Help with different batching sizes on different conveyors. How can I do it?

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Jesus M2 asked May 31, '18 Jesus M2 commented Jun 1, '18

Help with different batching sizes on different conveyors. How can I do it?

Hello to every one,

I am happy to be here again. This time, I have the following issue. I am attaching a PowerPoint file with the image for this case, and also I am attaching the Flexsim file with what I've done.

Here is what I need to do for this case:

- Each one of the sources (1,2,3 and 4) must arrival 01 box every 15 seconds.

- Conveyor 1, 2, 3 and 4 must not batch more than 01 box.

- Line A: Picking_1 must be capable of performing batching of boxes in this sequence: 2-2-1-1-1 and after this, the sequence must repeat until infite for this line.

- Line B: Picking_2 must be capable of performing batching of boxes in this sequence: 2-2-1-1-1 and after this, the sequence must repeat until infite for this line.

- Line C: Picking_3 must be capable of performing batching of boxes in this sequence: 2-2 and after this, the sequence must repeat until infite for this line.

- Line D: Picking_4 must be capable of performing batching of boxes in this sequence: 2-1-1-1-2 and after this, the sequence must repeat until infite for this line.

- Robot must take batches of boxes from Picking_1, Picking_2, Picking_3 and Picking 4 and and take each batch to Queue1. The only rule for the robot to take bathces is that the batch on each Picking conveyor is already set. There is no any preference for any line. For example: If batch in Picking_1 al already set, the robot will take that batch, and if Picking_2 is set while the robot is working with Picking_1, Pikcing_2 will have to wait.

-Queue1 can batch upto 1000 boxes.

I really appreciate your help, and I'd be very grateful with you.:)

Jesús Morales.

Software Version:

FlexSim 18.1.1

conveyors batching batch processing load multiple item

luc-0118.fsm (19.3 MiB)

flexsim-luc-0118.pdf (242.9 KiB)

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Jeff Nordgren commented · May 31, 2018 at 07:29 PM

@Jesus M2,

I'm not real sure what you mean when you say "must be capable of performing batching of boxes in this sequence: 2-2-1-1-1". Does that mean that it takes 7 boxes from the conveyor and puts them together in a "batch"? I'm just not sure what the sequences you list mean.

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Jesus M2 Jeff Nordgren commented · May 31, 2018 at 08:19 PM

@Jeff Nordgren, sure. What I mean with 2-2-1-1-1 for Line A is this:

When there are 2 boxes on Picking_1, the robot will take these 2 boxes and put them on Queue1. Then, the robot will have to take again 2 boxes and put them on Queue1, then the robot will take only 1 box and put it on Queue1, then 1 box more and finally 1 box more. And then, the robot will repeat the sequence, 2-2-1-1-1.

What I tried to say with 2-2-1-1-1 for Line A is that the robot will have to take 5 batches, 1st batch: 2 boxes; 2nd batch: 2 boxes; 3rd batch: 1 box; 4th batch: 1 box and 5th bacth: 1 box.

Please let me know if I was clear or if you need any other information.

Thanks a lot.

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Answer 1 · 2018-05-31T20:11:37Z

Joshua S answered May 31, '18 Jesus M2 commented Jun 1, '18

From what I understand from the sequence of batches, you mean that the robot picks up 2 the first time from the queue, then when it comes back it pick up 2 again, then 1, and so on for each queue right? The model I attached does this. it uses a table to store your sequences and look them up per batching queue. I removed your conveyor 3D models because they are .igs files and were causing issues with uploading and for opening the file. The only thing I don't have is the queues batching the specific amount, the robot picks up the required amount per your sequence, but what I didn't understand is if you expect items to come in every 15 seconds from every source, then do you expect them to pile up on the conveyor, or where are they piling up? And if they don't pile up and only have 1 item on the conveyor and a specific amount on the queues, then your 15 second interval source needs to be reevaluated because they will be blocked most of the time. Hope this helps.12186-luc-0118-change.fsm

12186-luc-0118-change.fsm (50.0 KiB)

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Jesus M2 commented · May 31, 2018 at 08:39 PM

@Joshua S thanks a lot. Ok, I already took a look to the file. Look:

1) Just as you say, if the sequence is 2-2-1-1-1, the robot will take batches like that: 1st: 2 boxes, 2nd: 2 boxes, 3rd: 1 box and so on. That's very good.

