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CAD Facilities Layouts can become enterprise decision making tools

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説明

You have embarked down the Integrated Facilities Model path - getting your facility into 3D to better communicate and lower risk as well as reduce installation costs - but what else can we do? By using the Factory Design Utilities and ProModel's AutoCAD Edition, we can add another layer of power - the ability to measure and predict throughput capabilities right in your layout model, while reducing operational cost. See how applying these methodologies and workflows can help your organization make better decisions faster in regards to manufacturing processes. See how your process will perform based on your criteria - and get solid, actionable data to reduce risk and maximize profits.

主な学習内容

  • Understand the benefits of discrete event simulation for manufacturing and AEC customers.
  • Understand how discrete event simulation and space planning are tied together.
  • Be able to provide strong metrics to support a business case
  • Provide both 2D and 3D animated process models utilizing AutoCAD, Inventor and Forge - with one button click.

スピーカー

  • MICHAEL jolicoeur さんのアバター
    MICHAEL jolicoeur
    I have been an agent of change in manufacturing process for over 25 years - utilizing technology to improve manufacturing customer's processes - helping make them more competitive and more profitable. I worked at Autodesk for over 22 years and specialized in manufacturing workflows - including expertise in Inventor, AutoCAD, and in particular the Factory Design Utilities.
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      Transcript

      MIKE JOLICOEUR: Hello, everyone, and welcome to CAD Facilities Layouts Can Be Enterprise Decision Making Tools. This will allow you to supercharge the CAD layouts and the work that you've already done and also all of your work that's going forward. My name is Mike Jolicoeur. I'm the director of the Autodesk Relationship at ProModel, which is a division of Bigbear.ai.

      So in the next 60 minutes, just want to make sure that everybody is in the right class. The class ID is IM502936 and we're going to be covering the following. So our goal is to make sure that everybody is getting what they want out of this.

      It's to see how an ROI can be developed from data gathered from a simulation. We also want to understand how discrete event simulation and space planning are tied together. We need to be able to provide strong metrics to support a business case, and also provide both 2D and 3D animated process models utilizing AutoCAD, Inventor, and Forge with one button click.

      So let's go ahead and get started. Discrete Event Simulation is not anything new. It's a valuable tool for validation, but again, it's really nothing new. It's been around in one form or another since Henry Ford rolled the Model Ts off the line.

      In fact, ProModel has been delivering PC-based simulation solutions for over 30 years to thousands of customers worldwide, and those are the customers large and small, job shops to volume production companies. So we pretty much support everyone.

      So Discrete Event Simulation inside of AutoCAD is new, though. So the ProModel consulting team will tell you that over 90% of the projects that they deliver started with an AutoCAD layout. A lot of effort had to be expended to utilize the drawing in the ProModel environment.

      And just for a frame of reference, any other discrete event simulation tool out there has the same issue. For that reason, ProModel and Autodesk teamed up to provide an easy-to-use, efficient toolset that runs inside of the AutoCAD you use today for layout.

      This new toolset helps build the foundation of the integrated factory model that is much more than a drawing that represents space claim. The CAD model now becomes a powerful enterprise decision-making tool.

      So employing the entire workflow across the entire team has many benefits, but we'll highlight just three of these in the presentation. Utilizing the Autodesk Factory Design utilities within the Autodesk Product Design and Manufacturing series allows users to rapidly create both 2D and 3D representations of their ideas.

      ProModel's AutoCAD edition allows the ability to add yet another layer of benefit, the ability to validate if your design will meet your production needs at the lowest cost. Combined, this toolset is very easy to learn and provides more value to your current AutoCAD layout workflow.

      So there are many factors to consider when planning. One of them is variability in processes. Reality is, what you think is the case many times isn't. Better, more reliable data is the key to success, and spreadsheets simply can't provide this. They have no understanding of variability or the concept of time.

      So let's face it, manufacturing processes are complex. There are many factors to consider when planning, and sometimes it can be as simple as adding more buffer into the system in key areas to reduce process sensitivity, or as complex as validating if adding automation to a line will not only solve the issues but pay for itself in a short period of time. Again, better, more reliable data is one of the keys to success.

