Plant Design and Optimization

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Benefits• Effectivecommunicationof

designprinciples• Enhancedcross-functional

teamcommunications• Globalizedworkflowand

releasemanagement• 50percentreductionin

factorydesigntimewhencomparedwith2D

• 15percentreductionintoolingandequipmentchanges

• Optimizedre-useofexistingcapitalequipment

• Upto70percentreductioninmaterialhandlingcosts

• Optimizedresourceutilizationandmaterialflow

• Reductionsinnonvalue-addedworkandindirectlaborcosts

• Optimizedspaceutilizationatfactoryandtransportlevel

• 5to20percentreductioninnewsystemcosts

• 20to60percentdecreaseinthroughputtimes

• 20to60percentreductionininventorylevel

• 15to20percentincreaseinproductivityofexistingsystems

SummaryTecnomatix®software’sPlantDesignandOptimizationsolutionenablesdiverseteamstolayoutandoptimizefactorydesignsinasharedenvironment.Youcanrapidlydevelopfactorylayoutsusing3Dandparametricsmartobjectsthatfacilitatetheearlydiscoveryofdesignflaws.Materialhandling,logisticsandindirectlaborareoptimizedbycomparingpartroutinginformation,materialstorageneeds,materialhandlingequipmentspecificationsandpackaginginformationagainstthefactorylayout.Thisapproachincreasesplanningaccuracyandefficiency,whichhelpsminimizecapitalinvestmentandmaximizeROI.

A comprehensive solution for collaboratively designing and optimizing your factory facilitiesTecnomatixPlantDesignandOptimizationenablesmanufacturingcompaniestocreatefactorymodelsfasterandensurethatthesevirtualplantswilloperateatpeakefficiencybeforeproductionrampup.Byallowingmanufacturerstoseetheoutcomeoftheirfactoryplansinvirtualmodels,

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impactofequipmentplacementonthefactoryfloorormaterialflowthroughoutthefacility.

Throughputoftheindividuallinesisalsocritical,asisefficientplanningandoptimi-zationoftherestofthefacility.assemblyprocessesrequirepreciseplanningofthefacility’sdeliveryconcepts,storageneedsandtransportconcepts.

PlantDesignandOptimizationaddressestheseissueswiththefollowingfourkeycapabilities.

3D factory design and visualizationTraditionalfactorydesignprocessesarepronetoerror.Designteamsfindithardtounderstandtheimpactofequipmentselectionandequipmentplacementonthefactoryfloorwhentheseactivitiesareexpressedin2Dlayoutenvironments.

With3Dfactorydesignandvisualization,PlantDesignandOptimizationprovidesfactoryteamswithcriticalinsightintothefactorydesign,layoutandinstallationprocesses.Theuseof“smartobjects”makesitmucheasierforteamstounderstandandrepresentallofyourfactoryresources(fromconveyors,mezzaninesandcranestocontainers,automaticguidedvehicles(aGV’s)andoperators).

3Dlayoutandplanninghelpsminimizeinterpretationerrorsbyenablingteammemberstoseehowfactorysmartobjectsinteractwithoneanotherinsideavirtualfacility.

PlantDesignandOptimizationletsyouavoidwastingtimeandresourcesfixingproblemsontheplantfloor.

PlantDesignandOptimizationisasolutioncomprisedoffourkeycapabilities,including:• 3D factory design and visualization

capabilities,includingparametric-basedsmartobjects,thatteammemberscanusetodevelopthefactorylayoutandidentifyearlydesignissues.

• Factory logistics analysis and optimization capabilitiesthatteammembersusetooptimizematerialhandling,logisticsandindirectlaborbycomparingpartroutinginformation,materialstorageneeds,materialhandlingequipmentspecificationsandpartpackaginginformationagainstthefactorylayout.

• Production throughput simulation capabilitiesthatprovideyouwiththedatanecessarytomakeintelligentbusinessdecisionsrelatedtotherequiredcapabilities,buffersizingandstrategiesofthefactoryandtheabilitytominimizecapitalinvestmentwhilemaximizinglongtermROI.

• Collaborative factory design managementthatprovidesdiverseteamswiththeabilitytocaptureandcommunicatethefactorymodel’sdesignprinciplesandstandardresourcesinacollaborativeenvironment.

Today’s factory planning challengesProducingandsellingmoreproductsdoesnotnecessarilyleadtomoreprofit.Ifyourmanufacturingoperationsarerunninginefficiently,youcouldendupspendingmoremoneythanyoumakebyhavingtocompensateforthosemanufacturingdeficiencies.

