TABLE OF CONTENTS

I.   INTRODUCTION

II.   INSTALLATION REQUIREMENTS  AND PROCEDURES

      A.   Arena 10.0 (CPR 7) and FactoryTalk Activation Client Tool

      B.   Flexible Manufacturing Simulation System

III.   INPUT INFORMATION

      A.   Number of Days to Simulate

      B.   Number of Machining Centers

      C.   Number of Load Stations

      D.   Number of Pallets

      E.   Number of Operators

      F.   Machining Center Type

      G.   Parts Definition

      H.   Cycle Times

        I.   Load/Unload Times

        J.   Pallet Assignment

      K.   Vehicle Speed and Transfer Times

      L.   Operator Break Schedule

      M.   Line Layout

      N.   Operator Assignment

     O.   Load Station Assignment

      P.   Machining Center Assignment

      Q.   Saving Scenario Data

      R.   Validating the Scenario Data

      S.   Running the Simulation Model

IV.   ANALYZING SIMULATION RESULTS

        A.   Machining Center Utilization

        B.   Load Station Utilization

        C.   Pallet Utilization

        D.   Pallet Stand Utilization

        E.   Operator Utilization

        F.   Rail-Guided-Vehicle Utilization  

        G.   Parts Completed

V.    TECHNICAL SUPPORT

WARNING!!
The Flexible Manufacturing Simulation System must be installed
in the directories specified in the setup program.   It cannot run
under any other directory.

The following is a User's Manual for the Flexible Manufacturing Simulation System (FMSS).   The primary purpose of FMSS is to determine the system requirements based on the customer's production demand and operating parameters.   The user can vary the following operating parameters to conduct "What-If" analysis:

•  The number of machining centers required - Flexible Manufacturing Simulation System has the capability to handle up to eight (8) different machining centers

•  The number of load stations required - Flexible Manufacturing Simulation System has the capability to handle up to eight (8) different load stations

•  The number of pallets in the system - Flexible Manufacturing Simulation System has the capability to handle up to one hundred (100) different pallets

•  The number of operators - Flexible Manufacturing Simulation System has the capability to handle up to eight (8) operators

•  The machining center type - Flexible Manufacturing Simulation System has the capability to handle up to ten (10) different machining center types

•  The number of part types to be processed - Flexible Manufacturing Simulation System has the capability to handle up to five hundred (500) different part numbers

•  Assign a specific part type to a specific pallet or group of pallets by operation

•  Assign a specific part type to a specific machining center or group of machining centers by operation

•  Assign a specific part type to a specific load/unload station or group of load/unload stations by operation

•  The number of parts to simulate and the respective daily production quantity - Flexible Manufacturing Simulation System has the capability to process up to five hundred unique part numbers

•  The number of parts per pallet by part type and operation

•  The vehicle speed

•  The vehicle load/unload times

•  The cycle time by part number and operation - this parameter indicates the amount of time necessary to process a single part by operation

•  The load/unload time by part number and operation

•  The number of days to simulate

The user can run Flexible Manufacturing Simulation System with the specified parameters and view the results.   All time based output units in this system are in minutes.   The application will generate an output report in graphical format for the following:

•  Machining center utilization

•  Load station utilization

•  Pallet utilization

•  Pallet stand utilization

•  Operator utilization

•  Rail-Guided-Vehicle (RGV) utilization

•  Parts completed

Flexible Manufacturing Simulation System can be used as often as is needed, based on the business/operating environment.   This will allow the analyst to evaluate future business and operating scenarios to optimize the utilization and throughput of the Palletech System.  

IMPORTANT NOTICE
Flexible Manufacturing Simulation System is a very powerful analysis tool.  
However, it is important to note,that the analyst must have a thorough understanding
of both the processes being analyzed and statistics .

INSTALLATION REQUIREMENTS AND PROCEDURES

The minimum requirements/recommendations for running the Arena software are as follows:

•  Arena software, version 10.0

•  Microsoft Windows 98, Windows ME, NT 4.0 (Service Pack 6a or later), Windows Server 2003, or Windows XP (Service Pack 1 or later).

