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SOFTWARE YOUR BUSINESS CAN'T AFFORD TO BE WITHOUT
SIM TECHNOLOGIES CORPORATION - LMPS Manual D I S C O V E R I N G T H E P O S S I B I L I T I E S |
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»LEAN MANUFACTURING PLANNING SYSTEM - Version 2 |
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TABLE OF CONTENTS I. INTRODUCTION II. GENERAL REQUIREMENTS III. ARENA INSTALLATION PROCEDURES IV. FORGING INSTALLATION PROCEDURES V. EXECUTING THE COMPUTER SIMULATION MODEL VI. INPUT INFORMATION
VII. RUN SIMULATION MODEL VIII. OUTPUT INFORMATION--SIMULATION RESULTS A. Part Process Time B. Station Queue Sizes C. Station Utilization D. Simulated Production Results IX. OPENING SCENARIO DATA X. SAVING SCENARIO DATA XI. CLEARING SCENARIO DATA XII. TECHNICAL SUPPORT INTRODUCTION The following is the Installation Guide and User's Manual for the Forging Operation Planning Tool (Forging). The primary purpose of Forging is to determine if sufficient capacity is available (in terms of equipment) to satisfy the stated demand. The user can vary the following operating parameters to conduct "What-If" analysis: 1. The time period to simulate up to 360 days 2. The number of shifts per day, hours per shift, and crews per shift 3. The part numbers to be produced - Forging has the capability to handle up to four hundred (400) different part numbers 4. The consolidation period - the number of days to consolidate into one order 5. The unit sales price 6. The rework station 7. The furnace temperature 8. The furnace batch size 9. The type of station used to process the parts (these stations can be either manual or automatic) - Forging has the capability to handle up to fifty (60) different station types 10. The station capacity 11. The operating sequence for each part type - this defines the sequence of operations (by station) for each part type up to sixty (80) processes 12. The cycle time efficiency factor by part number and process 13. The cycle time by part number and process 14. The setup time by part number and process 15. The rework rate by part number and process 16. The Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR) for each station - this is referred to as "Failure, Repair Times" in the user interface screen. FOPT uses an exponential distribution when assigning a value for MTBF and a normal distribution when assigning MTTR. 17. The preventive maintenance schedule The user can run Forging with the specified parameters and view the results. All output units in this system will be in minutes. The results are divided into three categories: 1. Throughput in terms of units and dollars 2. The simulated production by part number and time interval 2. Resource (or station) utilization, which would include the percent of time the resource was busy, idle, inactive, or down 4. Station queue sizes Forging 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 Process Area.
Important Notice! INSTALLATION REQUIREMENTS AND PROCEDURES The following hardware and software are required in order to run the computer simulation models: Hardware Requirements: CPU - Pentium processor 200MHz or higher 64MB or higher (preferable) Software Requirements: Windows 95 or higher Included with this manual is a CD containing the required files to run the Forging Operation Planning Tool. Load the CD into the CD drive. An autorun program will start and the following screen will appear. Select the "Install Arena" 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 Customer Information dialog box will appear. You must enter the user name, company name, and serial number to continue the installation. The serial number can be found on the Master Disk floppy.
Click Next to continue. The Destination Location dialog box for Rockwell Software will appear. This indicates where the Arena software will be installed on your hard drive.
Click Next to continue.
The Setup Type dialog box will appear. The typical installation is recommended for use with the Forging program.
Click Next to continue. The Destination Location dialog box for Visio will appear. This indicates where the Visio Simulator files will be installed on your hard drive.
Click Next to continue. The installation will now begin. All files will be copied to your hard drive. These dialog boxes will monitor the progress of the installation.
When all files have been copied successfully, the activation dialog box will appear. To activate the Arena software, you must insert the Master Disk floppy containing the activation code.
Click Finish to install the activation code. The final installation dialog box will appear. You must restart your computer before using the Arena software.
Click Finish to restart your computer.
 Click Next to begin the installation process.
