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Table of Contents
layouts
3
Airport Baggage Handling
3
High Volume Consumer Goods (HVCG)
4
Packing Line
5
Pallet-based Electronics Assembly
6
Palletizing Line
7
Paper Conversion
8
Enterprise Logistics
9
Plant Simulation. 10
Job Shop11
Standard Component Library
12
Manufacturing Components
13
Common Parameters13
Buffer13
Bundler13
Component Creator14
Component Sink14
Conveyor14
Conveyor Bend15
Conveyor Crossing X15
Conveyor Crossing Y15
Conveyor Merging X16
Conveyor Merging Y16
Conveyor Rotate16
Conveyor Vertical16
Dynamic Component (Part)17
Lifter17
Process Point17
Robot Palletizing17
Shuttle18
Wrapper18
Cartesian and Palletizing Robots18
Process Components
19
Process Component (order)19
Process Component Warehouse19
Process Order Creator19
Process Statistics
20
Process Workstation
20
Map of Finland
21
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airport BAGGage handling
1
2
4
3
5
This solution simulates aN airport Baggage Handling System where
Passenger luggage is transferred from the check-in desks to the
correct dispatch areas.
.
2.
3.
4.
5.
6.
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holders.
Creator components generate bags of d��������������������������������������
ifferent sizes, intervals, and colors.
Three Conveyor_Merging_x components combine the component flow into a single
conveyor.
Vertical bends change the height level of the conveyor line.
Five Conveyor_Crossing components divert the component flow to different output
conveyors. Routing
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is based on the bag color, so that all the bags of one color will be
diverted to the same output conveyor.
Five outfeed conveyors bring the bags to their pick up point for loading to the trolleys at
air-side.
The Show Statistics tool can be used to check the baggage flow for each conveyor.
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High Volume consumer goods Line (HVCG)
5
6
3
4
7
2
1
This layout exemplifies a typical high volume - high speed conveyor
solution found in many food and dairy production applications.
.
2.
3.
4.
5.
6.
7.
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Six ComponentCreator components feed components into the system with constant speed. Color
is used to identify products from different infeeds.
All components are combined into a single main conveyor using the Conveyor_Merging
component.
Based on product color the flow is diverted into two lines using the Conveyor_Crossing
component.
The Bundler collects incoming products into larger delivery units.
The bundled goods flow on a single conveyor.
A Shuttle is used to move components horizontally to the delivery area.
The Wrapper component wraps the bundled goods with a plastic film.
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Packing LINE
1
2
3
4
5
9
8
7
6
The Packing Line uses multiple product bundlers to collect goods into
a final delivery package.
.
2.
3.
4.
5.
6.
7.
8.
9.
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A ComponentCreator feeds product into the packing line.
The Bundler component accumulates products into a bigger package.
A Conveyor_rotate module is used to re-orient the products.
An additional product accumulation stage.
An a additonal product orientation stage.
The Shuttle moves goods horizontally to another line.
A Buffer is used to store items if the downstream route is blocked for any reason.
A Single Conveyor_Crossing module delivers products evenly to one of three workstations.
The workstations have an assigned process time to represent any type of process such as an
inspection or manual operation.
A Gantry robot stacks bundled product into a delivery sized stack.
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standard component library | manual
Pallet-based Electronics Assembly
6
5
4
3
2
1
7
THIS Layout Demonstrates a pallet based electronics production
assembly system. the Product
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sits on a pallet throughout the assembly
process and when finished the pallets return to the start of the system
on a lower track.
.
2.
3.
4.
5.
6.
7.
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New pallets are created with a single ComponentCreator component. The pallets are
transferred onto the conveyor loop with a Conveyor_Merging component.
In this layout the first workstation handles every second product and changes the product colour
on completion of its task.
Parts that have not yet been processed at the first workstation are identified by their color and
diverted to the second workstation area for processing.
The Workstation placed before the buffer (5) has been assigned time-to-failure “������
MTBF”�����������
and
����������
timeto-repair “������
MTTR”���������
values.
��������
The Buffer stores components if there is no room in the downstream workstation/conveyor. If
���
the workstation in front of the Buffer fails, the buffered products will feed into the line to avoid
interrupting production for as long as possible.
The Workstation after the buffer also has MTBF and MTTR values assigned.
The Lower track and two end Lifters complete the pallet handling system.
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Palletizing line
1
3
2
4
Two in-feed conveyor lines with accumulators feed bundled products
to a palletizing robot. The Bundles are placed on a Pallet which passes
through a pallet wrapping machine.
