Simulation Model Overview: NASSCO Steel Production Operations

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Simulation Model Overview NASSCO Steel
Production Operations

• Mike Iuliano and Chuck McLean
• Manufacturing Systems Engineering Group
• Manufacturing Systems Integration Division
• National Institute of Standards and Technology
• Gaithersburg, MD

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Topics
Brief background on Manufacturing Simulation and
Visualization Program at NIST NASSCO simulation
model objectives Simulation system
overview Shipyard data file processing User
interface displays Demonstration of current
system Future work Discussion
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NIST Manufacturing Simulation and Visualization
Program Goals

• Identify, specify, prototype, test, and evaluate
  data interfaces and methods for integrating
  manufacturing simulation and visualization
  applications with each other and with other
  manufacturing software to reduce the cost,
  increase the accessibility, and improve the
  interoperability of manufacturing simulation
  technology for U.S. industry.

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NIST Program Approach

• Identify simulation and engineering tool
  integration requirements from hands on experience
  with software tools and interactions with users
  and vendors
• Capture relevant definitions, theory, algorithms,
  and data models as part of the science of
  manufacturing system integration
• Develop draft interface specifications to advance
  the near term interoperability of engineering,
  simulation, and production management
  applications
• Implement test beds and proof-of-concept
  demonstrations to show the feasibility of
  candidate specifications
• Work with IMS MISSION and Object Management Group
  SIMSIG to develop define, evaluate, test, and
  promote candidate standards

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Modeling and Simulation Environments for Design
Planning and Operation of Globally Distributed
Enterprises (MISSION)

• The goal of MISSION is to integrate and utilize
  new,knowledge-aware technologies of distributed
  persistent data management, as well as
  conventional methods and tools, in various
  enterprise domains, to meet the needs of globally
  distributed enterprise modeling and simulation.

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U.S. MISSION Team Participants

• Government
• NIST
• Defense Modeling Simulation Office
• Software Vendors
• Autosimulations
• Deneb Robotics
• EAI-CimTechnologies
• Knowledge Based Systems Inc. (KBSI)
• Nyamekye Research and Consulting
• ProModel Corporation
• Systems Modeling Corporation
• Tecnomatix Technologies

• Industry
• Black and Decker
• TRW
• Academia
• Arizona State University
• Florida International University
• Iowa State University
• Pennsylvania State University
• Virginia Polytechnic Institute
• University of Illinois
• University of Maryland
• University of Tennessee

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MARITECH Project 10 Simulation Modeling
Objectives

• Model as-is steel fabrication and assembly
  processes to
• Evaluate resource allocation and scheduling
  constraints,
• Analyze layouts of production areas, lines, and
  workstations,
• Perform capacity planning analyses,
• Determine production and material handling
  resource problems, and
• Compare performance of the systems against best
  in class benchmarks for shipyard production
  operations.
• Model to-be steel fabrication and assembly
  operations incorporating process improvements to
• Identify possible constraints in the new systems
• Compare performance of the new systems against
  best in class benchmarks for shipyard
  production operations.

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Simulation Focus - Stages of Construction

• SOC 1 - Fabrication
• SOC 2 - Subassembly
• SOC 3 - Block Assembly
• SOC 4 - Unit Assembly
• SOC 5 - On Block
• SOC 6 - On Board
• SOC 7 - Test and Trials
• current focus areas for the simulation
  modeling effort

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Simulation Model Overview

• Simulation model implemented using Promodel 4.2
• Key Promodel constructs used to implement model
• Locations
• Entities
• Attributes
• Arrays
• Some major capabilities that were added
• New calendar, shift, clock module
• Project management data input and execution
• Work content computation
• Space allocation management
• Schedule execution
• Generalized job and task management
• Multi-screen user interface
• Labor pool resource management

• Global variables
• Resources
• Macros
• Processing logic

• External Files
• Distributions
• Views
• Subroutines

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Simulation Architecture

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Entity Processing Locations

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Shipyard Input Data

• Schedule data for each item to be produced
• Precedent networks for each job template
• Product characteristic data for each item
  produced
• Production data set index
• Labor rate data sheets and staffing level
  parameters
• Part identification data
• Bill-of-materials data for each end-item

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Input Data File Processing

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User Interface - Simulation Status

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User Interface - Space Allocation

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User Interface - Task Status

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Demonstration of Current System

• Stage of Construction 3 - assembly of blocks and
  major assemblies at Tables 1 - Flat, 1 - Pin Jig,
  2 - Pin Jig, and
• 11- Flat
• All shipyard data files (Microsoft project plans
  and Excel Spreadsheets) automatically processed
  into a neutral Promodel input format
• Part identification and BOM files created
  manually from shipyard data
• Schedule for 8 blocks or subassemblies
• Macro task templates containing 6-33 tasks per
  assembly job
• Work content computed with statistical variation
  for each task
• Inventory consumption logged in schedule file
  format for input into simulation models of other
  production areas
• Labor allocation by statistical distribution
  within valid range

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Demonstration Scope - SOC 3
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Future Work

• Phase I
• Complete final integration and testing of SOC 3
  code (i.e., labor allocation module)
• Optimize code for faster execution
• Validation of input file processing routines with
  NASSCO staff
• Configure generic models from current simulation
  as SOC 1 and SOC 2 area models
• Phase II
• Continue with modeling of later stages of
  construction
• Begin integration of independently executing
  models using MISSION and HLA distributed
  simulation architecture under Integrated
  Simulation Environment plan
• Add other functional capabilities implementation
  of pull-system simulation for shipyard order
  flow, inventory area management

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Integrated Simulation Environment
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Simulation Systems View
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Simulation Federate
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Questions and discussion?

• For further information, please contact
• Chuck McLean (301) 975 -3511
• Email charles.mclean_at_nist.gov
• MSID
• Building 220 Room A127
• National Institute of Standards and Technology
• Gaithersburg, MD 20899