We will be visiting one of the world largest shuttle warehouses in the consumer goods industry. The warehouse was simulated using Tecnomatix Plant Simulation.
The simulation started with the determination of the required buffer sizes and the conveyor technology in the design phase of the new distribution center of Hugo Boss AG. This was followed by the support of detailed planning. The detailed model included the various warehouse areas, incoming goods, order picking, packaging, value-added services and shipping.
The offers of the individual system providers were checked and compared on the basis of the simulation in order to examine the functionality and feasibility of the offered system even before the contract was signed.
André Wiesner
André Wiesner works for Hugo Boss since 2006 in the Global Logistics Strategy & Planning department. He is the intralogistics project manager for the new central distribution center for flat-packed goods.
Dirk Wortmann
Dirk Wortmann, born in 1967, finished his studies in computer science at the GKS Bad Homburg in 1988. He started his professional career in a Frankfurt engineering office and was involved in the development of simulation software and the implementation of simulation projects in the field of production and logistics. In 1992 he founded the company SimPlan together with his partner Sven Spieckermann. From the founding until 2013 he had been a member of the board. From 2010 to 2018, he set up and developed SimPlan’s Chinese subsidiary in Shanghai.
Please note - the tour to Hugo Boss AG is fully booked.
Presenter: Dr. Georg Piepenbrock, Product Manager Plant Simulation, Siemens Industry Software GmbH
AGV‘s driving freely, Cost Simulation; New Sankey Chart, New Gantt Chart, Automatic Conveyor routing; Enhanced Worker Strategies; Conditional Breakpoints; Teamcenter Wizard; 3D poses and much more.
Presenter: Anastasiya Pershina, Ideal PLM, Russia
Anastasiia Pershina was born on Tomsk, Russia, and studied technology artistic processing of materials and product lifecycle management in Tomsk Polytechnic University and also was an exchange student at the University of Maribor, Slovenia. She is a PLM systems consultant in Ideal PLM CIS since 2018. Anastasiia works in the group of Industrial Consulting, makes pre-sale projects as a consultant and Plant Simulation specialist.
A simulation model was developed for the operation of the painting shop for our project to optimize the conveyor line for painting wagons using Plant Simulation. The input parameters obtained from production were set and cyclograms were analyzed for the development of the model. The aim of the development of the model was to eliminate the bottleneck, which is this workshop, in the general cycle of manufacturing cars.
An important nuance of production is the number of different types of wagons (four types) that are handled at this shop, and the sequence of their supply is determined quite randomly. Thus, it becomes impossible to reduce the setup time. Another difficulty is the time of the painting operations, which cannot be reduced. Based on this and on the basis of a simulation model, organizational decisions were taken to optimize production and reduce downtime.
Presenter: Silvia Furtáková, Ladislav Papánek, CEIT, (Central European Institute of Technology, Žilina, Slovakia)
Silvia Furtáková, born in 1985, studied Industrial Engineering at Faculty of Mechanical Engineering at University of Žilina (Slovakia). In 2012 she finished her PhD studies with topic Simulation metamodelling of manufacturing processes. After that she worked as a researcher at the Department of Industrial Engineering. Since 2017 she has been a member of a team of specialists for digital technologies and is dealing with a computer simulation (in Plant Simulation) of manufacturing and logistics systems at Digital factory division at Central European Institute of Technology
In manufacturing plants, there occur many organizational and procedural shortcomings that are, from the point of complexity of the system, difficult to be solved without the use of tools of digital factory. These support activities in designing of new manufacturing systems, in projection and optimization of production and logistics system layout, in detailed workplace designs, or in dynamic verification of designs and future changes of the system. Computer simulation is the last step in the phase of designing the system and verification of system changes. We use Plant Simulation in the areas of manufacturing, internal and external logistics, warehouse management, and production planning and scheduling. Such a set of digital tools completed with the implementation of technical solutions and online monitoring is the basis for complex solutions for smart factories and for advanced manufacturing systems in the spirit of Industry 4.0.
Presenter: Mr. Zhaocheng Xu, EMAG GmbH & Co. KG
Today’s manufacturing industry is coping with an increasing variety and complexity. Material flow simulation offers significant benefits to manage this complexity and therefore reduces operation costs. The acquiring of detailed simulation input parameters and the evaluation of performance results of manufacturing systems are time consuming processes. In this circumstance, a simulation kit was developed at EMAG to standardize the input and statistic output of simulations.
Co-Presenters:
Marc Philip Hermans, Audi Hungaria Zrt. & GraphIT
Marc Hermans is born in Maaseik, Belgium. He studied at the maritime academy Antwerp. He has a master degree in Nautical Science. In 2004 he started working at the AUDI Hungaria planning department as a junior planning engineer. In 2008 he joined the digital fraction within the planning department. Since then, he drives all material flow studies conducted with Plant Simulation within the engine department, not only for Audi Hungaria but also for Audi AG.
Zsolt Molnar, GraphIT, Hungaria
Mr. Zsolt Molnar has an MSc degree in Mechanical Engineering from the Technical University of Budapest. He is also a professional business coach. Zsolt Molnar has been working in various positions at graphIT Kft. (the Hungarian Smart Expert Siemens partner) for the past 20 years.
Zsolt Molnar is a senior engineer in different fields of digital manufacturing, manufacturing simulation and production planning and scheduling. He has been working on countless projects in several industries, like automotive, electronics, food and beverage and others to improve manufacturing processes and help companies to enable a digital factory vision. He strongly believes that the future of manufacturing is in the digital twin concept, which focuses on the continuous and parallel improvement of the two parts of the digital twin – the real and the digital factory.
In leaving conventional conveyor systems and switching to the use of automated guided vehicles, AUDI faced unknown territory. With first simulations with relative freely moving AGVs, it became clear that conventional push, pull and conwip controls, where insufficient. In conventional systems, the production sequence and daily production program can be seen as each other’s mirrors. Turbulences in the sequence is relatively restricted and only occurs at defined weak spots in the production flow. This behavior makes it quite easy to control and manage the sequence over a relatively small amount of control points. Due to the use of AGVs, it becomes quite simple to reuse resources within the production flow, but this simplicity comes with a high price. With this study using Preactor and Plant Simulation, we want to give you an idea on the complexity of the problem and a good solution to keep the sequence in a production flow upright. After giving some insight into the problems encountered, we will show you how we used the ODBC Interface to pass vital information between Preactor and Plant Simulation. In the final part, we will show you how we used the scheduling information from Preactor calculated to reach higher granularity in our PULL controls between the different resources, restoring the production flow.
Presenter: Steffen Bangsow, steffen bangsow advanced simulation services
Steffen Bangsow has been working with material flow simulation since 1999. He already used previous versions of Plant Simulation, such as Simple++ and eM-Plant. Since 2002 Mr. Bangsow has been in the business of factory planning e.g. for automated production lines. In addition, he is the author of several books on Plant Simulation in German and in English. Mr. Bangsow works as an independent contractor for discrete event simulation projects as well as an instructor. He is teaching Plant Simulation basic, advanced and customized training classes. In his role as Plant Simulation mentor, he officially received the title of Plant Simulation black belt, leading the list of Plant Simulation related blogs with over 850 Kudos in the Plant Simulation forum.
As part of investment projects, MSF identified the need for in-depth simulation support in body shops. Although the system suppliers provided models, in direct comparison with data from the current plant it turned out, that they were completely useless for most questions during the operation. The main reason was the low detailing of the models. Because of this MSF decided to develop new in-depth models for the body shops. In order to meet the requirements of the production department, the new models had to be much more detailed. Basic elements of the models are now e.g. all robots and workers with their individual process steps (at the same level of detail as the cycle time diagrams). In addition, all conveyor elements must be included, which have a direct link to the robot programs and are controlled by them. Parallel to the modeling process, MSF started to develop "BIG DATA methods" to automatically acquire and provide important data from the real plant to the model (e.g. failure data and robot sub-process data). The presentation will show motivation, basic approaches and benefits from more than three years work with the digital twins.
Presenters: Heinz-Josef Lennartz, Magdi El-Awdan, Bernd Lehmann, Siemens AG, Germany
Mr. Lennartz was born in 1962. After school, he served 13 years in the German Airforce and finished college 1997. From this time, he works for Siemens in the Glass industry. Today he is responsible for the countries China, Brazil and USA in Head Quarter Glass Karlsruhe and in addition Global Account Manager for the Company Fuyao.