 Click Agree to accept, or click Disagree to terminate the installation.
 Click Next to continue.
 Click Next to continue.
 Click Next to continue.
 The final installation dialog box will appear. To conclude the installation, click the checkbox next to Forging and then click finished.
EXECUTING THE COMPUTER SIMULATION MODEL In Windows Explorer, locate the file Forging.xls located in the C:\Wyman Gordon directory. The following message will occur when you open Forging.xls. Select "Enable Macros" and proceed.
Next open the Arena 5.0 program from the C:\Program Files\Rockwell Software\Arena directory. Click Tools, on the menu bar and select Options. Next select the Array Sizes tab. Set the values in this dialog box accordingly to the following parameters:
USERNAME AND PASSWORD
If the username and password you enter is correct, you will receive the following welcome message:
Click Apply to save the changes, then click OK. Finally, exit the Arena program and return to the forging.xls. You are now ready to begin the Forging Operation Planning System. FORGING OPERATION PLANNING TOOL MENU
This is the main screen in the Forging Operation Planning Tool. The menu toolbar contains five (5) menus: File, Input, Simulation, Results, and Help. The following is a brief description of the items contained in each menu: File Menu
Input Menu
Results Menu
Help Menu User's Manual - Allows the user to open the Forging User's Manual in Microsoft Word. Technical Support - Provides the user with technical support contact information. About CPSS - Contains information about the Forging Operation Planning Tool.
MENU NAVIGATION To enter a menu, place the cursor on the menu of your choice and click the left button on the mouse one time. The menu items will then appear. Place the cursor on the menu item of your choice and click the left button on the mouse one time. If the menu item contains a sub menu, there will be an arrow to the right of the menu item name. To enter the sub menu, place the cursor on the arrow and the sub menu will appear. To select a sub menu item, place the cursor on the sub menu item of your choice and click the left button on the mouse one time. Each menu on the toolbar is accessible by shortcut. Following is the list of shortcuts for each menu. To open the File Menu press ALT + F To open the Input Menu press ALT + I To open the Simulation Menu press ALT + S To open the Results Menu press ALT + R To open the Help Menu pres ALT + H To return to the main screen at any time, place the cursor on the File Menu and click the left button on the mouse one time. Place the cursor on the Main menu item and click the left button on the mouse one time.
 All sheets are password protected to keep specific data from being accidentally changed.
PART NUMBER DEFINITION
To enter the Part Number Definition, place the cursor on the Input Menu and click the left button on the mouse one time. Then place the cursor on the Part Number Definition menu item and click the left button on the mouse one time. To enter or change the time periods to simulate, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the number of time periods to simulate and press the ENTER key. To enter or change the shifts per day, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new shifts per day and press the ENTER key. To enter or change the hours per shift, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new hours per shift and press the ENTER key. To enter or change the crews per shift, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new crews per shift and press the ENTER key. To enter or change the part number, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new part number and press the ENTER key. To enter or change the consolidation period, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new consolidation period and press the ENTER key. To enter or change the unit sales price, place the cursor on the price that is to be replaced. Click the left button on the mouse one time. Type in the new unit sales price and press the ENTER key. To enter or change the rework station, place the cursor on the down arrow next to the rework station box and click the left button on the mouse one time. Then select the appropriate rework station and click the left button on the mouse one time. If the rework station needed does not appear on the screen, use the correct directional arrow on the keyboard until that station appears. To enter or change the furnace temperature, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new furnace temperature and press the ENTER key. To enter or change the furnace batch size, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new furnace batch size and press the ENTER key.
PRODUCTION REQUIREMENTS
To enter the Quarterly Production Requirements, place the cursor on the Input Menu and click the left button on the mouse one time. Then place the cursor on the Production Requirements menu item and click the left button on the mouse one time. Finally place the cursor on the Quarter submenu item and click the left button on the mouse one time. To enter or change the production requirements, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new production requirements and press the ENTER key.