•  Internet Explorer 5.01. (This does not need to be your active browser, but some of the IE components are necessary for Arena to work)

•  Adobe Acrobat Reader 5.0 or later to view documentation.

•  Hard drive with 75-250 MB free disk space (depending on the operating system and options installed)

•  64 MB of RAM (recommended 128 MB of RAM or higher, depending on the operating system)

•  Minimum Pentium processor 300Mhz or higher
Note: The running and animation of Arena and some large simulation models can be calculation-intensive, so a faster processor with additional memory may result in significantly improved performance.   In addition, a large monitor and a screen resolution of at least 1024 x 768 is recommended for improved animation viewing

•  Under Microsoft Windows NT, 2000, Server 2003, and XP, you must have Administrator privileges to install the software.   To run Arena, you should be a Standard user (member of the Power Users Group) or better

Included with this manual is a CD containing the required files to run FMSS.   Load the CD into the CD drive.   If it does not start, browse to the "autorun.exe" file on the CD and double-click the file to start the installation.   An autorun program should start and the following screen will appear.   The installation program will examine your system and determine if there are any required system updates that need to be installed and installs them.

After the updates are completed, the following screen will appear.   Select the "Install Arena 10.0 (CPR 7)" option.

The InstallShield Wizard setup dialog will then appear.   This wizard will guide you through the installation.

Click Next to begin the installation process.

The Arena License Agreement dialog box will appear.   You must accept the agreement to continue the installation.  

Click Yes to accept, or click No to terminate the installation.

The "Setup Type" screen will appear.   Select "Standard Feature Set Installation to Default Location".   Then select the "Next" option.

The "Ready to Install the Program" screen will appear.   Select "Install".

The "Installing Arena 10.0 (CPR 7)" screen will appear.   Select "Next" when prompted.

The "InstallShield Wizard Complete" screen will appear.   Make sure you "Uncheck" both boxes and select the "Finish" button.

The following screen will appear and select the "Next" button.

The Customer Information dialog box will appear.   You must enter the user name, organization and then select the "Next" button..

The "Setup Type" screen will appear.   Select the "Complete" option and then select the "Next" button.

The "Ready to Install the Program" screen will appear.   Select the "Install" button.

The "Installing FactoryTalk Activation Client" screen will appear.

The "InstallShield Wizard Completed" screen will appear.   Select the "Finish" button.

The "FactoryTalk Activation Tool v.1.9.8.18" screen will appear.

The "Welcome to the Rockwell Software Activation Wizard" screen will appear.   Select the "Next" button.

The "Enter Product Information" screen will appear.   Enter the serial number and product key included with your software and then select the "Next" button.

The "Activation Status" screen will appear.   Select the "Next" button to complete the activation process.

The Activation Wizard screen will appear.   Select "I need product activation for this computer" and then select "Next".

The following screen will appear.   Select "DISK_SERIAL_NUM=b4ab7a56" and then select "Next".

The following screen will appear to confirm the information.   Select "Next".   Your computer will then connect to Rockwell's activation center and then prompt you with the activation was successful.

Click Finish to restart your computer.

After the Arena installation is completed and you have restarted your computer, open the Windows Explorer and locate the application on the CD named FMSS.   Double-click on this file.   This will begin the installation of the Flexible Manufacturing Simulation System.

Click Next to begin the installation process.

The License Agreement dialog box will appear.   You must accept the agreement to continue the installation.

Click Agree to accept, or click Disagree to terminate the installation.

The Destination Directory dialog box will appear.   This indicates where the Flexible Manufacturing Simulation System will be installed.

Click Next to continue.  
The Start Menu dialog box will appear.   This specifies the folder in the Start Menu where you want to place the FMSS program.

Click Next to continue.

The Review dialog box will appear.   It shows the directory where the files are being copied to and where the shortcuts will be placed.   Be sure the checkboxes are checked to add shortcuts to the desktop and start menu.