.
2.
3.
4.
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Two ComponentCreators feed product onto the lines at constant intervals.
Bundlers accumulate incoming products into larger packs.
The Palletizing robot creates new pallet stacks.
The Wrapper module completes the palletizing process.
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Paper converSION
7
6
3
5
4
2
1
A High
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volume PAper
��������������������������������������������������
tissue roll Packaging line that accumulates
individual rolls into a large distribution pack.
.
2.
3.
4.
5.
6.
7.
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Four ComponentCreator modules feed products into the line at a constant rate.
Elevation sections move the product flow upwards.
All tissue rolls are combined to a single highway with the Conveyor_Merging component.
Rolls are manipulated and bundled several times in order to create the correct pack size for
retail stores and consumer delivery.
A tunnel section for vehicle and plant access (e.g. forklifts) is created by combining a
elevated section with a lifter component.
Bundles are packaged into delivery sized packs and wrapped with plastic film.
A Sink component collects statistics at the end of the line.
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Enterprise Logistics
1
2
3
4
The Enterprise Logistics layout demonstrates A process/order
flow through 3 refineries, 3 factories and 1 terminal.
.
2.
3.
4.
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Order Schedule and Reporting components generate the orders and collect information
from the finished orders.
The order starts in one of the refineries as defined by the first stage process in the
order’s route property.
The order proceeds to the next factory as per its routing property.
After completing all processing stages the order arrives at the distribution terminal (in
Helsinki) where the results of the simulation can be viewed. The
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red path an example
route.
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Plant simulation
3
1
2
This layout represents schematically
�������������������������������������
several
�����������������������
Production and
packaging lines. The orders flow through the different lines
depending on the routing stages defined in the order schedule.
.
2.
3.
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Order Schedule and Reporting components generate the orders and collect information
from the finished orders.�
The production starts when an order arrives at the beginning of the production line queue.
Order´s flow from one line to another until the route is complete. The red arrows is an
example route.
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job shop
5
4
1
3
2
The JOB shop queues product Batches at different Machine and process
centers based on an order schedule with a defined routing for each
batch.
.
2.
3.
4.
5.
The Order Schedule and Reporting components generate orders and collect information from
the finished orders. �
The Process component warehouse contains information of available raw resources that will
be needed for some process to start and also includes the replenishment times when outages
ocurr.
The Cutter module has an “MTBF”�����������������������������������������������������������
������� failure
����������������������������������������������������������
mode defined and also input material requirements
that must be met before the process can start. The process will stop if there is a failure or
shortage of input resources.
The Drills are not defined with a failure mode or any resource requirements.
The Lathe modules
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have “MTBF” failure
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modes defined as well as input material requirements
that must be met before the process can start�.
The orange and red routes are example routes an order may take through the job shop. On
completion of the simulation the statistics of the production run can be viewed using the reporting
component(1)
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Standard Component Library
The Standard Component Library is a set of highly-customizable simulation components that
can be used to create a wide variety of production system layouts including all the example
layouts in the preceeding chapter - without programming. They are intended for fast layout
development and as a template for the development of new component models.
Manufacturing Simulation Components
Additonal manufacturing components:
Process Simulation Components
Additonal process simulation components:
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Manufacturing Components
Common parameters
Following are several parameters commonly
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found in
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the equiment library.
Structure weight
The structure weight is a geometrical feature that allows the material handling components to vary
fro a light weight to a heavy construction. The following examples show the effect of varying the
Structure Weight parameter for the values of 1, 1.5 and 2.
Structure Weight = 1
Structure Weight = 1.5
Structure Weight = 2
Size and Speed
The size of the component is defined in most cases by Length, Width and Height.
The speed is a quantity, typically in mm/s. In the case of the
Buffer and Bundler
the size is also dependent on the quantity and size of the products in storage.
Buffer
The Buffer component is used to queue parts at a specific location. It
contains several parameters and behaviours to fit with a large variety
of applciations.
The Buffer has two storage modes - First in, first out (FIFO) and Last
in, first out (LIFO). The storage columns, rows and levels define the
storage capacity of the buffer.
The Buffer creates a matrix to store the incoming parts based on
Product dimensions.
Bundler
The Bundler component is used to group product into a larger package
for handling.
The Bundler acts as a buffer for products until it’s full. The capacity is
defined by the Storage columns, rows and levels.
When full the Bundler creates a new component equivalent in size to
the bundled products and releases the new product bundle to the next
operation.
