Why use simulation?
Factory simulation can help solve a number of issues inherent in the automation industry. But the main goal is to reduce risk. How can it do that? By reducing physicality. By moving as much as possible into the digital domain. How and why this is done is discussed below.
If you'd like background information on this topic, see:
Benefits for business owners & managers
- Reduced commissioning time Whether on your floor or the customer's, time spent here is more expensive than in the office.
- And since you're spending less time on your floor, you don't need as much floor space (smaller buildings!).
- Fewer mistakes A sim is a great communication tool and can be the 'source of truth' because:
- Everyone can actually see what the machine looks like and understand how it works because it moves ( CAD does not move).
- Mechanical, electrical and software can come together and be cross-checked. (See article?)
- It is possible to tie it to various systems (BOMs in databases, electrical drawings, etc.) with some programming.
- Shorter schedules Parallelizes the build and debug phases; PLC programmers can test their software before the machine is built.
- Reduced staff turnover Smoother projects result in happier people.
PLC Programmers
- Increased productivity More time working productively at your desk instead of on the shop floor waiting for trades, parts, etc.
- Increased comfort Ability to test your program without risk of damaging tooling, parts, equipment, etc.
- Increased creativity Ability to experiment with approaches algorithms.
- Increased understanding Understand clearly the intended machine operation just by watching an animation. And perhaps reviewing the simulation code (sequencers only). No need for timing diagrams or lengthy 'sequence of operations' documents.
Installers
- Reduced onsite time Anyone who's been involved with getting a machine running knows that it can be gruelling: long days, away from home, constantly dealing with unforeseen issues. Having a sim greatly reduces unforeseen issues (they will be foreseen) and much less testing will have to be done onsite. Tweaking the program for mechanical and environmental issues will be the main task.
Social
The items above address cost primarily: more successful projects result in more profitable businesses which is good for owners and employees alike. A more difficult cost to calculate is the social cost of this type of work.
There is a large physical component to this industry (physical machines making physical parts in a physical place) compared to the pure software industry (a website can be made and published anywhere). This places a significant physical burden on the people in the industry. They need to handle machines, parts and be in the same location of the machine therefore requiring travel. This places strain on the person and their family resulting in burnout, injury, divorce and other social ills. Minimizing the physicality of the industry can help relieve all these factors. And limiting unforeseen issues greatly reduces stress especially onsite.
Why is no one using simulation?
The simple answer is cost. This comes in two forms:
- Software cost: the per-seat cost of commercial simulation software is significant (even prohibitive for small outfits). And there is often expensive training required to become proficient with the software.
- Time cost: This is the main reason; the perception is it takes too long to create a simulation. The feeling, perhaps, is that the actual machine can be built faster than the simulation, rendering the simulation useless.
How can it be cheaper to create a sim than not?
The answer: by reducing risk. More risk = more cost. A sim reduces risk. Therefore, the more risky your project, the more valuable a sim.
What increases risk on a project?
- Size: number of I/O, physical size.
- Complexity: sophisticated components (servos), many scenarios (multiple product lines)
- Duration: longer projects will have personnel turnover therefore more succinct communication and a single 'source of truth' will be important. Of course, there are also financing costs and more.
- Uniqueness: if the machine you are building is new to you or your industry it will be harder to complete within budget.
- Access Scarcity: limited access to the site, plant or line (due to distance, security or scheduling).
- Part Scarcity: if machine components (say, welding guns) or product parts (say, diaper fabric or tires) are scarce (hard to source) then it will be hard to build and test your machine. This is very common when building a machine for a new part (which is typically when a new machine is required, so, very often).
- Space Scarcity: lack of space to build or test your machine.
- Information Scarcity: your customer is simply not communicative, purposely (for security reasons) or not.
Wrap up
Simulation reduces risk and risk is expensive. Simple as that. See the other articles for more: