Using Operator as a Combiner Subtitute

Question

question

James M7 asked Jun 30 2020 at 7:16 AM tannerp edited Jul 06 2020 at 4:58 PM

Using Operator as a Combiner Subtitute

Hi I have a question regarding preventing a long line of product due to combiner's downtime using operator. On my model below, I have an incoming product called FG that go through ConvA, ConvB and ConvC.

My question is that, in case the combiner is going through a downtime, how can I model and build the logic so that the two operators, OP_1 and OP_2, to do the combiner's job by taking some amount of FG from ConvA/ConvB/ConvC, pack it on a case and put it on ConvOP (in front of OP_1)?

To do this, do I need to add a processor next to the Operator to input the time taken for each one of them to do this job?

I attached my model below. Any kind of help is appreciated.

FlexSim_Trial.fsm

Software Version:

FlexSim 19.2.4

conveyor queue flexsim 19.2.4 combiner downtime

flexsim-trial.fsm (106.6 KiB)

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Answer 1 · 2020-06-30T17:59:47Z

tannerp answered Jun 30 2020 at 5:59 PM tannerp edited Jul 06 2020 at 4:58 PM

@James M7,

I developed a sub-flow in which operators load bottles and manually deliver them to the conveyor like you described. That said, I couldn't figure out why the MTBF/MTTR wasn't working for awhile until I noticed that you have a negative downtime. You might need to re-evaluate the Down Time function as shown so that negative values aren't possible. Maybe use a triangular distribution so you can define the minimum as 0.

With that out of the way, I'll try and explain the sub-flow at a high-level. Then, if you have questions, feel free to ask.

When the combiner breaks down, a token is created in the SubFlow at the Start activity. The token stops input to the combiner, grabs an operator, loads a tote, fills the tote with bottles, and then delivers it to the conveyor. I took some liberties and set the requested number of bottles to 10. This could be whatever you'd like. I also had the operator travel to arbitrary locations while doing all this.

Hopefully this helps.

flexsim-trial_1.fsm

negative-downtime.png (20.5 KiB)

flexsim-trial-1.fsm (109.1 KiB)

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James M7 commented · Jul 01 2020 at 7:23 AM

Hi Tanner,

I received your file and it looks great. I kinda understand how the logic of the subflow works and really appreciate your help. However, I notice that the operator only do the manual packing when the combiner stops working instantaneously but not while it is not working. After sometimes, this can trigger the ConvB for stopping the flow and I got an error.

Is it possible to make the operator do the manual packing as long as the combiner stops working?

I attached the modified file below. Again, thank you so so much.

flexsim-trial-2.fsm

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tannerp James M7 commented · Jul 03 2020 at 4:36 PM

@James M7,

Unfortunately, the model file didn't get uploaded properly (this is a problem with our Answers site, not your model). Would you be able to upload it again? For now, I'll do my best to answer some of your follow up questions. Keep in mind that my model was only an example and it shouldn't be relied on for your modeling purposes. You'll need to update it yourself.

It sounds like your main concern is how to get the operator to continue to do the manual packing as long as the combiner is down. You can add a Decide activity towards the end of the Process Flow that will check the state of the combiner. If the state is still "down", then you can loop the token back through and load another tote of bottles.

I've updated your model to do this. I'd recommend doing some Process Flow tutorials if you haven't yet. That way you can understand these activities better and update them to meet your needs.

flexsim-trial-1_1.fsm

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