The presentation shows how to use Tecnomatix Plant Simulation in combination with cloud-based XHQ models, to tell the whole project story. The real 3D data is taken from OEMs to realize the Tecnomatix Plant Simulation models. The XHQ model has a connection via interface. A perfect synthesis between automation- and virtual world.
Presenter: Robert Van Til, Ph.D., Chair & Pawley Professor of Lean Studies; Industrial & Systems Engineering Dept., Oakland University
Robert Van Til is the Pawley Professor of Lean Studies and Chair of Oakland University's Industrial and Systems Engineering Department in Rochester, Michigan, USA. His educational and research interests focus on manufacturing systems, lean and PLM. His projects have been supported by the National Science Foundation as well as by companies such as Fiat Chrysler Automobiles, Ford Motor Co. and Siemens PLM Inc. He has served in visiting positions at universities in Hawaii, the Netherlands and Australia.
Oakland University’s Industrial and Systems Engineering Department is an academic partner of Siemens PLM, integrating several Tecnomatix tools, Teamcenter, SIMATIC IT and MindSphere into its curriculum. This presentation shows how Plant Simulation is used to provide Industry 4.0 education to students as well as to working engineers engaged in lifelong learning. Plant Simulation has been integrated into several courses, enhancing the educational experience by providing industry-relevant assignments. For students wanting to take a deeper-dive into Plant Simulation, the department has created a new course: PLM Applications - Throughput Simulation. It provides a combination of training/education by teaching Plan Simulation and using it to complete various assignments.
Presenter: Christian Lieb, Technical University of Munich (TUM)
Christian Lieb, studied mechanical engineering and management, majoring in control theory and logistics at the Technical University of Munich (TUM). In 2016, he joined the Chair of Materials Handling, Material Flow, Logistics (fml) at TUM as a researcher and teaching assistant. There he is responsible for the teaching of material flow simulation. His research focus is on the design and impact of dynamic production supply, which he is also doing his doctorate on.
The demand for flexible and dynamic production systems is continuously increasing. As a result, the requirements for internal production supply are also changing. In order to avoid bottlenecks even during peak loads, static supply concepts usually have to be oversized. Dynamic approaches, on the other hand, promise a stable and efficient system.
The internal transport in production supply can be divided into direct and collective transport. While direct transport, e. g. by means of forklifts, is already flexible, there are usually no suitable concepts for exploiting the advantages of collective transport in dynamic production systems.
The presentation will show various such concepts. Solving the vehicle routing problem under practical constraints is fundamental for each. In addition, the implementation of the internal production supply in Plant Simulation, as well as the evaluation of the control approaches, are presented.
Presenter: Carsten Eckert, HPC Hamburg Port Consulting GmbH
Carsten Eckert holds a diploma in naval architecture and ocean engineering and has started his career in simulation at Flensburger Shipyard where he worked on the development of simulation models for cargo handling operations on RoRo terminals. He joined HPC in 2015 and is now responsible for the ongoing development of HPC’s in-house simulation toolbox HPCsim. During recent years, Carsten has worked on numerous simulation projects for clients all over the world dealing with all kinds of marine and intermodal terminals.
Ports are the backbone of international logistics. Insufficient port resources, such as tugboats, pilots and berths, but also spatial limits of the port’s approach channel regularly lead to unwanted waiting times for vessels. Simulation can be used to analyze the vessel traffic in ports and to assess improvement options. Next to equipment numbers (tugs, pilots…) also the impact of adaptations of port traffic regulations and deepening of waterways can be evaluated.
Based on HPC’s existing simulation toolbox, HPCsim, a marine traffic simulation module has been developed. All kinds of ports, different vessel types and complex port regulations can be modelled. The toolbox also includes weather and tidal conditions.
In the presentation, the underlying concepts and challenges during use of the simulation models as well as representative results of some of HPC’s previous projects will be presented.
Presenter: Michael Goerges, BLG Logistics Group AG & Co. KG
Michael Görges, studied industrial engineering with a specialization in logistics at the University of Bremen. In 2013 he joined BLG LOGISTICS GROUP AG & Co. KG. where he works as R&D project manager focusing on data analysis and simulation topics. In this context, he develops solutions in the fields of offshore wind logistics, seaports and general logistics. Moreover, he led the standardization working group “logistics” which developed the ISO 29404 as a subcommittee of DIN Standards Committee Shipbuilding and Marine Technology. Currently, Michael Görges leads the collaborative research project “Isabella”, which is funded by Federal Ministry of Transport and Digital Infrastructure.