Click Next to continue.   The Progress dialog box will appear.   This monitors the progress of the installation.   It will automatically go to the next setup screen after all files have been copied.

Another program will automatically open and begin to copy and install files.

Click the OK button to begin the next part of the installation.

The Destination Directory dialog box will appear.   This indicates where the Flexible Manufacturing Simulation System will be installed.

After all files have been copied to the directory click the OK button.

The final installation dialog box will appear.   To begin the Flexible Manufacturing Simulation System, click the checkbox next to FMSS and then click Finished.  

Select the "Finished" button.   Then go to Windows Explorer and open the "c:\fmss" directory.   Double-Click on the "CREATE_FSCOMMAND_DIR" batch file.   A DOS window will appear and disappear quickly.   If you want to run the FMSS program with animation, go to Windows Explorer and open the "c:\fmss" directory.   Double-Click on the   "ANIMATION_ON" batch file.   A DOS window will appear and disappear quickly.   If you want to run the FMSS program without animation, go to Windows Explorer and open the "c:\fmss" directory.   Double-Click on the "ANIMATION_OFF" batch file.   A DOS window will appear and disappear quickly.

INPUT INFORMATION

This screen is the main menu, which will allow the user to access all of the input and output screens. The user has two choices for the operating parameters to be used in the simulation model.   The first would be to open an existing file that contains the required operating.   The second choice is to create a new scenario with new data.    

To use the first option, go to the "File" pull-down menu and select the "Open" command.   The following screen located below will appear.   Locate the file to be used in the analysis and open it.   The data in this file can be modified and saved as required.

The second option is to create a new scenario with new data.   The following is a description to change any of the operating parameters as required.   To begin, any variables on the main screen must be changed first, and they must be changed in the order given.   Select the number of days you want to simulate.   Simply place the cursor in the box and type in the number.

Next, select the number of machining centers you want to include in the model.   Click your cursor on the down arrow and your choices will appear (FMSS is capable of accommodating up to eight (8) machining centers).

Next, select the number of load stations you want to include in the model.   Click your cursor on the down arrow and your choices will appear (FMSS is capable of accommodating up to eight (8) load stations).

Next, select the number of pallets you want to include in the model. Click your cursor on the down arrow and your choices will appear (FMSS is capable of accommodating up to one hundred (100) pallets).

Next, select the number of operators you want to include in the model.   Click your cursor on the down arrow and your choices will appear (FMSS is capable of accommodating up to eight (8) operators).

Next, select the machining center type.   This specifies the type of machining center used in the Palletech System.   Click your cursor on the down arrow and your choices will appear (FMSS is capable of accommodating up to ten (10) different machining center types).

Once the "Main Screen Variables" have been determined, the user is now ready to enter part specific information.   Select the "pull-down" menu labeled "Define" from the top left portion of your screen.   This will pull down the different variables to change.   Select Parts and the Parts Definition screen will appear.

Parts Definition

You are now ready to enter the necessary information. To enter a new part number or change an existing one, move the cursor to the appropriate position in the "Part Number" box.   Click the left button on the mouse one time to select the cell of information to be added or changed.   Use the backspace key to delete information that needs to be changed then type in the new information.   If you wish to delete a part number you can choose the Delete Part Button.   If you wish to change everything, you can choose the Clear Table Button.   Enter the corresponding Daily Build Quantity, Part Family and Priority for each part number that has been listed.   The Part Family allows similar parts to be grouped on the same fixture (pallet), with up to a maximum of 4 unique Part Numbers on one fixture (or pallet).   If you do not want to group different Part Numbers on the same fixture, leave the Part Family column blank.   The Priority specifies the order in which part numbers are processed in the system.   Note, that the priority only affects the priority at the time the parts enter the system.   Parts can have the same priority or none.   If you do not want the respective part number   to have a priority, leave the corresponding cell blank.

