Linked Activities" and "From Resource"
Step 3) Define Card dispatch logic on ware house storage
The below video demonstrates all the above steps in detail.
We also cater to Batch Production using Kanban. To support this, we allow creation of "Batch Building Box". Batch building box is used to accumulate a set of production cards before it can be sent to production. It is basically a box with slots to hold the production cards. Each slot will have an associated Part reference which will ensure only the production card of that part reference is held in this slot.
The benefit of using a Batch Building Box is that it allows you to easily organize your production by batch. It also provides a visual representation of inventory consumption and highlights emerging problems.
The above video demonstrates the steps to define Batch building Box, and also shows the behavior during simulation.
We also have additional options w.r.t managing Part references in the Batch Building Box.
1) Merging References: We can merge multi part references when creating a Batch Building Box, with this, we will create a single slot which can hold any of the Merged "Part references" Production card.
Launcher: We can also define a "Launcher" for each production Line to hold\\queue the production cards that will be produced by the production line. So during Production, looking into the Launcher of all the Productions lines, we can estimate the load on each of the production line and choose the correct Line for production.
Also Based on Launcher content different warning\\alerts are raised during simulation, which can be used to optimize the production further:
1) Alert when number of cards exceed the maximum number of launcher
2) Alert when card duration exceeds the maximum number of launcher
2) Alert when number of cards goes below the minimum number of Launcher
2) Alert when card duration goes below the minimum number of Launcher
These alerts are registered in Kanban output XML and Resources specific HTML.
Below video demonstrates all of the above points.
Next up we look into the different Logic options on Batch Building Box to shuffle the Production cards accumulated and to dispatch the cards to the right production line.
Sequencing Logic: During simulation, once the slots of Batch Building Box are full for a part reference, all the production cards will be sent for production. These production cards can be sequenced before sending for production using the Sequencing logic.
- Fifo: Cards are dispatched in the order of accumulation in the Batch Building Box
- Group by Reference: Cards are grouped by part references and then dispatched for production
Queuing Logic: During simulation, the selection of Production Line for production can be done using the Queuing logic.
- Least Queue Content: With this option, the Batch Building Box will dispatch the production card to the resource with least Production cards in Queue.
- Least Time in Queue to start production: With this option, the Batch Building Box will dispatch the production card to the resource with least duration to start the production.