2) For example, for the sequence 2-2-1-1-1, when the 1st batch (2 boxes) is on Queue_3, it cannot enter another box into Queue_3, until this 1st batch is gone, and so on with the other batches and Lines.

3) For your question: "what I didn't understand is if you expect items to come in every 15 seconds from every source, then do you expect them to pile up on the conveyor, or where are they piling up? And if they don't pile up and only have 1 item on the conveyor and a specific amount on the queues, then your 15 second interval source needs to be reevaluated because they will be blocked most of the time." -----> This is the idea. I need to find a reasonable production rate under these conditions, so I can go for example from 15 seconds to 20 seconds, so do not worry about that. I can change that time.

Could you help me with point No. 2?

Thanks in advance.

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Joshua S Jesus M2 commented · Jun 01, 2018 at 02:06 PM

@Jesus M2

Alright, I think I got it all figured out. Now it batches the amount it's supposed to at the Queue. 12186-luc-0118-change.fsm

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12186-luc-0118-change.fsm (54.9 KiB)

Jesus M2 Joshua S commented · Jun 01, 2018 at 02:29 PM

@Joshua S Right, this is the way. But something is not working good. Look:

After 60 seconds, the robot only takes batches from Queue_3 and Queue_4, and after 90 seconds the robot only takes batches from Queue_3. The operation is not continuous. By fixing this, I think we're done :)

Could you help me with this issue?

Thanks a lot.

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Answer 2 · 2018-05-31T23:15:26Z

Jeff Nordgren answered May 31, '18 Jesus M2 commented Jun 1, '18

@Jesus M2

OK, I think I have your model working the way you describe. Take a look at the attached model and make sure that it is doing what you are wanting it to do. If not, we can make some adjustments.

I colored the flowitems so that you can see better what the robot is doing and how many flowitems it is picking up and dropping off in Queue1.

Let me know if you have any questions or problems.

Thanks.

luc-0118-jn1.fsm

P.S. That graphic file you are using on the "Conveyor Queues" must be a huge one. You model is over 20 Mb and it's not even a complicated model. I would look to replace that graphic with one that is a LOT smaller. Just food for thought.

luc-0118-jn1.fsm (19.2 MiB)

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Jesus M2 commented · Jun 01, 2018 at 01:08 PM

@Jeff Nordgren Thanks a lot for your help. Ok, look:

1) I have replaced the graphic for “Conveyors Queues”. Just as you said, the file is smaller now. Thanks. I'm attaching the file with the changes.

2) For Picking_1 and for every Picking conveyor, one rule must be met. I’ll give an example for Picking_1: the sequence of picking for the robot on Picking_1 is as follows:

- 1^st batch: 2 boxes,

- 2^nd batch: 2 boxes,

- 3^rd batch: 1 box,

- 4^th batch: 1 box,

- 5^th batch: 1 box,

So summarizing, the sequence here is 2-2-1-1-1. When the first batch (2 boxes) is on Picking_1, it cannot enter any other box inside Picking_1, so the rest of the boxes must be waiting on Conveyor1. When the robot takes this first batch, it will enter the second batch (2 boxes) inside Picking_1 (same for this, the rest of the boxes must be waiting o Conveyor1), and when the robot takes the second batch, it will enter the third batch (1 box) inside Picking_1 and so on for this sequence.

Can you help me with this?

Please let me know if I’m being clear. English is not my native language. I try to do my best.

Thanks a lot in advance.

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12191-luc-0118-jn1-v002.fsm (41.6 KiB)

Jeff Nordgren Jesus M2 commented · Jun 01, 2018 at 07:22 PM

@Jesus M2,

OK, I think I understand better now what needs to happen. Attached is your model with the changes that I've made to make it work as you describe. Take a look at the model and see if it will work for your situation.

Thanks.

12191-luc-0118-jn2-v002.fsm

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12191-luc-0118-jn2-v002.fsm (41.2 KiB)

Jesus M2 Jeff Nordgren commented · Jun 01, 2018 at 07:48 PM

@Jeff Nordgren thanks Jeff! This is very useful for me!

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