STATION DEFINITION
To enter the Station Definition, place the cursor on the Input Menu and click the left button on the mouse one time. Then place the cursor on the Station Definition menu item and click the left button on the mouse one time. To enter or change a station description, place the cursor on the description that is to be replaced. Click the left button on the mouse one time. Type in the new station description and press the ENTER key. To enter or change the capacity for a station, place the cursor on the capacity that is to be replaced. Click the left button on the mouse one time. Type in the new capacity and press the ENTER key. If the station capacity you enter is less than one, you will receive the following error message:
OPERATION SEQUENCE
To enter the Operation Sequence, place the cursor on the Input Menu and click the left button on the mouse one time. Then place the cursor on the Operation Sequence menu item and click the left button on
It is very important that you click the Save button after changing data for a part number. If you change data and then select a new part number without saving the data, it will be lost. When making an operating sequence for a new part number, first place the cursor on the down arrow next to the part number box and click the left button on the mouse. Then move the cursor to the appropriate part number that will have an operational sequence change and click the left button on the mouse one time. If the part number you wish to change is not on the screen, use the correct directional arrow on the keyboard until that number appears. The computer simulation model has been designed to accommodate up to sixty (60) different operations for a part number. When changing or creating an operation sequence for the part number, first place the cursor on the down arrow next to the operation number you wish to change. Then move the cursor to the appropriate station name and click the left button on the mouse. If the station needed does not appear on the screen, use the correct directional arrow on the keyboard until that station appears. Continue this process until all of the operating sequences for the part number have been selected. The user can then repeat the process for more part numbers. To enter or change the cycle time efficiency factor, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new efficiency factor and press the ENTER key. To enter or change the cycle time, place the cursor on the time that is to be replaced. Click the left button on the mouse one time. Type in the new cycle time and press the ENTER key. To enter or change the setup time, place the cursor on the time that is to be replaced. Click the left button on the mouse one time. Type in the new setup time and press the ENTER key.
REWORK RATE DEFINITION
To enter the Rework Rate, place the cursor on the Input Menu and click the left button on the mouse one time. Then place the cursor on the Rework Rate menu item and click the left button on the mouse one time. To enter or change the rework rate, place the cursor on the rate that is to be replaced. Click the left button on the mouse one time. Type in the new rate and press the ENTER key.
EQUIPMENT DOWNTIME
To enter the Equipment Downtime, place the cursor on the Input Menu and click the left button on the mouse one time. Then place the cursor on the Equipment Downtime menu item and click the left button on the mouse one time. To enter or change the mean time between failure, place the cursor on the time that is to be replaced. Click the left button on the mouse one time. Type in the new time and press the ENTER key. To enter or change the mean time to repair, place the cursor on the time that is to be replaced. Click the left button on the mouse one time. Type in the new time and press the ENTER key. When you have finished entering the data for this screen, place the cursor on the Save button and click the left button on the mouse one time. It is now safe to enter another screen. Mean Time Between Failure (MTBF) of a station will be represented by an exponential distribution with mean defined by the user in the MTBF column. The Mean Time To Repair (MTTR) will be represented by a normal distribution with the mean defined by the user in the MTTR column. Important Notice!
PREVENTIVE MAINTENANCE
To enter the Preventive Maintenance Schedule, place the cursor on the Input Menu and click the left button on the mouse one time. Then place the cursor on the Preventive Maintenance menu item and click the left button on the mouse one time. To enter or change the preventive maintenance, place the cursor on the number that is to be replaced. Click the left button on the mouse one time. Type in the new number and press the ENTER key.
RUN SIMULATION MODEL To enter the Simulation, place the cursor on the Simulation Menu and click the left button on the mouse one time. Then place the cursor on the Run Simulation menu item and click the left button on the mouse one time. Once the model begins, the screen will transfer to the Arena environment. 
