5.6 Prototypical Implementation
127
The production line is operated in a two-shift model, from 6 am to 2 pm and
2 pm to 10 pm, with ten shifts per week. For all five machines, a preventive maintenance schedule exists with weekly occurring services. The produced quantities
are highly dependent on the customer’s orders, but a maximum quantity of 60
parts per shift cannot be exceeded. The assignment of the machine logic types
is done according to the complexity of the production machines following the
suggestion in section 5.3.2. Processing times 8 , durations of technically required
machine states and other relevant key figures used in the simulation model can be
found in Table 5.1.
Table 5.1 Process parameter of the die-casting production machines
CNC 1
CNC 2
Drilling
Sandblasting Washing
Machine
logic type
High
complexity
High
complexity
Medium
complexity
Medium
complexity
Low
complexity
Process time 14 mins
13 mins
4 mins
4 mins
90 mins
Capacity
1 part
1 part
1 part
1 part
12 parts
Preventive
maintenance
40 mins/week 40 mins/week 40 mins/week 60 mins/week 120 mins/week
Warmup
31 mins
27 mins
19 mins
23 mins
–
Fast
warmup
13 mins
17 mins
–
–
–
Output
quantity
Depends on the customers demand → production schedule
Shift model Two shifts a day summing up to ten shifts per week, operation time 6 am to
10 pm.
The assignment of the power consumption profiles to the individual machine
states is done manually. The database for the scenario has been specially created,
whereby the data are in principle based on the course of real production data.
The data has been adapted to make differences in of machine states changes
more clearly and recognizable. This procedure was deliberately chosen to make
errors in the construction of the simulation model and the selected optimizations
identifiable and transparent. The data available for the case study has a resolution
of one measured energy consumption value per minute. The testing of different
resolutions does not make any sense for the fictional example due to missing
8 Due to the rather long process times in the described production line, the simulation model
time in AnyLogic is set to minutes.
127
The production line is operated in a two-shift model, from 6 am to 2 pm and
2 pm to 10 pm, with ten shifts per week. For all five machines, a preventive maintenance schedule exists with weekly occurring services. The produced quantities
are highly dependent on the customer’s orders, but a maximum quantity of 60
parts per shift cannot be exceeded. The assignment of the machine logic types
is done according to the complexity of the production machines following the
suggestion in section 5.3.2. Processing times 8 , durations of technically required
machine states and other relevant key figures used in the simulation model can be
found in Table 5.1.
Table 5.1 Process parameter of the die-casting production machines
CNC 1
CNC 2
Drilling
Sandblasting Washing
Machine
logic type
High
complexity
High
complexity
Medium
complexity
Medium
complexity
Low
complexity
Process time 14 mins
13 mins
4 mins
4 mins
90 mins
Capacity
1 part
1 part
1 part
1 part
12 parts
Preventive
maintenance
40 mins/week 40 mins/week 40 mins/week 60 mins/week 120 mins/week
Warmup
31 mins
27 mins
19 mins
23 mins
–
Fast
warmup
13 mins
17 mins
–
–
–
Output
quantity
Depends on the customers demand → production schedule
Shift model Two shifts a day summing up to ten shifts per week, operation time 6 am to
10 pm.
The assignment of the power consumption profiles to the individual machine
states is done manually. The database for the scenario has been specially created,
whereby the data are in principle based on the course of real production data.
The data has been adapted to make differences in of machine states changes
more clearly and recognizable. This procedure was deliberately chosen to make
errors in the construction of the simulation model and the selected optimizations
identifiable and transparent. The data available for the case study has a resolution
of one measured energy consumption value per minute. The testing of different
resolutions does not make any sense for the fictional example due to missing
8 Due to the rather long process times in the described production line, the simulation model
time in AnyLogic is set to minutes.