Modeling, Simulation and Optimization of The Main Packaging Line
Modeling, Simulation and Optimization of The Main Packaging Line
OF A BREWING COMPANY
Figure 6: Pallet entity arrivals.
Figure 2: 3D SIMIO model (despalletizer)
2.4.2. Depalletizer and Unpacker Machines
The depalletizer is the first equipment unit in the
packing process. The module “Separator” provided by
SIMIO is used to represent the depalletizer’s operation,
which is shown in Figure 7. On the right side of this
picture, we can see the properties associated with the
“Separate” module, i.e. the property “Processing Time”
determines that each pallet is processed in a time of 50
seconds. Each pallet that is full of drawers enters to
depalletizer to be processed and then 50 new entities
representing the drawers are generated by the model.
Figure 3: 3D SIMIO model (unpacker)
2.4.11. Transports
There are two transport lines, one for bottles and other
for drawers. “Basic Node” and “Conveyor” elements
were used in the simulation model to represent the two
transport lines. It is worth to remark that some
components of SIMIO have important parameters that
must be set by the user. In particular, some “Conveyor”
properties are given in Figure 23. From the picture, it Figure 25: 2D SIMIO model (distribution processes)
follows that these properties might be used to vary
things like conveyor speeds, traveler capacity, or the
option for accumulating or non-accumulating conveyors
Figure 26: SIMIO processes (Bottles distribution) Scenario 1: system with engine capacities and
speeds and actual transport, and percentages of
2.4.12. Sensors rejections of inspectors,
Several sensors control the number of bottles or drawers Scenario 2: system based on theoretical speeds
that are on the line. Such devices, located on strategic of the machines, provided the design of the
points of conveyor belts, emit signals so that transports line ("V Line").
or machines can start or stop their activities. These Scenario 3: system considered in scenario 2,
sensors are switches that are activated or deactivated where, in addition, use is made of a battery
according to whether they are in contact with the object. drawer between the packer and unpacker
To represent the above behavior, “monitor” and machine,
“variable” elements were used in the simulation model Scenario 4: system considered in scenario 2
so that the logic of each machine can be properly with the modification logic combiner boxes
defined. For example, the unpacker machine has three found after the depalletizing machine,
possible states: (i) stopped, (ii) low speed or (iii) high
Scenario 5: system considered in scenario 2
speed. A variable was defined to determine the machine
with the increased transport speed that are in
state at a given time. The possible values of this
the area of the clean room due to the high rate
variable are: 0 (if the machine is stopped), 1 (if the
of accumulation of bottles with those found
equipment is operated at low speed) or 2 (if the machine
before the empty bottle inspector .
is running at high speed). In addition, three monitors
were defined for associated transports. If a capacity
Throughout the model, we adopt a series of
change is detected in them, the monitors trigger a
measures for evaluating performance goals achieved by
process determining the speed at which the equipment
the line and compare its performance against changes
should operate. This value is then saved in a predefined
that may occur. The proposed changes were modeled
variable. On one hand, if there is no accumulation in
using the tools Ape presents the simulator and that were
output transport and there are drawers in input transport,
mentioned earlier. Thus, modifications were made on
the machine operates at low speed. On the other hand, if
these variables, as they are directly related to the
there is accumulation in the input conveyor, the
operation of the packaging line and determined the
machine changes to high speed.
degree of improvement that can be achieved are
effected once.
The performance parameters are considered for
carrying out the analysis of the system is discussed
below.
Speed (bpm)
the line under study for a work shift of eight
38.000
hours,
36.000
Changes in speed and stability of the
machines: they want to reduce machine 34.000
downtime seeking stability thereof thus 32.000
explores the reasons why change their speed 30.000
(or shortage of product accumulation) and
proposes improvements.
Machine
Theoretical Speeds Real Speeds
3. RESULTS
The original design of line speeds under study is based Figure 28: "V" line with ideal and actual speeds
on the concept of the "V" which takes the limiting speed
of the machine, i.e. the filler, as a reference for defining Furthermore, the company determines the
machine speeds and hind to the same. The procedure for productivity of the packaging line from the
this calculation is carried out to increase between 10% measurement of the efficiency of their equipment. This
and 15% speeds as they move away from the filler. is calculated from the values corresponding to the
Ideal speeds (assuming ideal speed machine bottleneck, number of bottles produced during an operating period
550 bpm) and actual speeds of the machines determined in relation to the theoretical amount of
(considering uptime, downtime and uptime internal) bottles that must have occurred during that period
over a month of work were considered. Table 1 and (Equation 1). The bottles theoretical amount calculated
Table 2 show the results obtained from the analysis of from the limiting speed of the line which, as mentioned
speeds detailed above. above belongs to the filling machine.