      The tools in the factory design utilities excel in helping customers avoid excessive cost and risk in changeover. That is, making sure everything will physically fit into the space allotted, and that the equipment interfaces physically with other equipment as well. This helps avoid change orders on installation, which can drive project costs up substantially.

      What it does not allow for is planners to see how this plan change will affect the cost of the products being manufactured, or the ability to confirm that the design will meet the required throughput to meet their demand, both currently and in the future.

      That's where ProModel comes in. We allow those that plan change, be it for new products, process improvement, or automation, or bringing acquired companies into the new corporate fold to fully understand if the process that is being designed will meet the production needs and be cost-effective, either lowering the cost of manufacturing or allowing more manufacturing agility.

      The combination of these toolsets allow customers to build out facilities and build out a facility's digital twin that can be used over and over again to test ideas before committing any capital or hiring any people. So the Autodesk ProModel solution reduces cost and risk, not only for installation of the new process, but operational risks for producing the product throughout its lifecycle.

      So here's a brief overview of the user interface. Straightforward, easy-to-navigate interface makes the tool easy for new users to master quickly and experienced users to be able to apply macros, logic, and other advanced tools easily to further refine their simulation outcomes.

      And a tab is added to the AutoCAD ribbon. It contains all of the command structure necessary to create a simulation in ProModel inside of the AutoCAD environment. We also have browser panels that provide detailed information and interactive feedback in regards to the simulation being studied.

      So let's have a quick demonstration in a simple build of the model. The goal here is to show how easy it is to start using this tool and how easy it is to learn. So what we usually tell people is, like all things, you want to crawl, then walk, then run. So we're start off very simply in an existing AutoCAD drawing that has very simplified shape.

      So in this demonstration, we're going to show how easy it is to streamline your layout process and ensure design confidence in a manufacturing process design. So we have a representation of a proposed new manufacturing area in AutoCAD. So AutoCAD blocks are here to represent a basic footprint of some CNC and washing equipment we require to manufacture our new part.

      So the ProModel interface consists of a tab on the ribbon bar, then panels that act in the browser for the manufacturing process. We'll add our locations by simply picking the blocks. The ProModel now understands where the stations are and where the processes will occur.

      So we're also going to add an entity. So in this case, it's going to be a part or an assembly that we would like to be processing through the system. We can handle multiple products through here, but for this demonstration, we'll show it with just one part.

      We can add initial costing to that part. And because this is in AutoCAD, we can provide a size envelope for a part as well as a basic shape. So once we have this, we have these two process elements. We can now start designing the flow of the part through the system.

      So we'll zoom in a little closer to see clearly where we're working here, and let's go ahead and add those flows. So I'm going to select from the tab here and say simply to Add that flow. So now we're going to simply select in the order that we want from the part that's going to flow through the system.

      So once we've selected those, we're going to go from the machine to the washer to the other machine over here, and then to the other parts washer, and then exit the system. So we'll just keep it very simple. So right now, we don't really know what those machines are just yet, but we just want to know that this is basically the flow that we're going to be following. So in a matter of a few seconds, we now have enough information to do a very simple flow if we needed to.

      In this case, though, the process engineer, the industrial engineer supplied us with some information. He knows what machines he wants to use and also he has some times that are in there. Now he's got these put in as just regular numbers, but we can also build distributions from here.

      So we can use either Triangular Uniform or we can use Log Normal, anything that we're looking for so we can get a better average. And if we run multiple iterations of the simulation, we're going to be able to run an average on those and get a very accurate number.

      So in this case, we're just going to go ahead and hardcode the numbers in place and drop those in there. You notice, too, we can use the seconds or minutes. Again, very easy, typical kind of UI that you would expect for a tool like this. Again, very easy to use.

      So let's go ahead and just shut that document off there. We don't really need that now. So we're going to go up now and take a look at our run. So in this case, we're just going to select Simulate, and we'll allow that process to run in ProModel.

