question

Meghan W2 avatar image
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Meghan W2 asked Sebastian Hemmann commented

How to rebatch tokens with dynamic batch sizes

Hi,

I have a model that I batch tokens to go through the first manufacturing step and then I want to rebatch the tokens with a dynamic batch size.

The batch size is driven by a PO from a schedule source. For the first batching, I used the max wait time to release the batch with all the tokens that get released at the same time. I want to rebatch the tokens later with a dynamic batch size. I want the batch size to be based on a timed release (i.e. at time x, pull this much material into a batch to move onto the next processing step).

I tried to do this by creating a source and moving it into a batch using the max wait timer. I then have the batch reference the other batch from this new schedule source. However, it is not correctly setting the batch size.

batching-logic.fsm

FlexSim 18.2.2
token rebatching
batching-logic.fsm (48.9 KiB)
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1 Answer

Sebastian Hemmann avatar image
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Sebastian Hemmann answered Sebastian Hemmann commented

Hey, there are some other Error Messages in your model, and I sadly don´t have enough time to figure out what else is wrong there.

But for your question:

I would use a List. On one side you can push all "Items" to this list. On the other side you only have to create Orders at the right time and pull as many Items from the list, as this Order needs. Did you ever use Lists?

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Meghan W2 avatar image Meghan W2 commented ·

I tried using lists, but wasn't able to execute. If there are any suggestions on how to execute based on pull to list, that would be great. When I did it, i had a global table with times and associated volumes needing to be pulled in column 1. It didn't reference the table correctly.

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Sebastian Hemmann avatar image Sebastian Hemmann Meghan W2 commented ·

Attached is the model (I´ve just turned off the "Pull" function in your Processor to stop Exceptions). 15442-batching-logic-sh.fsm

In the model I´ve deleted your "Batch" activitys and added a "push to list" and a "pull from list" through your ProcessFlow.

Further I´ve changed your Source "API Orders" to create only one token per Time but give every token a Label (NumberCount) that has the Quantity of needed material as value.

In the pull from List I´ve set the Request and the Require Number to call the Label value.

So now it is possible to let go on as many material as needed for the order.

Attention: be aware that this way lets material go on as soon as the order arrives. This means if the order arrives, needs 10 but there are only 8 on the list, 8 go on and the order waits for another 2!

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15442-batching-logic-sh.fsm (42.5 KiB)
pf-incl-list.jpg (113.1 KiB)
Meghan W2 avatar image Meghan W2 commented ·

This works, but runs into a similar challenge I was having before. I want the original tokens to move. I was using the API source just as a trigger to set how much material needed to be pulled to API manufacturing in the primary chain.


On other alternative I thought of was just making the intermediate manufacture one subflow and then API another, but I think I may run into the same issue.

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Sebastian Hemmann avatar image Sebastian Hemmann Meghan W2 commented ·

Please explain more exactly what is the challenge. I´m afraid I missed something!

I thought you are creating material on the one side. And on the other side, depending on a time, you are creating orders that need an amount of this material.

Is the challenge that all tokens (and so their reference to an item) that once are used for an order, have to stay with this order?

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Meghan W2 avatar image Meghan W2 commented ·

Hi,

This was all really helpful and I was able to get it to move tokens correctly. However, now I need to move the tokens into the final manufacturing stage and then a queue once it is done. An error is getting thrown somewhere and the tokens/boxes are not moving into the final manufacturing step.

Any help would be much appreciated.test-model.fsm

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test-model.fsm (512.9 KiB)
Sebastian Hemmann avatar image Sebastian Hemmann Meghan W2 commented ·

Hi @Meghan W2,

I think it is a very good idea of @Tanner Poulton to make a new post and add this second question to it.

If you are creating another post, please be so kind and add me directly.

Also it would be great, if you can answer following questions (in the post) to make us able to help you:

1. You are creating tokens that are members of Orders. This tokens later create items that are members of this Order?

2. So do you want to handle as many parts as the Order holds in Processflow and material (items) should be routed through 3D Objects depending on what ever happens to the Order in PF? Wouldn´t it be easier to have just one token in PF that represents the Order?

orderprocess.jpg

3. In the picture your are in 1 creating the box (in the model), in 2 you are sending the box to the Queue. Why aren´t you creating the box in the Queue?

4. You are setting a Label (PO) and write a reference to an item in there. In the Delay (3) you want to set the item as Delaytime!? What do you try to do?

5. After your Boxes leave Processor (Manufacturing2) you are moving all boxes to Stock1. Here you are doing anything strange in "Send to Port" in Flow Tab. What are you trying to do?

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orderprocess.jpg (90.2 KiB)
tannerp avatar image tannerp Meghan W2 commented ·

Hi @Meghan W2,

It might be useful to post this as a new question because it seems to be a separate issue from before. A benefit to posting it as a new question is that more people will likely see it and you could get a quicker answer. You can post a new question here.

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