 After exiting out of the Arena environment, the MS-DOS window labeled "Finished-forging" will appear. Close the MS-DOS window by moving the cursor to the upper right hand corner of the window and selecting the "X" button with the cursor. You will then automatically return to the simulation mode screen. To return to the main menu, place the cursor on the Return to Main button and click the left button on the mouse one time.
Important Notice!
SIMULATION RESULTS The Simulation Results file shows the results of the simulation. It is divided into four categories:
PART PROCESS TIMES
To enter the Part Process Times, place the cursor on the Results Menu and click the left button on the mouse one time. Then place the cursor on the Part Process Times menu item and click the left button on the mouse one time. This screen shows the average total cycle time for each job number.
STATION QUEUE SIZES
To enter the Station Queue Sizes, place the cursor on the Results Menu and click the left button on the mouse one time. Then place the cursor on the Station Queue Sizes menu item and click the left button on the mouse one time. The Station Queue Results indicate the average, maximum, and final values of the number of parts queued at each station (in a tabular format).
 To enter the Station Queue Sizes Charts, place the cursor on the Results Menu and click the left button on the mouse one time. Then place the cursor on the Chart Station Queue Sizes menu item and click the left button on the mouse one time. Finally, place the cursor on the Station sub menu item and click the left button on the mouse one time. This chart is a graphical representation of the average, maximum and final values for each Station Queue size. This chart can be printed out by pressing CTRL + P.
STATION UTILIZATION
To enter the Station Utilization, place the cursor on the Results Menu and click the left button on the mouse one time. Then place the cursor on the Station Utilization menu item and click the left button on the mouse one time. The Station Utilization Results show how much of the available station capacity was used during the time period simulated. The results are displayed in a tabular format and are average utilizations.
STATION UTILIZATION CHART  To enter the Station Utilization Charts, place the cursor on the Results Menu and click the left button on the mouse one time. Then place the cursor on the Chart Station Utilization menu item and click the left button on the mouse one time. Finally, place the cursor on the Station sub menu item and click the left button on the mouse one time. This chart is a graphical representation of the average station utilization. This chart can be printed out by pressing CTRL + P.
SIMULATED PRODUCTION RESULTS
To enter the Simulated Production, place the cursor on the Results Menu and click the left button on the mouse one time. Then place the cursor on the Simulated Production menu item and click the left button on the mouse one time. Finally, place the cursor on the Quarter sub menu item and click the left button on the mouse one time. The Simulated Production Results screen show the required production (white column) and the projected production (gray column) for the time period specified. The final columns of the screen show the total required production quantity, the total projected production quantity, and the total price for each part. The total price is automatically calculated based on the following formula: unit sales price * total projected production quantity
OPENING SCENARIO DATA To open a scenario file, place the cursor on the File Menu and click the left button on the mouse one time. Then place the cursor on the Open Scenario menu item and click the left button on the mouse one time. The following Open dialog box should appear: Choose the scenario you want to open and click the open button once. After the scenario has been opened the following message will appear:
SAVING SCENARIO DATA To save a scenario file, place the cursor on the File Menu and click the left button on the mouse one time. Then place the cursor on the Save Scenario menu item and click the left button on the mouse one time. The following Save As dialog box should appear:  Specify the directory where the scenario data is to be stored. Next type a name for this scenario such as Scenario 1 or Scenario 2, etc. This scenario file must be saved as a text (tab delimited) file. Click the save button once. Your scenario data will be saved for later retrieval. After the scenario has been saved the following message will appear:
CLEARING SCENARIO DATA To clear a scenario file, place the cursor on the File Menu and click the left button on the mouse one time. Then place the cursor on the Clear Scenario menu item and click the left button on the mouse one time. After the scenario has been cleared the following message will appear:
It is now safe to open another scenario. If you do not clear the previous scenario data before opening a new scenario, your data may become corrupted. 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:
Live online support can be accessed through the Contact page of our website by clicking the icon in the lower right corner. If all representatives are busy the icon will prompt you to leave a message. When your message is received, the next available representative will contact you promptly. |
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the mouse one time. 