      So we're right inside of the AutoCAD environment. We can see the parts that are going through the system. The slider at the top allows us to be able to control the speed of the clock.

      So you'll notice at the upper right that things speed up all the way through, and we've now simulated 40 hours of runtime in a matter of seconds. So we now see that we can get 477 parts through the system as it is right now. So this represents our crawl state just basically kind of starting off and figuring out how everything's going to go through the system.

      So we're going to leverage the capabilities of the Factory Design utilities here, and we're going to replace those boxes with some more accurate representations of those machines. So we're going to put a couple of Chirons in place here, and we're going to add some part washers.

      So these part washers, we're just going to do a search in the factory library, a Boolean search saying that we're looking for an industrial washer, and it'll go looking through the 2,500 standard components plus all of the components that I added as custom components, and we'll find that part for me.

      So in this case, I'm going to rotate that washer to get it in place so that it's facing in the right direction. You'll notice, too, if I drag these, if I move this, you'll notice that the flow arrows automatically update. So again, it reduces the chance of making an error. If a change is made here, it's reflected everywhere. So that way, we can make sure that everything's up to date.

      So the next thing we need to do, because there's a pit in between these two machines, we need to get the parts from one side to the other side without walking. So let's use the Factory Design utilities to add some conveyor to this line. So in this case, we're going to go look in here in our library, and we're going to drop in a straight belt conveyor in here.

      So you'll notice as I drop it, if I bring another one next to it, they kind of snap together like magnets. So that's my design in the Factory Design utility. The idea is to make it very easy for people that are not CAD people to be able to do layouts very quickly.

      We'll add a couple of stations at either end. Basically these are going to be the spots where they put the parts on and off the conveyor. And now we're going to go ahead and add that conveyor to our system. So we simply select those three conveyor objects. ProModel is smart enough to know what a conveyor object is, so if I selected something else, it would filter it out.

      But in this case, we now have the conveyor in place. We can control the speed of that conveyor, direction of that conveyor, and also apply things such as cost, uptime, downtime, whatever we'd like. So we're going to go ahead and add into our route here now.

      So right in the middle of our routing, we're now going to add in this ball transfer table, because that's where our parts are going to go. So we're going to go from there to the conveyor, and then we're going to go from that conveyor to the next ball transfer table.

      So we'll take, again, right click, Add a Route, and just pound it right in there like that. We'll go ahead and bring the machine in the line again here also. So again, we're just adding the routes as we need to to our existing layout. So we now got the conveyor and the other parts of the system added in. So the speed of the conveyor and also the queuing capability of that conveyor also will come into play.

      So from here, because we're using the Factory Design utilities, 3D is just a click away. So literally all I have to do is say Open in Inventor, and I now see a representation of that model in 3D generated inside of Inventor. So we can use this for viewing capabilities, but we can also do things such as creating all kinds of different drawings and so on.

      And to get to a simulation from here is as simple as a single button click. So in this case, we just go to the ProModel button and we now see this thing running, so we can see the parts running through the system.

      This is the easiest way to 3D, especially 3D simulation in the market period. One button click, and it just works. So very easy to be able to get to that, and be able to share this kind of information with people that don't understand 2D drawings.

      So we can see now that our throughput has gone down, right? So it's got 332 parts instead of what we had before. That's because it's taking into consideration that the conveyor is there, that the speed of the conveyor is there as well. So in this case, we can see this is our baseline, this is how many parts we were able to get out, and also we can go in here and provide things such as cost.

      So based on the casting cost and the cost of all of the machining and processing that goes on, that gives us an overall feel for how much it's going to cost to make those parts over the shifts. So now, we're going to add a little bit more information to this. We're going to have a small line change. As we know, when we were working with a team, nobody can ever get anything done on the first try. Somebody's got some idea that they need to add.

      So again, let's go back and just talk about what it is that we want to accomplish. We want to get 300 parts out of this thing in a 40 hour shift, right? So again, we're just going to run the simulation.

