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SudheerReddy avatar image
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SudheerReddy asked tannerp commented

Regarding Fixed Resource PF- Material Consumption & Replenishment

I am trying to use Material Consumption and Replenishment module available in Fixed Resource PF for the following set up.

Each Processor has multiple parts consumption as explained below

For Processor 1 to complete the assembly, it consumes Part11-2parts, Part12-4parts, Part13-1part. In similar way for Processor 2 and Processor 3 as shown in the table.

But in Material Consumption and Replenishment Process Flow template for each processor there is only one 1 part consumption. So how to scale the below scenario to the available standard template. Please any feedback and suggestions helps me to achieve this.

FlexSim 20.0.0
fixed resource process flow
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Benjamin W2 avatar image
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Benjamin W2 answered Priyanka Bhoite commented

Hi @Sudheer R,

The easiest way to do this is to have 1 processor for each part and adjust their processing times accordingly. Please see the attached picture and model.

Let me know if this does not work for your situation. It will require some difficult and in-depth process flow manipulation if you want to use multiple parts on each processor.

materialconsumptionandreplenishment.fsm


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SudheerReddy avatar image SudheerReddy commented ·

@Benjamin W2

Thanks for the feedback and model. I will try the same.

Each instance has different StartLevel, DepletionUnit, ReorderLevel and ReorderQty. Instead of going to each instance and update the Process Flow Variables, could it be possible to update the Process Flow Variables through global table or any other way. As the instances increases, updating for each instance respective process flow variables is difficult.

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SudheerReddy avatar image SudheerReddy commented ·

As shown in below image, when we have processor for each part and adjust their processing times accordingly for example

Processor 1: 10 sec process time is split into

2 sec for Queue1(Part11) , 3 sec for Queue2(Part12) and 5 sec for Queue3(Part13)

Processor 2 : 10 sec process time is split into

5 sec for Queue4(Part21) and 5 sec for Queue5(Part22)

Processor 3 : 10 sec process time is split into

3 sec for Queue6(Part31), 1 sec for Queue7(Part32), 2 sec for Queue8(Part32), 4 sec for Queue9(Part34).

Now the speed of the line is changed from 10 sec before adjusting to 5 sec after adjusting (max of above all adjusted times).Now the bottleneck process time shifted from 10 sec to 5 sec, so material consumption happens at rate of 5 sec. Which is faster than required.

Instead if I don't split, each Processor runs at 10 secs. So consumption happens at 10 sec for all parts.

Is my logic makes sense. If so how to handle this situation.

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SudheerReddy avatar image SudheerReddy commented ·

@anthony.johnson

Each instance has different StartLevel, DepletionUnit, ReorderLevel and ReorderQty. Could it be possible to update the Process Flow Variables through global table or any other way.

Any ideas or sample model for this

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tannerp avatar image
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tannerp answered tannerp commented

Hi @Sudheer R,

You might consider using combiners, as this is the purpose of the combiner object. You just need to specify how many of each product to "assemble" (combine) at each station, how many to reorder, etc. I did this using a Global Table, which also identifies the location of each queue.

The Process Flow I used is very simple and just listens to the content of each queue to make sure the parts are replenished when the content drops below the specified level.

I added some color to the boxes for fun, too.

This works as long as you can take the statistics you need from FlexSim and then break those out into more detailed statistics. For example, for every 10 seconds at Processor1, you know there were 2 seconds spent for Part11, 3 seconds for Part12, and 5 seconds for Part13, etc. This can be done in FlexSim or in Excel after running your model.

Hopefully this helps. I've attached an updated model.

material-consumption.fsm


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SudheerReddy avatar image SudheerReddy commented ·

@tanner.p Thanks for your answer.

I have gone through the model. Following is the question I have on the model you have shared

In a simulation it would be overkill to simulate each part as its own object. As model size increases number of parts will be high and each part pack quantity will be high for example bolts pack quantity is 1000. If each part as its own object as shown in the below image will be overkill. Instead if we can able to achieve material supply and demand as simple number quantities. Just like standard Fixed Resource Process Flow- Material Consumption & Replenishment where each part quantity is stored in a variable and when flow item enters a station required part quantity is reduced instead of creating a object for each part.

Is that possible?

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tannerp avatar image tannerp SudheerReddy commented ·

Hi @Sudheer R,

This is possible and you are correct in that it is much more efficient to go this route than to create thousands of 3D objects and use those. Rather than having me explain it in pieces, I recommend you review Process Flow Tutorial 4 in the User Manual as it explains all the details necessary to achieve this, including the incorporation of visuals to accompany the numeric values being pulled from. The key is using a label with the quantity and then using a Query to pull from that label quantity. Hopefully this helps get you started. If you run into any problems, feel free to post a new question.

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