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Operator Handling Semi-automatic machines priority problem

Dear All,

I have a unique scenario where I am stuck in simulation model unable to make any progress at all, which is an urgent deliverable.

 Shift beginning (1st part):-

Load part in STN_10 (Manual process of STN_10) - > Automatic process of STN_10 -> Unload part

Load part in STN_15 -> Automatic process of STN_15 -> Unload part

Load part in STN_20 -> Automatic process of STN_20 -> Unload part

Load part in STN_20A -> Automatic process of STN_20A -> Walk to STN_10

Next part onwards:-

1.If the part is not available in succeeding station, operator has to wait in current station.

2.We observed that if part is not available in succeeding station, the operator walks to any station which demands his presence. This is not acceptable condition.

3.Operator has to follow the loop.

a)ST10 -> ST15->ST20->ST20A->Walk back to ST10

a)Every station has a buffer in the end, where the operator unloads finished part 1st.

b)Then he loads new part

c)Then he walks to next machine with finished part if next machine is available.

 

The key point in shopfloor scenario is the Operator will not skip the order of machine and go to next machine.

If for eg, he is in ST10, ST15 and ST20 have finished processing Automatic process.

He should not walk to ST20 but go to ST15 first.

 

If ST20 manual process is completed and ST20A is ready to push out the part, he should not wait for ST20 to complete but walk to ST20A to complete (resulting in ST20 waiting).

I am not able to proceed after 1st cycle end.

 

I am not proficient with Importer control, Workplace control and Broker control.

Any help is appreciated.

Attached sample model for reference.

 

 

5 REPLIES

Re: Operator Handling Semi-automatic machines priority problem

Gears Esteemed Contributor Gears Esteemed Contributor
Gears Esteemed Contributor

I moved the "opening" of buffer2 into the exit control (rear) of buffer11. 

for the next steps:

 

The worker is not able to unload the station, if the transport importer of the stations is active and the worker is occupied. So you will need a second buffer as destination for the raw part first. Then you can activate the transport importer of the station (to the finish part buffer). If the finish part buffer is occupied you can activate the transport importer of the raw part buffer (to the station). After finishing the worker part of the process time you can activate the transport importer of the finish part buffer.

 

Another possibility is to unload the station with a connector (no transport importer). Here the worker can wait, until the station is empty, he loads the machine and at the end of the worker phase, you activate the transport importer of the station buffer.

 

 

 

Steffen Bangsow
freelance simulation specialist  
web: www.bangsow.eu
mail: steffen@bangsow.net

Re: Operator Handling Semi-automatic machines priority problem

Hi,

The problem is if Buffer2 exit locked is based on Buffer111 rear exit control, the operator has to keep waiting till St_20A has completed entire cycle.

For 1st part:-

Once ST_20A_Pos becomes "2" ie Automatic process starts, operator should walk to Buffer 2.

For 2nd part:-

Once ST_20_Pos becomes "2", operator should unload 1st part from ST_20A and walk to Buffer 2.

and so..on.

The operator WILL wait in machine to complete Auto time only if subsequent machines are free.

He is to follow cyclic loop - with sequence Unload finished part - Load new part - Auto process starts - He walks to next machine

Re: Operator Handling Semi-automatic machines priority problem

Genius
Genius

Hi,
I suppose it's chaku-chaku-line. One possible solution for chaku-chaku-line is in the model.

Could help.

Regards
Nadin

Re: Operator Handling Semi-automatic machines priority problem

Dear Steffen,

I have built a simplified model wherein all 4 machines have 1 part already entered to start the simulation.

I have provided Entrance and Exit logics to control the operator movement so that he goes to ST10 and completes the process of 1st part.

2nd part he loads to the machine 10 but doesn't go and perform operation in ST15.

The sequence he has to follow in a loop is:

 

STN_10->ST10_UL->Buffer2-> ST10_L->STN_15-> ST15_UL->Handover_1-> ST15_L->STN_20-> ST20_UL->ST15_UL-> ST20_L->STN_20A-> ST20A_UL->ST20_UL-> ST20A_L

 

Since I am not at all able to work with Importer control logic trying this option.

It would be really helpful if you can make him follow the loop.

Attached the model.

 

Highlighted

Re: Operator Handling Semi-automatic machines priority problem

Gears Esteemed Contributor Gears Esteemed Contributor
Gears Esteemed Contributor

the Broker mechanism is really not made for a sequencial behavior of the worker

 

In the attached example I extended the worker by a attribute arrived and an observer control for location; if you now send the worker with goTo to  a destination worker.arrived will become true, if he arrives its destination.

 

Now you can program your (not very simple) sequence straigt ahead...

 

Steffen Bangsow
freelance simulation specialist  
web: www.bangsow.eu
mail: steffen@bangsow.net