      And we can see now that we've also got people involved in here, too. Those are called Resources in our system. Resource could be people. It could be a robot. It could be an AGV. Again, we can assign those and we can assign a path network for those so we know where those people are going to travel.

      So in this case right now, we've got two operators, and we can see that we're running 300 in a shift. That looks good. And our guys are only utilized about 60% of the time, which also looks good. OK, so that's where we're looking to go. And again, we can take a look at the 3D model in here and also see that model run if we needed to.

      Again, though, one of the industrial engineers has said that we've had success in the past by adding an inspection station to our line. So in the Factory Design utilities in the 3D Environment, we're going to go ahead and add a table here from the library. So these are parametric objects, and we can design or move them or change the size of them to make them fit the way they need to.

      So in this case, because we're in 3D, it's very easy to put the inspection station on top of the table, and by simply selecting that object and selecting different sizes from its parametric choices, I can now change the size of that table so it fits the way it should. So again, the whole idea here is we make things very easy for people to put this together.

      The next thing we need to do is add a couple of containers, one container for good parts, and one container for the reject or the parts that don't pass inspection. So we'll go ahead and Save this off, and we'll Open it in the AutoCAD environment, and we can see that that 2D information is now represented from the 3D model that was created. So we can see that that information is now added in the 2D environment, and we can go make a modification to our throughput model.

      So we're going to Add a route, just like we did before, except now I'm going to say I want that visual inspection station to be there, and I want to route parts to both of these containers. Now what I want to do, though, is, instead of first available, I want a percentage of these parts to go to one container representing good parts, and then also to go to the other container, 10% of those to be considered as reject parts.

      Now we could do a study also that has variability in that, but for now, we'll just keep it simple. You'll also notice, too, that I assigned the person that's in the other cell to also now have to look at the inspection station as part of the responsibilities of that operator.

      So we can see that the operator is moving all over the place, right? Back and forth from here to there. And if we were zoomed over to the left a little bit here, we'd see that the conveyor is actually backing up.

      And if we look at it this way now, we're not even close to where we were before. We had 330 parts, I believe. We now are only getting 229. And that person that's on that second machine is utilized over 95% of the time. So that's an unacceptable way to work.

      What we're going to do is add a scenario here, and we're going to just do a very simple scenario. In this case, what we're going to do is add another person to this operation. So people are expensive resources, so we want to make sure that if we're using them, we're using them the right way.

      So in this case, I'm just going to tell the simulator that I want to use two people down on the end of the line there. And we'll see as we zoom in here when we get in closer, that the simulation now automatically added the second person. And we can see that that person is hanging out over by that inspection station, which would make sense, because it takes a while to inspect these parts.

      So let's take a look at that. Now remember, this is our baseline. So now we can compare the new design against that baseline. And we can see not only are we making more parts, but the people are now not as used. They're not being used as heavily. So they're only in about 60%. And again, like I said, we can now see that in 3D. So we see this running, we see things running down the conveyor, and everything acts as it's supposed to.

      So again, we can zoom around in here, because this is inside of the Forge environment in the Large Model Viewer. So this allows us to be able to view this in a very efficient manner. So we can zoom in close, get a better look at what's happening, and get a better feel for how things are working.

      So as we can see, we were able to validate space claim in 2D and 3D, and we're able to validate that our line would be able to meet our production needs for throughput as well as validating the correct number of people required to efficiently run that line. So this will provide confidence that the investment made in equipment will pay back. And moreover, you can reuse a simulation over and over again to test for different scenarios, process changes, or new processes based on this process.

      So let's do another demonstration. In this case, let's do something that's a logistical, or a warehouse, example. So in this case, we've got a warehouse that we're going to be unloading trucks, and we want to make sure that we can unload all of the product in an efficient time frame. So we want to make sure that we can do that.

      So let's see here. There we go.

      So in this example, the customer is looking to validate their truck on loading. So they have snowblowers and tractors that need to be unloaded in a 10 hour shift. So as we can see, the layout consists of Factory Design utility assets representing the racks, as well as the fork truck that will do the unloading tasks.