Logistic processes in sea and inland ports play an important role for finished vehicle logistics. Highly flexible and efficient processes are required to cope with short-term change demands. Due to these volatile conditions, planning logistics processes for an automobile seaport terminal is a challenging task on different time scales (i.e. short-term, mid-term and long-term). In this context, the collaborative research project “Isabella,” which is funded by Federal Ministry of Transport and Digital Infrastructure, addresses these challenges by combining a multi-touch table environment with logistics simulations.
Presenter: Ali Ahmad Malik, Mads Clausen Institute, University of Southern Denmark
Ali holds a diploma in mechanical engineering, a bachelor in industrial engineering and a master in innovation and business with a focus on production technology. Ali started his career as a design engineer in gearbox manufacturing company in Pakistan and later joined Danish company Danfoss. Ali joined LINAK, Denmark, in 2017 and is part of the technology development team working on human-centred flexible assembly systems. Ali is writing his Ph.D. thesis at the Mads Clausen Institute of the University of Southern Denmark. In his research work, he is working with collaborative robots and is developing simulation models for performance evaluation of human-robot collaborative assembly cells.
The dream combination of humans and machines working together is now being realized through collaborative robots or cobots. The right amount of automation can be attained through a balanced interaction of humans and robots where each is doing what it is best at. Nevertheless, the current application of cobots in dexterous assembly work is limited. The challenges are the need of reconfigurability and adaptability to production changes. This study explores human-robot collaborative assembly systems for reconfigurability through modularization. Modular assembly cells are developed with collaborative robots, flexible feeding systems and various form of human-robot interactions leading to productivity variations. The design data is developed using Siemens NX, and Process Simulate is used for process verification and cycle time calculations. The need of having a stochastic simulation model becomes necessary to optimize various possible assembly cell configurations, productivity analysis, and bottlenecks depiction. The varying robot speeds due to variation in the interaction levels with humans are evaluated through the simulation model.
Presenter: Mr. Sebastian Schuesslbauer, Siemens AG
Sebastian Schüßlbauer (M.Sc.) studied Applied Research in Engineering Sciences at the Technical University of Applied Sciences in Nürnberg. He was continuously involved in different simulation topics and tools during his academic education. In 2017 he joined Siemens AG Factory Automation and he is now part of the team for the solution management for virtual commissioning with the Siemens software portfolio. His focus is on the connection of simulation model, mainly Plant Simulation, and automation code for validation of the logic before deployment for the purpose of virtual commissioning. Additionally, he is also involved in innovation topics in regards of digitalization for industry.
The chemical & process industry is driven by the market needs of commercial and domestic consumers. Equipment manufacturers need to be able to supply highly reliable customized equipment that can keep up with the ever-changing demands. Processes, like mixing liquids and filling containers, are typical in the food and beverage (F&B) branch but can also be found in chemical or pharma industries among others. In Tecnomatix Plant Simulation the simulation of the discrete and also the process part is possible in regards to the material flow. But if more detailed information about the processes are required, it is possible to couple a multi-physics simulation by Simcenter Amesim for a co-simulation. This enables the detailed sizing of the sub-systems and a better understanding of the production. The introduced setup is also used for the virtual commission by connecting PLCSIM Advanced to test the automation code before deployment. Plus the Simcenter Amesim model can be used as a digital shadow next to the real machine running on SIMATIC Edge in the SIMATIC LiveTwin app for additional value.
Presenter: Auke Nieuwenhuis, cards PLM Solutions B.V.
Auke has over 12 years of experience in the field of digital manufacturing. During his career he gained firm experience in the field of CPG, automotive and process industry. After completing his master’s in industrial engineering, Auke started as junior Plant Simulation Consultant at cards PLM Software. Over the years he has gained massive experience in Discrete Event Simulation / Process Simulation. Within his role as Business Development Consultant, Auke is advising his customers in the discrete and continuous industry by designing, validating and optimizing material handling systems, assembly, warehousing, automation and virtual commissioning.