FMSS has been designed to accommodate up to five hundred (500) different part numbers.   Select the OK button when finished.   This will return you to the main screen.   You are now ready to select the next variable.

IMPORTANT NOTICE
The quantity to be included per pallet must be evenly divided
Into the total Daily Quantity to Produce

Machining Cycle Time By Part Number and Operation

The following is a sample screen along with a description to change machining cycle time by part number and operation.

To change the cycle time by part number and operation, place the cursor on the number you would like to change. Click the left button on the mouse one time to select the cell of information to be added or changed. Use the backspace key to delete information that needs to be changed then type in the new information.   If you wish to change everything, you can choose the Clear Table Button.   Type in the new cycle time and press the ENTER key to ensure the information has been recorded.   It is important to note that the cycle time must be in "minutes" and the cycle time entered must be for one (1) part .   For example, if there are four (4) parts per pallet and t he machine cycle time for the pallet is four (4) minute, then the cycle time per part is one (1) minute.   This is the value that is entered into the "cycle time definition" screen.

Load/Unload Time By Part Number and Operation

The following is a sample screen along with a description to change load/unload time by part number and operation.

To change the load/unload time by part number and operation, place the cursor on the number you would like to change. Click the left button on the mouse one time to select the cell of information to be added or changed. Use the backspace key to delete information that needs to be changed then type in the new information.   If you wish to change everything, you can choose the Clear Table Button.   Type in the new load/unload time and press the ENTER key to ensure the information has been recorded.   It is important to note that the load/unload time must be in "minutes" and the time entered must be for one (1) part .  

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Pallet Assignment and Parts per Pallet by Operation

The following is a sample screen along with a description to change pallet assignment and quantity of parts by part number and operation.

To change the pallet assignment and quantity of parts per pallet by part number and operation, place the cursor on the number you would like to change. Click the left button on the mouse one time to select the cell of information to be added or changed. Use the backspace key to delete information that needs to be changed then type in the new information.   If you wish to change everything, you can choose the Clear Table Button.   Type in the new pallet assignment and quantity of parts per pallet by operation.   Press the ENTER key to ensure the information is recorded.   It's important to note that when specifying a range, it must be a sequential range and the range should include the starting pallet ID and the ending pallet ID.   For example, if pallets 1 through 10 are used for part 1, then the user should input "1-10" with no spaces between the hyphen and the number.   If only one (1) pallet ID is required, then only that number needs to be entered.  

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Vehicle Speed and Transfer Times

The following is a sample screen along with a description to change vehicle speed and transfer times.

To change the vehicle speed, place the cursor on the box labeled "Vehicle Speed (ft./min.)".   Click the left button on the mouse one time to select the cell of information to be added or changed.   Use the backspace key to delete information that needs to be changed then type in the new information. Type in the new vehicle speed.   Press the ENTER key to ensure the information has been recorded.   It is important to note that the speed be in "ft./min.".  

There are two (2) transfer times to be used in FMSS.   One is the time required to transfer a pallet to or from the vehicle, onto or off-of a load/unload station or pallet stand.   The other is the time required to transfer a pallet to or from the vehicle, onto or off-of a machining center station.

To change the transfer time, place the cursor on the appropriate box.   Click the left button on the mouse one time to select the cell of information to be added or changed. Use the backspace key to delete information that needs to be changed then type in the new information. Type in the new Load/Unload time (units must be in minutes).   Press the ENTER key to ensure the information has been recorded.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Operator Break Schedule

The following is a sample screen along with a description to change operator break schedules.

When changing an operator break or lunch time, place the cursor on the time that is to be replaced.   Click the left button on the mouse one time.   Use the backspace key to delete the old time, they type in the new time and press the ENTER key to ensure the information is recorded.

It should be noted that all times entered must be in military time (24-hour clock).

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Line Layout

The following is a sample screen along with a description to change the line layout.