      So we can create the product flows right inside the AutoCAD drawing that represents the proposed layout. So ProModel's easy-to-use interface allows us to rapidly create this simulation. So first thing we're going to do is add our locations. This would be where the fork truck will have to put away the items. And we'll also specify how many can be loaded into each rack.

      So from here, we're just going to go ahead and add that information. You can see the user interface. Very simple, easy to work our way through. We're going to go ahead now and add those locations. So we can add those one at a time, or we can select those as an entire window if we need to.

      You'll also notice that all the tabs are available for us to work here. It kind of works left to right and top to bottom for us to be able to put it together.

      So let's go ahead and add our locations. In this case, we just select one, and that gives us our location. Or we can say, just give me a whole bunch of them. So in this case, we're going to just use a Window select, and we're going to grab all of these down this line.

      So we can see now, as we put them in there, we'll go ahead and grab the next line and the next line and so on. And all of those locations are added for us. So we can see each one as they are. And you'll notice as I highlight them in the browser, they automatically highlight in the selection window, too.

      So let's go ahead and turn down the simulation property. So we're going to do, is we're going to add capacity for each of these, and we're also going to add a number like a counter to each one of these so we know how many are on each shelf as we work through. So let's go ahead and put that on there.

      And the next thing we need to do is we need to tell the system what path it should be following for the fork truck. So we have to create what's called a path network. So it's just as simple as dropping in the points where we think the fork truck is going to stop and put the product in. So I'm just clicking along as I go here.

      So we've got one there, so now we're just going to use AutoCAD commands. We're going to simply copy that, and put it between all of the racks. So in this case, we've got it down this aisle, down the next aisle, and so on. So we'll take those and just drop them in there.

      And then what we're going to do is connect all of those together. So we're just going to draw a line using the Connect tool to connect all of those. So we notice now the fork trunk can only run around the ends and down the aisles. It can't cross in any other direction.

      We're going to do the same thing now. So what we've got here is we have our entities, the tractor and the snowblower, and we're going to have a flow right now for the tractors first. So we're going to look at the tractor unloading. That's our first task that we need to do. We have to get the tractors off of the truck before we can get at the snowblowers, anyway.

      So I'm going to select the tractor as my object that I'm going to be running through this flow. So in this case, we'll just grab that and Paste it into place. And we can see now where the locations are. So in this case, I'm just going to start selecting each of these. This is my start point. This is my staging point. And then I'm going to go and select where the next location is going to be. In this case, I'm going to start all the way down at this end.

      So we're going to have to go ahead and add those flows for each one. So it'll take just a few minutes for us to go and add those routes. So we can go add the route to the next one, and be able to do it all the way along here until we get all of our routes. So again, each of these places.

      So the fork truck is going to come from the truck and over to the rack and put the parts on there as it needs to. So it can only carry one tractor at a time, so it's going to be going back and forth. The fork truck will be.

      So now that we've got that in place, let's add another flow. In this case, what we need to do is say that we're going to have the snowblower. So the snowblower also follows the same methodology. We can put that information in and we can see that's where the snowblowers are going to go. So we can see exactly as the crow flies, if you think of it that way, that's the distance that's going to be covered.

      So what we need to do now is assign a path for the fork truck to go ahead and follow. So we've got that path network that we have there. Our resource, in this case, is going to be the forklift truck. So what we're going to do is we can say, for example, we can put costing on here. We can control its speed. We can have acceleration and deceleration as well to get a very accurate reading as we need to go there.

      So now that we have it, let's go ahead and simulate that. We've told the fork truck to go ahead and run along those paths and do its thing. So you can see now the fork truck is now bringing the products down, and it's putting them up on the racks as it needs to. So now what it's doing is it's filling one rack and then it goes to the next one and the next one.

      So what I did is we put this in as first available, but we could alter that as well. And we can see that the number is counting down as it goes here, because that's the number of parts that were in the truck. It started with 100, and we're now counting those down.

      So we're working with only one fork truck here, and as you can see, he's coming in here and he's unloading. He gets four on there, and then he goes back and he loads onto the next rack. So we can keep doing that as well.