Testing and optimizing of operations systems such as Warehouse Management Systems (WMS) is a complex task. For a fully-integrated test, all hardware must be in operation. With big systems such as Automated Storage and Retrieval systems (ASRS), this is a timeconsuming job, it makes the whole commissioning time complex and long. By connecting a simulation model to the development of the WMS system, hardware and software development of different layers in the operation can be done simultaneously. Time for real-life testing will be reduced dramatically and issues are found in an early stage when the software is tested on the virtual twin of the ASRS operation.
Presenter: Dr. Thomas Stoffel, Siemens AG
Thomas Stoffel joined the Siemens AG in 2008. He studied electrical engineering and received Dr.-Ing. (PhD) in Transportation and Applied Mechanics from TECHNISCHE UNIVERSITÄT Berlin in 1996. In his doctoral thesis, he investigated structural dynamics of magnetic levitation trains. In addition, he worked on the control and transient behaviour of nonlinear dynamic systems. Later on, he worked in IT management for putting into operation ITIL-based organisations. In his next position at Siemens AG, he was responsible for an SAP rollout of quality management and subsequent SAP data analysis. Currently, he is in charge of digital factory optimization using Plant Simulation in various production areas of the Gas Turbine Burner Plant in Berlin.
This presentation shows the first practical results of using Plant Simulation for optimized workers allocation and workstation usage in the Gas Turbine Burner production at the Siemens plant in Berlin. It covers the domains parts, routing, workstations, human resources and client (load plan). With its capabilities especially in human resources management it shows strong improvements of worker productivity.
Presenter: Steffen Bangsow, steffen bangsow advanced simulation services
Steffen Bangsow has been working with material flow simulation since 1999. He already used previous versions of Plant Simulation, such as Simple++ and eM-Plant. Since 2002 Mr. Bangsow has been in the business of factory planning e.g. for automated production lines. In addition, he is the author of several books on Plant Simulation in German and in English. Mr. Bangsow works as an independent contractor for discrete event simulation projects as well as an instructor. He is teaching Plant Simulation basic, advanced and customized training classes. In his role as Plant Simulation mentor, he officially received the title of Plant Simulation black belt, leading the list of Plant Simulation related blogs with over 900 Kudos in the Plant Simulation forum.
In order to model the impact of the workers on the throughput of a body shop line, both robots and workers have to be modeled in detail with their processes. The presentation shows several approaches to do this.
Presenter: Lars-Boris Böttcher, SSI SCHÄFER
Since 6 years Lars-Boris Böttcher is responsible for the simulation and data analysis department of the SSI Schäfer Automation Group. His team is conducting simulation studies for all market sectors worldwide, evaluating and optimizing concepts in the field of intralogistics. Before he worked another 6 years as a consultant and technical sales manager in the field of simulation and emulation. During his studies of computer science, he already focused on simulation, writing his master thesis about the simulation of supply chains at Volkswagen AG in 2008.
Following a constant growth over the few last decades, simulation in intralogistics has experienced a surge within the last 3 years. This is due to increasing size and complexity of systems and smarter solutions. Current discussions about AI and Digital Twin are amplifying this effect.
Observing the market, different tools are competing in 3D animation, offering high-quality 3D visualizations. Therefore, SSI Schäfer was using 2D simulation in addition to 3D animations. This changed due to the improved 3D capabilities of Plant Simulation software. SSI Schäfer is constantly expanding its 3D modeling, meanwhile running the largest and most complex studies with >250,000 simultaneously moving items in 3D.
This talk is to share experiences, limitations, concepts, quick wins and motivations in large scale 3D models. It will show examples of large intralogistics simulation models naming run-times, pitfalls and lessons learned.
Presenter: Thomas Neuhaeuser, Fraunhofer IGCV
Thomas Neuhaeuser, studied industrial engineering and management (M. Sc.) at the Technical University of Kaiserslautern and the University of Copenhagen. In 2018, he joined the Fraunhofer Research Institution for Casting, Composite and Processing Technology (IGCV) where he is working as a researcher and consultant in the department of factory planning and evaluation. His research focus is in the field of data analytics in the production environment and factory layout optimization with Building Information Modeling, where he is also writing his doctoral thesis.