Inefficiencyusuallybeginsintheearlystagesoffactorydesign,especiallyduringfacilityandworkcelllayout,whendiversecross-functionalteamsfailtocommunicateeffectively.Inaddition,antiquatedtools,suchas2Dlayoutandpaperdrawings,areunabletoproperlyaccountforthe

Plant Design and Optimization

Features3Dfactorydesignandvisualization:• “Smart”3Dfactoryobjects

withbuilt-indesignrules• abilitytobuildparametric

factoryequipmentwithxMLtoolkit

• abilitytolinkfactorylayoutwiththroughputsimulationviaSDx

• DirectimportandtoolingandproductdatafromJT™technology,nx™software,SolidEdge®softwareandParasolid®applications

Factorylogisticsanalysisandoptimization:• computationand

visualizationofmaterialflowdiagrams

• analysisandvalidationofoperatorwalk-paths

• calculationofmaterialhandlingequipmentneeds

• Spatialdesignofmaterialstorageareas

Productionthroughputsimulation:• Bottleneckanalysis• 3Dvisualizationofthe

simulation• Optimizationofsystem

parametersbasedongeneticalgorithm

• Hierarchicalsimulationstructurewithobjectinheritance

• Integratedobjectlibrarymanagement,whichalsofacilitatessharedprojectdevelopmentwithinateamenvironment

• Statisticalevaluationandautomaticreportgeneration

collaborativefactorydesignmanagement:• In-contexteditingofmultiple

factoryregions,departmentsandstations

• concurrentdesignoffactoryfacilities

• abilitytoseamlesslymoveobjectsbetweendatasets

• Managementofobjectversioning,effectivityandincrementalchange

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potentialwithina2Dor3Denvironment.Theseevaluationscanincludetransportstrategies,lotsizesanddeliveryconceptsacrosstheentirefactory.Optimizingthecharacteristics–workerschedules,requirednumberofresourcesandcapacities–ofyourproductionsystemsenablesyoutomakeverifiedbusinessdecisionsearlybasedonrealnumbers,whichsavesyoumillionsofdollarsduringfullproduction.

Collaborative factory design managementnumerousdisciplinesparticipateinthedesign,layoutandinstallationofatypicalfactory,includinggroupsresponsibleforthebasicarchitecture,industrialengi-neeringandlayoutplanning–aswellasexternalsupplierssuchaslinebuildersandequipmentvendors.Thesedisciplinesoftenfinditdifficulttocommunicateeffectively,properlycontroldesignrevisions,managethereleaseprocessoraccountforexternalsupplychainactivity.

PlantDesignandOptimization’scollab-orativefactorydesignmanagementcapabilitiesprovideyourdiverseteamswithasingleenvironmenttheycanusetocaptureandmanagethelargevolumesoffacilitydatatheyshare.Theyalsocanusethisenvironmenttoworktogetherinavarietyofautomatedlayoutandfacilityengineeringprocesses.

Production throughput simulationnumerousfactorsimpacttheoperationalefficiencyandthroughputofyourmanufacturingoperations.companiesfinditdifficulttodeterminetheoptimalconfigurationfortheirnewproductionsystems.Theyalsofindithardtoestablishproperlevelsofwork-in-processinventory,appropriateproductionschedulesandtherightproductionthroughputtoresourceutilizationratio.

Throughproductionthroughputsimulation(discreteeventsimulation),PlantDesignandOptimizationallowsyoutomakeintelligentbusinessdecisionsaboutyourfactorydesign,buffersizing,capacitiesandproductionstrategies.Bytyingyourfactorylayoutwithdiscreteeventsimulation,thisTecnomatixsolutionenablesyoutorapidlydevelopmultipleproductionscenariosandanalyzethemforbottlenecks,efficiencyandthroughput

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contactSiemensPLMSoftwareamericas 8004985351Europe 44(0)1276702000asia-Pacific 85222303333

Factory logistics analysis and optimizationManufacturingoperationstrytosqueezemaximumproductivityoutoftheirdirectlaborinvestments,includingmachinesontheline,toolingandfixtures,workersattheirstationsandtheirproductionprocesses.However,manycompaniesfinditdifficulttoquantifyandanalyzetheirindirectlabororadoptleanmanu-facturinginitiatives.

PlantDesignandOptimization’sfactorylogisticsanalysisandoptimizationcapabilitiesenableyoutooptimizeyourfactorylayoutonthebasisofmaterialflowdistances,frequencyandcost.Youcanevaluatetheimpactofyourpartrouting,materialstorage,materialhandlingequipmentandpartpackagingneeds.asaresult,youcancreateanoptimizedandproductivefactorywithreducedparttraveldistances,lotsizesandinventorylevels.

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