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Aditya Kamath avatar image
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Aditya Kamath asked Sam Stubbs commented

How to create a replenishment task sequence?

I am trying to simulate an operator who is loading parts into a processor, processing them and then unloading them. I also have a rack where there are additional parts stored. I want to create a task sequence such that every time the operator finishes processing all parts from the queue next to the processor, he travels to the main storage rack, picks up 4 more parts all at once, unloads them in the queue next to the processor and then begins processing each part individually. I referred to the "Kanban replenishment" example in the Process flow tutorials but I was unable to modify that model to suit this situation because ideally I know this would work best with lists like in that example here. I have attached my model, any help is greatly appreciated.

Thank you!

replishment-task-sequence.fsm

FlexSim 16.2.2
listsprocess flow tasksequencereplenishment
replishment-task-sequence.fsm (31.0 KiB)
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Sam Stubbs avatar image Sam Stubbs ♦ commented ·

It looks like the model you posted is a 2017 model, but you listed your version as 16.2.2. Which version of the software would you like me to use, to create an example for you?

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Aditya Kamath avatar image Aditya Kamath Sam Stubbs ♦ commented ·

Hi Sam, it would be best in v16.2.2 please. Thank you for the help!

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1 Answer

Sam Stubbs avatar image
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Sam Stubbs answered Sam Stubbs commented

Here is an example for your situation. I think you had the right idea, you just needed to implement the List Push/Pull functionality. This example handles both the replenishment and item processing via a continuous Process Flow. You can alter the processing to be handled via ports and 3D model logic if you need to change it. At least this model should give you insight in how to utilize the lists for the replenishment process.

replenishexample.fsm


replenishexample.fsm (29.7 KiB)
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Aditya Kamath avatar image Aditya Kamath commented ·

Hi @Sam Stubbs . Thanks so much for the model! It works perfectly, however, I wanted to recreate what you modeled so that I cement my understanding. I have an issue with my model and some other conceptual questions regarding your model.

1. My model stops after the operator processes the first 4 parts picked and stops at the 'Decide' step. Not sure what's causing this.

2. What is the logic behind the labels 'creationRank' and 'rank'?

--> In the first sub-process, the value of creationRank is a string creationRank? How can we then increment this?

--> for the second sub-flow we keep the array size as 1...why is this?

3. In the decide step, why do we select the 'Assign Labels' option.

4. Lastly, in the pull from list activities, why do we select 'Insert in front of'?

Please find my model attached.

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dorogi-3.fsm (30.2 KiB)
Logan Gold avatar image Logan Gold ♦♦ Aditya Kamath commented ·

@Aditya Kamath, all you need to do to get your model working is change a field in the "Release operator" activity. In the "Resource(s) Assigned To" field, it is currently using the default resource label. However, in the "get operator" activity, you are using the operator label. So if you change the "Release operator" activity to use the operator label, the model should continue running after the first batch.

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Aditya Kamath avatar image Aditya Kamath Logan Gold ♦♦ commented ·

Thanks for debugging it Logan. Wroking perfect now, can't believe it was such a small one!

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