To change the number of inches for the machining centers, load stations, or pallet stands, place the cursor on the appropriate box.   Click the left button on the mouse one time to select the cell of information to be added or changed. Use the backspace key to delete information that needs to be changed then type in the new information. If you wish to change the entire line, choose the Clear Button at the end of the row.   Type in the new number of inches.   It is important to note that the point of origin in which all distances are referenced is the left side of the line layout.   Press the ENTER key to ensure the information has been recorded

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Operator Assignment

The following is a sample screen along with a description to change operator assignment by load station.

To chage number of operators for a load station, place the cursor on the number you would like to change.   Click the left button on the mouse one time to select the cell of information to be changed.   Use the backspace key to delete information that needs to be changed and then type in the new information.   If you wish to change everything, you can choose the Clear Table Button.   Type in the new load station assignment and press the ENTER key to ensure the information is recorded.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Load Station Assignments

The following is a sample screen along with a description to change Load Station Assignments by part number and operation.

This screen allows the user to specify the load station(s) the part can be processed on by operation.   To change the load station assignment, first place the cursor on the number you would like to change.   Click the left button on the mouse one time to select the cell of information to be changed.   Use the backspace key to delete information that needs to be changed and then type in the new information.   If you wish to change everything, you can choose the Clear Table Button.   Type in the new load station assignment and press the ENTER key to ensure the information is recorded.

It is important to note, that when specifying a load station, you must enter a range of load stations.   For example, if Part 1 requires load stations 1, 2, 3, & 4 for Operation #1, then you must enter "1,2,3,4".   If the Part 1 only requires load station 1 for Operation #1, then you only have to enter "1".

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Machining Centers Assignment

The following is a sample screen along with a description to change machining centers assignment by part number and operation.

This screen allows the user to specify the machining centers the part can be processed on by operation. To change the machining center assignment, place the cursor on the cell you would like to change.   Click the left button on the mouse one time to select the cell of information to be changed.   Use the backspace key to delete information that needs to be changed, and then type in the new information.   If you wish to change everything, you can choose the Clear Table Button.   Type in the new machining center assignment and press the ENTER key to ensure the information is recorded.

It is important to note that when specifying a group of machining centers to process the part, you must enter each machining center number followed by a comma.   The last machining center number entered does not need a comma following the entry.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Saving the Input Data

If you would like to save the changes to the scenario that you are about to conduct, then select the "File" pull-down menu and then select either "Save" or "Save As".   If "Save" is selected, then the input data will be saved to the last file that was either opened or saved.   If you want to save the input data to a different file name, then select "Save As" and specify the file name and directory you want the input data saved to.

Once you have saved all of the changes you have made, you are ready to Validate the Scenario Data.

IMPORTANT NOTICE
The filename cannot contain hyphens or spaces.

Validating the Scenario Data

To validate the scenario data, choose validate scenario from the simulation menu.   If no errors occurred in while entering of data, the following screen should appear:

If any error occurs during the entry of data, a screen similar to the following will appear:

Once you have validated the scenario data, you are ready to Run the Simulation Model.

Running the Simulation Model

To run the model you select the "pull-down" menu labeled "Simulation" from the top left portion of your
screen.   When you select "Execute", the model will run based on all the operating parameters specified by the user.

Once the model begins, the screen will transfer to the Arena environment.

The following window will appear.

You can press the F5 key or use the tool bar controls for "Fast Forward", "Play", "Stop", etc. when running the model.   There is no animation with this computer simulation model.

A window will appear, after the model has completed running, asking the user if they want to view the simulation results.   These are the output results of the computer simulation model based on the operating parameters the user has defined.   To view these results, select the "Yes" button.   The application will open a text file called "Merc1.out" in a Notepad environment.

Computer Simulation Output Report

The following screen shows an example of an output report (Reference Appendix A2).