In the department of factory planning and evaluation at Fraunhofer ICGV, Plant Simulation is one of the basic tools to visualize, analyze and optimize value streams. The individual configurability allows our factory planners to develop new libraries of process modules, add-ons to calculate certain key performance indicators and visualizations for industrial partners. Due to the deep knowledge of CFK processes, the researchers of the Fraunhofer IGCV build highly sophisticated CFK process modules, which lead to realistic CFK value chains, what-if scenarios and performance evaluations within minutes. This knowledge is not only used in the CFK industry, the simulative verification is a key component in almost every project in each industry and the knowhow is also transferred in different seminars and workshops at the Fraunhofer IGCV.
Presenter: Thomas Kienzl, CEO, edddison technologies OG Austria
Thomas Kienzl is an architect and designer by profession and obtained a master’s degree from „Technische Universität“ (TU) in Graz, Austria“ and „Det kongelige Danske Kunstakademi“ in Copenhagen, Denmark. He is the founder of edddison technology, developing the interactive software add-on for Plant Simulation, and the agency, Kommerz (now called 3D Schmiede), specializing in producing 3D Visualization for the AEC and design industry.
edddison is an add-on for Tecnomatix Plant Simulation. It enables non-technical people to navigate and interact with a 3D model and use the key features of Plant Simulation. The simplicity of the solution allows you to involve customers, managers and colleagues in the planning and design process. Made for people who want to plan and present better with Tecnomatix Plant Simulation.
For 25 years the companies have accomplished a lot. They have implemented quite a number of impressive customer projects won prestigious awards and presented at globally-renowned trade shows. With his team, he has been working successfully for several well-known companies such as: Nokia, Red Bull, City of Vienna, Graz, Istanbul, Daimler, Egger Wood, Magna, ÖBB, Permasteelisa, Tesla, EDF and others.
Presenter: Eduard Kinas, CEO, more3D GmbH & Co. KG
Eduard Kinas, born in 1974, has nearly 15 years of experience with VR. He joined the first steps of VR and took an important part in the evolution of VR hardware when he started working for more3D in its first steps on the market. In addition to that, he supervised the development of VR software, nowadays as managing director of more 3D. MoreViz is one of the notable results of his work with more 3D.
more3D presents on the 2019 Plant Simulation User Conference the pioneering moreViz software. After a short outline of the history of virtual reality (VR), a detailed picture of the profit of VR in connection with Plant Simulation will be drawn. An interactive demonstration of the VR bridge moreViz is the complement of the presentation.
Presenter: Stauber, Forstner, SimPlan AG
Value stream simulation is used to assist value stream analysis and design. The workshop provides a first introduction to the app-based Value Stream Simulation Solution “SimVSM” which also uses the Plant Simulation “Value Stream Mapping” library. The participants will get an insight into the developed cloud base service concept and the automatic model generation based on XML Structures. Modelling a value stream, performing various simulation runs and comparing the KPI results will complete the workshop.
Presenter: Dr. Matthew Gilbert, MTC Limited, UK
The MTC has developed a set of standard functionalities as a custom Class Library that has been used to complement the existing functionality offered in Siemens Plant Simulation. The use of this custom Class Library will be demonstrated using live models. Example functionalities include automatic inheritance verification, management of custom utilization states, enhanced multi-skilled worker allocations and a data-driven automatic model build mode.
Presenter: Dirk Wortmann, SimPlan AG
Dirk Wortmann, born in 1967, finished his studies in computer science at the GKS Bad Homburg in 1988. He started his professional career in a Frankfurt engineering office and was involved in the development of simulation software and the implementation of simulation projects in the field of production and logistics. In 1992 he founded the company SimPlan together with his partner Sven Spieckermann. From the founding until 2013 he had been a member of the board. From 2010 to 2018, he set up and developed SimPlan’s Chinese subsidiary in Shanghai.
The EU research project “Optimised” was started in 2015 and finished in 2018. “Optimised” stands for Operational Planning Tool Interfacing Manufacturing Integrated Simulations with Empirical Data. The primary objective was the development and pilot implementation of a manufacturing scheduling optimisation system, which uses smart sensors and big data analytics to monitor, react to and improve manufacturing performance. Three demonstrators of different industries and application focuses were developed:
Demo 1: Alstom’s train fleet management for Virgin´s Westcoast Line in the UK
Demo 2: Production order scheduling for a large machining parts production at Goimek in Spain
Demo 3: Planning and optimisation of building components manufacturing at Laing O´Rourke (LOR) in UK