      Now again, this can be configured in any way you wish it to be. I just did something very simple so we can kind of get the concept. So again, we just use the slider to go ahead and control the speed here. And if we look up in the upper right-hand corner, we have a clock there that's telling us how long it's taking for us to do our simulation.

      So it's running through here right now. It's in hour six right now, and we can see we're not even close. We don't even have all of the tractors off of the truck. We're not even getting to the snowblowers until the ninth hour. So we definitely got a problem there. We need to make a change. So we can go ahead and look at the simulation results as we need to here, but we're not going to at the moment, because we obviously see that there's a problem.

      So again, we're going to add a scenario. And in this case, we're just going to go with two fork trucks. Now I could do things like, hey, I want to do a scenario where I can put six things on a rack. Maybe we're going to use taller racks. Or we can add, like I said here, just a fork truck. And we'll just do it with the fork truck here to kind of get the idea across.

      So I can run as many scenarios as I want to as well. So I'm only running two right now, but I could run up to 10 of them if I wanted to. And I can run iterative runs on each of those so each time it will run 10 times, so that way we can get an average if we've got variability built in.

      So we can see already that at the fourth hour now, we've already got all of the tractors unloaded. So now we're starting to unload the snowblowers. So we're looking good here. It looks like we're going to be able to get it done. In fact, in 10 hours, it looks like we're able to unload the entire truck, and we can see exactly what happened where.

      So now we can see, compare the baseline against our new designs. So we can have those things as we can see them. And we can do things such as time plots in here. We can start looking at the racking as it goes here. We can look at variability in this, and we can start looking at how things are getting filled over time. We can add things such as pie charts.

      So again, this is all completely configurable for you, depending on what answer you're looking for. And this also supports a 3D workflow. So in this case, we've got the Inventor model that was already there. So now we can run that same simulation in a 3D environment and be able to see the fork truck now going down here and dropping off the boxes or the tractors where they need to go.

      So again, it takes and puts all of that into play for us as well. So very easy for us to be able to do logistical studies.

      Here's one that's a little bit more involved, however. So we've got a large warehouse that we're working with here. And we're not only using four trucks. We're also using pallet jacks and we've got people that are involved here, too. Not to mention the semis that are supplying, or bringing the products to us.

      So now we're looking at also an environment where we've got mixed pallets of things, and we also have pallets of just the same part. So again, all of these things are being considered, and we're looking at this over quite a bit of time. So we're looking at this over weeks rather than over hours.

      So we can go ahead and put all that information in. We can also even add calendars to this that allow us to be able to see things such as holidays or plan downtime or shifts. So we can add that as well. So again, very easy to be able to add all this information and make a very accurate idea or get across our idea.

      So by applying the entire solution, cost savings and design confidence can be assured not only in the installation phase, but also validation that the design will meet production output goals with financial information to support it. And as we've shown here, it's pretty easy to learn how to use these tools and be able to work with them.

      We also have, in all cases, proved that our ideas are going to work with clear, actionable data that can be used over and over again for testing new scenarios of production.

      So by applying the entire solution, cost savings and design confidence can be assured in not only the installation phase, but also validation that the design will meet production output goals with financial information to support it. This allows us to have complete design confidence.

      So would you like to know more? Well, if you would, please stop over and see us at booth number 220 in the exhibition hall. We have consulting staff available to answer further questions and see how it would apply to the problems that you're looking to solve.

      We are also offering special show pricing for AU for ProModel, and there is a coupon available at the booth that you can use that you have to buy in a certain amount of time, but we will offer a substantial discount on the software for the annual subscription.

      Reseller partners are available also to provide software and training, and these reseller partners may be partners that you're already working with. We have done recruiting with partners globally for delivery of consulting and also for training and to be able to provide software and support it as well.

      So I'd like to thank everyone for sitting through this presentation. I hope you'll enjoy the rest of your Autodesk University. I hope you're able to learn a lot more things. I'm certainly looking forward to sitting in on some classes and learning a lot more, myself. I'd like to thank you for your time.

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