The output report is divided into two categories:

•  Time-Dependent Statistics

•  Counter Statistics

The time-dependent statistics measure items such as machine utilization, queue sizes, and time required to process parts.   The counter statistics keep track of parts completed.   The time-dependent statistics are further divided into two categories:

•  Tally Statistics - which primarily measures the time required to process parts

•  DSTATS - which primarily measures items such as resource (i.e., machine and operator) utilization and queue sizes

The Tally Variable Statistics have primarily five key measures:

•  Average value - defines the average value of the statistic over the time period simulated

•  Half Width - defines the confidence interval for   the average (or mean) value

•  Minimum value - defines the minimum value of the statistic over the time period simulated

•  Maximum value - defines the maximum value of the statistic over the time period simulated

•  Observations - the number of observations that the model collected statistics - in this case this is the number of parts

The DSTAT Statistics (labeled as "DISCRETE-CHANGE VARIABLES" in the output report), have primarily five key measures:

1  Average value - defines the average value of the statistic over the time period simulated

2  Half Width - defines the confidence interval for the average (or mean) value

3  Minimum value - defines the minimum value of the statistic over the time period simulated

4  Maximum value - defines the maximum value of the statistic over the time period simulated

5  Final Value - defines the final value of the statistic at the end of the time period simulated

The important statistics to review in the output report are:

•  Loader Queues - indicates the number of pallets waiting to get to a load station

•  Operator Queues - indicates the number of parts waiting for an operator

•  Pallet Use - measures the amount of time a specific pallet is being used during the time period simulated

•  Storage Stand Utilization - is divided into 3 categories

1. Percent of time pallet had finished product (ex. PAD1 FINISH     13%)
2. Percent of time pallet had in process material (ex. PAD1 IN PROCESS      .5%)
3. Percent of time pallet was empty (ex. PAD1 EMPTY       15%)

Please note that this information is found in the last column (Final Value) of the output report.

•  Load Use - measures the amount of time pallets are occupying the load stations during the time period simulated

•  Machine Use- measures the amount of time specific machining centers are used during the time period simulated

•  Operator Use - measures the amount of operators are being used during the time period simulated

•  RGV Use - measures the amount of time the vehicle is being used during the time period simulated

Reference the sample output report in Appendix A2.   The output report can be printed in the Notepad environment.   The "File" pull-down menu contains the print command.   It is recommended to change the orientation of the page to a "Landscape" orientation to ensure the results line-up correctly with the headers on the report.   To exit out of the Notepad environment, move the cursor to the upper right hand corner of the window and select the top "X" button.   Then exit out of the Arena environment by moving the cursor to the upper right hand corner of the window and select the top "X" button.

After exiting out of the Arena environment, the MS-DOS window labeled "Finished-maz" will appear.   Close the MS-DOS window by moving the cursor to the upper right hand corner of the MS-DOS window and select the "X" button with the cursor.   You will then automatically return to the main menu where you can conduct additional analysis.

ANALYZING THE SIMULATION RESULTS

After the execution of the simulation, FMSS allows you to analyze the results.

The following results can be analyzed in this simulation:

Machining Center Utilization

The machining center utilization charts the amount of time specific machining centers are used during the time period simulated.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Load Station Utilization

The load station utilization charts the amount of time pallets are occupying the load stations during the time period simulated.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Pallet Utilization

The pallet station utilization charts the amount of time a specific pallet is being used during the time period simulated.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Pallet Stand Utilization

The pallet stand utilization charts the amount of time a pallet had finished product, in process material, or was empty.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Operator Utilization

The operator utilization charts the amount of time operators are being used during the time period simulated.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

RGV Utilization

The rail-guided vehicle (rgv) utilization charts the amount of time the vehicle is being used during the time period simulated.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

Parts Completed

The parts completed charts the amount of parts completed during the time period simulated.

To return to the main menu, place the cursor on the OK button and click the left button on the mouse one time.

TECHNICAL SUPPORT

Technical assistance will be provided Monday through Friday, 8AM to 5PM by calling (513) 753-6258.

Any correspondence can be sent to the following address:
SIM Technologies Corporation
1003 Kennedy's Landing Suite 5Cincinnati, Ohio 45245
stcemail@aol.com