question

Amy M3 avatar image
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Amy M3 asked Logan Gold commented

bundler (combiner)

What is the best way to model a bundler machine? I need to combine 4 bags and I have a rate of 18 bundles per min on the bundler. I first used a combiner with the process time set to 1/18 but then it became a bottleneck because I think it does the process time after I have the 4 bags. I changed the combiner process time to 0 and added a processor right after to handle the process time. This seem to work but I can't get decent utilization statistics because it shows idle as the 4 bags are collecting.

FlexSim 24.1.0
combiner
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Joerg Vogel avatar image Joerg Vogel commented ·

@Amy M3, you simulation run time is in minutes, right? Otherwise your process time should be 60/18 for a simulation run time in seconds.

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Amy M3 avatar image Amy M3 Joerg Vogel commented ·

Yes minutes. But the issue is the process time does not occur until after I collect the bags. The fix i did to have a separate processor worked but stats just aren't right...was hoping this was a common machine others have modeled.

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1 Answer

Logan Gold avatar image
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Logan Gold answered Logan Gold commented

The Combiner should be in a collecting state after the container flowitem arrives (the item coming through the first port, like a pallet or tote). And I believe the collecting state is considered a utilized state by default. If it's not, you can always change that in the State Table used in your utilization charts on the Dashboard. Let me know if I am misunderstanding the issue you are seeing with the statistics.


Nevertheless, you could set the Process Time of each bundle by first figuring out how long it takes to collect all the items and then subtract that from the 1/18 minutes. I am attaching an example model (Combiner_IncludeCollectingInProcessTime_Example_24.1.fsm) to show you what I mean.

The Combiner is set up to use a label on the container (pallets in this case) called ProcessTime. And the Process Flow is what sets the ProcessTime label on the pallets.

The Process Flow creates a token every time an item enters the Combiner, and then weeds out the tokens created when the boxes enter, so only one token is used for each bundle.

It waits for the first item to enter the pallet and keeps track of the time that happens. Then it waits until the Setup Time finishes on the Combiner (which is just before the process time starts) and figures out the time it took to collect all items in the bundle. It subtracts this collection time from the total bundle process time (1/18 minutes or 3.33 seconds) and uses that to set the ProcessTime label on the pallet. It also checks if ProcessTime is negative and sets it to 0 if it is. The end result is the total time a bundle stays on the Combiner (from the time the first box enters) is 3.33 seconds (or possibly longer if the collection time is more than 3.33 seconds), and so you should have about 18 bundles leaving the Combiner a minute.

The example has boxes being produced continually, but that can be changed to something more akin to your process to double check that is works correctly.


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Amy M3 avatar image Amy M3 commented ·

Thanks Logan, the collection time is just based on the lines feeding it so will vary on how fast the bags get there and change with each product. I'm wondering if it would just be better to use process flow..l had to put in a fake pallet that's not reallly there to get combiner to work. Then I could set state on the machine. I don't have any process flow controlling this now.

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Logan Gold avatar image Logan Gold ♦♦ Amy M3 commented ·

Yeah, Process Flow could make things easier. Where you have a "dummy" object to represent your bundler and then set up a Process Flow to control all the logic on that object, including when you want to change the state of that object.

If you want help getting something like that set up, just let us know.

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