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Component Creator
The Component Creator dynamically loads “part” components
into the 3DWorld. Several parameters control its behavior.
The color is defined by the material list. The size is defined by
the dimension parameters.
The Interval defines the time taken before another part is created
and the Creator Limit sets the total amount of parts generated.
Component Sink
The Component Sink is a component used to receive parts at the
end of a simulation and is used for completing the information
needed for statisitical reports.
Typical data collected includes part and order throughput times.
The product
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size
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defines the size of the Component Sink.
Conveyor
The Conveyor component is used for transportation. It is highly
parametric, and can be configured to a variety of forms. All the
example layouts in this manual use this conveyor component.
The Length, Width and Height control the size of the conveyor
component. The speed and capacity control the part flow
through the conveyor.
The most important visual parameters are the Conveyor Type,
the Structure Weight, and the Amount of Feet. Below are some
examples.
Length = 2000
Legs = 3
Radius = 20.00
Length = 1000
Type = Roll
Type = Belt
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Width = 1000
Weight = 1.5
Type = Chain
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Conveyor Bend
The Conveyor Bend has the same functionality as the straight
conveyor.
The amount of bend is defined with the parameters
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for
Conveyor Angle and Conveyor Radius.
Conveyor Angle values can range from 1° to 360°. A left hand
bend can be made by un-checking the TurnRight option.
Bend = 35°
Bend = 35°
Turn Left
Type = Belt
Conveyor Crossing X
The Conveyor Crossing X is used to divert or divide the flow of
components into three lanes.
The Radius of the bend cannot be directly controlled - it only
provides a 90° bend.
The Routing of the Conveyor Crossing is defined by the Route
parameters. If the rules are defined as depicted in the parameter
tab panel, the Conveyor Crossing will divert one product to
each lane, starting from the center, then to the left and then to
the right.
If the rules are defined by Color, the same pattern will be
followed.
Conveyor Crossing Y
The Conveyor Crossing Y is used to divert or divide the flow of
components into two lanes.
The Conveyor Crossing Y functions in the same way as the
Crossing X.
The bend can be defined with Turn Right checkbox.
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Conveyor Merging X
The Conveyor Merging X is used to merge the flow of
components from three lanes into one.
The Route rules are automatic, and cannot be directly affected.
If components are at all entry points, it will cycle through each
input to infeed the parts.
Conveyor Merging Y
The Conveyor Merging Y is used to merge the flow of
components from two lanes into one.
The bend can be changed with the Turn Right check box. The
Routing rules work the same way as with the Conveyor Merging
X, taking a part from each input alternately.
Conveyor Rotate
The Conveyor Rotate component is used to orientate a single
component or a bundle of components to suit the transportation
mode.
The Rotate function replaces the input component with a new
output component in a new orientation.
The Rotate paramater can be defined for all three axis ranging
from -90°, 90° and 180°.
It is recommended that you use the same size of the output
component as the input.
Conveyor Vertical
The Conveyor Vertical is used to raise and drop the material flow
level.
The bend of the conveyor can be controlled with the Conveyor
Angle, Radius and Turn Down checkbox. For a better visual effect
use two conveyors in the form of an S-curve.
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Note that the Turn Down checkbox cannot be modified once the
conveyor has been connected to another.
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Dynamic Component (Part)
The Dynamic Component is the “part” loaded by the Component Creator into the 3D
Environment. The parameters of this part are changed by all the other components, and there are
no direct interaction parameters.
Lifter
The Lifter component has the capacity to receive and to feed
components from 4 distinct ports. Two of the ports are found at the
bottom, and two at the top of the lift.
The height of the lift is defined by the Lift Height, and this defines
the position of the higher entry/exit ports.
If a component arrives at any of these ports,
the lifter will behave according to the rules set
in the Route tab page. By default, it will first
check the capacity of Port 1, then 2, 3 and 4.
It won’t use ports that are not connected to a
conveyor.
Process Point
The Process Point component is used to simulate any time taking
part process. The processing point defines where the parts stop
and for how long.
The Process Point parameters behave the same way as a normal
conveyor and the Size, Length, Width, Weight parameters can
all be changed on the parameter tab page.
The process capabilities are modified by the Function Parameters.
Here you can modify the Process Time, which is the time a part
stops at the Process Point. The Variation defines the random stoptime variation from part to part. MTBF (Mean Time Before Failure)
defines the time the Process Point works without breaking down.
