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Simulation of reception, expedition and picking areas of a pharmaceutical products plant.
Authors: Josep Casanovas García Wilfredo Pérez Rivero Jordi Montero García Pau Fonseca Casas
Introduction
Detailed simulation model of some main processes in a pharmaceutical products plant involved in deep structural changes due to the merge of different new company activities. s Using an Object Oriented Simulation methodology called LeanSim, specially designed to create models for manufacturing and logistics systems.
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Situation
Order’s expedition is partially automated. s Storage of complete production is organized for their later distribution. s Merge of several company units. s Increase in throughput is required and bottlenecks problems are expected for intermediate and terminated product.
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Planned modifications
Robot carrying out picking of complete boxes. s Evaluate cost and potential use of automatic dispensers for the picking of product fractions. s New politics of orders preparation s Increase in production levels
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Expected performance
Maintain current quality and due time, evaluating alternative shift policies to reach 24 maximum hours to customer service. s Production cost and picking of fractions should be reduced. s Alternatives comparison and possible decisions.
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Project structure (I)
Analyze month type demand s Plant capacity analysis s References assignments to each picking types. s Use of automatic dispensers, necessary channels and approaches for the dynamic channels recharges.
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Project structure (II)
Optimal size for pallets expeditionreception area. s Re-palettition unit dimension and associated processes. s Packaging analysis with the objective of diminish picking of units. s Determine scenarios and more interesting alternatives scenarios and simulate them.
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Development phases
Macroscopic specification and modeling. Only considering main plant objects. s Microscopic model with highest level of detail in machines, conveyors, resources and other elements.
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Software technologies (I)
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Object Oriented
• • • • • Quick development Quality increased Easier maintenance Code and user interface reusability Risk reduction in development of very complex systems
Software technologies (II)
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Component based modeling (COM)
• Binary standard for component interconnection • Programming language independence • Implemented in multiple platforms • Allows robust evolution of applications and systems based on components • Communication among components, in different processes or in networks
Leansim methodology (I)
Identify objects s Define state list and draw a finite state machine diagram for each object s Define channels to communicate objects each others s Define an external event list for each object s Define a SDL flowchart, peer to peer
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Leansim methodology (II)
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SDL State’s diagram (“Reposició” Object)
Leansim methodology (III)
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SDL State IDLE (“Reposició” Object)
Leansim methodology (IV)
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SDL State service (“Reposició” Object)
Visual Representation (I)
Virtual reality simulation environment. s User can observe the system modeled in the simulation like a replica of the real system. s Easier model validation increasing overall process credibility from final user point of view s Ability to become a powerful operators training tool.
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Visual Representation (II)
Small errors or inconsistencies debugging during the specification and better understanding of the model. s Shows a nearest representation of the real image of the studied system. s Interactive representation integrated during model execution.
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Model parameters
Visual representation (I)
Visual representation (II)
Visual representation (III)
Visual representation (IV)
Simulation results
Results (I)
Bottlenecks in each of the scenarios s Saturation of the simulation objects and consequently of the real objects (robot, robot assistant car, picking station) in the final layout s Shift organization with different levels of saturation. Operations synchronization.
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Results (II)
Other performance measures. Equipment speed calibration and adjustment. Not served shipments,… s Robot design, banks, extraction strategies evaluation (extraction priority for star-class references, extraction priority for pallets, re-sending references to the robotized silo,…)
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Demo