MTTR (Mean Time To Repair) defines the time it will take for the
Process Point to start working again. The Change Color and
Product Color options control the part color after the operation
is completed and this is used in decision logics of downstream
processes.
Robot Palletizing
The Robot Palletizing component serves as the base for the two
palletizing robots - the Palletizing Robot and the Cartesion Robot.
It has handling logics for these robots, and generates the robot
tasks on the fly based on inputs from the system.
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It contains three Input ports and one Output. The Output port
behaves as a normal conveyor and buffer. The buffer size is
defined by the Storage Columns, Rows and Levels. The Product
Length, Width and Height define the final product or bundle size.
The circular base represents the working area of the robot.
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Shuttle
The Shuttle component is used to change the component flow
from one lane to another. It behaves in the exactly same way as
the Lifter component, except that the movement of the parts is
horizontal.
The Shuttle size is modified the same way as the conveyor. The
only differences are the Track Length, which defines the distance
the shuttle will travel and the Shuttle Speed, which defines the
speed at which the shuttle will move.
The Shuttle component has four ports, which can be either input
or output, and will follow the routing rules defined in the Route tab
page. Only ports with connections are used.
Wrapper
The Wrapper component is used to simulate a pallet wrapping
station.
The Wrapper makes three full rotations before releasing the
component onwards. The time the rotations take is a function of
the Process Time parameter.
The size of the final component and the color are defined by the
Product Length, Width, Height and Product Color.
Cartesian and Palletizing Robot
The Caterisan and Palletizing robots are full robot components with links, joints and kinematic
structures. Both of these robots are commanded by the Robot Palletizing base, but they can be
used by themselves in other tasks in connection with the robot teach page.
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Process Components
Process Component (order)
The Process Component or Order is a simple dynamic component used to represent orders in
abstract process simulation layouts.
It contains several parameters such as Product Count, Route, Order Start time, Deadline and
Priority, as well as the order’s time scale (Seconds, Hours, Days).
This component and its parameters are not accessed directly, but are modified through the
process simulation components.
Process Component Warehouse
The Process Component Warehouse holds stock materials
required for different processes. In the warehouse you can define
the capacity and the replenishment times for exhausted stocks to
be replaced.
By default, it stores ten different components, but more can be
easily added using 3DCreate’s Create page functionality.
Process Order Creator
The Process Order Creator defines the simulation
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layout’s orders.
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It sets the Route, Priority, Volume and Deadline for the products.
There are two ways of introducing orders. One is by modifying
the parameters according to your needs, and then pressing
Create Order. Then you can change parameters for a second
order, and press Create Order once more. The list of orders is
saved in the layout. This list can be accessed through the Orders
tab page found in the parameters of the component. This list can
be modified directly, following the same sequence of details as in
the general parameter page.
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Process Statistics
The Process Statistics component collects all process related
statistics produced from a simulation run.
Information is only gathered for components with the statistical
behaviors that were added during the Create process. All the
standard equipment components have this behaviour built-in
The following Statistics window appears once you have pressed the Order Statistics button and it
disappears automatically if you select any other program or window.
Process Workstation
The Process Workstation component simulates invidual
processing points or complete process steps in the production.
Orders are moved automatically from one workstation to another
based on defined routing and no connections are needed
between components. Each workstation processes one order at
a time while waiting in queue. After the process is complete, the
order is moved to the next workstation, if the next workstation
is busy it is queued. Orders with highest priority (lower Priorityvalue) are processed from the queue first.
Drill
The Workstation’s general statistics parameters can be accessed from Tools > Show Statistics.
The Model parameter is used to change the appearance of the process workstation. It has five
modes - Drill, Cutter, Lathe, Factory and Production Line. The Scale is used to define the time
scale of the process.
Cutter
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Lathe
Factory
Production Line
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The Process Name is used to define the route the orders will pass through the system. The route is
defined in the Order Creator component.
The Process Time is the cycle time for a single product. The total process time for the order is the
Process Workstation´s Process Time multiplied by the Order´s Order Product Count paramter. The
format is HH::MM::SS.
The Buffer Capacity defines how many orders can be in the queue. MTBF (Mean Time Before
Failure) defines how often the process stops for any reason such as an error, maintenance,
material replenishment. This value in randomized at the start of the simulation and is repeated
with a 10% random variation. MTTR (Mean Time To Repair) defines how long it will take for a
process to resume production after a failure.
Map of Finland
An example component with the map of Finland. The only
parameter that can be changed is the scale, which makes it bigger
or smaller. It accepts integers as input.
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