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Create the Simulation
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Analyze the Movements Enhance the Simulation
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Create Output files
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Conduct Tool Validation
Module 2
Overview
Simulation studies generate valuable information to organizations regarding processing sequence and optimization. In order to develop a simulation study, an initial process must be created. Once created, processes can then be stored in libraries and re-applied to other projects at a later date. This module takes a step-by -step approach to creating a process, from creating the process library to final validation.
Objectives
Topics in this module are: Create the Process Library Create the Process Plan Use the Pert Chart Link Product Data Verify the Process
3 hours
Toolbars
B Create a Process Plan Attach Process Library Insert Activities Insert Subtype Activities
C Link Product Data to the Process Link Product Data to Activity Use the PERT Chart Manipulate the PERT Chart Link Activities Modify Process
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Verify the Process Prepare Verification Dialog Box View Disassembly and Assembly 3 hours
A Process Library allows you to arrange process activities according to manufacturing area (Bodyshop, Powertrain, etc.) or discipline (Assembly, Machining, etc). During the creation of a process library, activities and subtype activities can be defined to add detail. The activities in a process library are used to represent the actions that need to take place in order to complete a process. Once completed, a process library can than be attached to multiple processes.
Now that the process library has been created it will need to be populated with Activities and activity subtypes.
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Locate the ProcLibCreation toolbar, and click on the Create new activity type icon.
The next step in creating the process library is to add subtype activities. Highlight the activity to which the subtype activity will be attached, and select the Create new activity subtype icon. Name the subtype activity then click OK.
Highlight the subtype activity just created, and select the Create new activity subtype icon.
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Scope: In this exercise you will create a process library for the assembly of a 3.5 HP engine. Later, the library will be inserted into the engine assembly process. Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R16 DPM Assembly / PROJECT DATA
In this exercise you will: Create a process library Create an activity Create subtype activities
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Do It Yourself (1/4)
Starting point
Ending point
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Do It Yourself (2/4)
2. To build the process library for the 3.5 hp engine project, you will need the ProcLibCreation Toolbar.
3. The exercise is focused on one activity, the 3.5 hp engine. Use the Create New Activity Type icon to insert Engine assembly into the process library.
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Do It Yourself (3/4)
4.
For this exercise, you will be adding subtype activities which will represent the engines subassemblies.
5. 6. 7. 8.
To add the subtype activities, click on the engine assembly activity. Click on the Create New Activity Subtype icon. When the New Type dialog box appears, type Block Assy as the subtype name. Click OK.
9. For the next subtype activity, repeat the procedure. 10. Name the subtype, Exhaust Valve Assy. Remember to click on the Engine Assembly activity first.
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7. Finish the library by adding the remaining subtypes: Intake Valve Assy, Muffler Assy, Carburetor Assy, Air Filter Assy, Crankshaft Assy, Piston Assy, Piston Rod Assy, Cam Assy, Crankcase Assy, Head Assy, Coil Assy, Flywheel Assy, Cover Assy,
Create a Process Plan Attach the Process Library Insert Activities Insert Subtype Activities
Inst. Inst.
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Double click on the Process node from the PPR tree. From the Main Menu choose INSERT, then select Insert Activity Library (or use the Activity Library icon on the Activity Management toolbar by clicking on the icon first, then the Process node).
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When the File Selection dialog box appears, locate and select the desired process library and click Open.
The Dialog box will close but the screen will not appear different. What has happened is that the link to the library has now been established. This permits the activities to be placed into the process node of the PPR tree. The activities can be placed using the menu or by clicking on the Insert Activity icon.
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Click on the activity type in the Insert Activity dialog box, then click on the Process node in the PPR Tree. With the selection Add As Child, you will see the activity type appear under the Process node.
It is important to understand that each action that is to be represented in the simulation has a corresponding activity in the process node. Although activities can be added or removed from the process at any time, it is more efficient to populate the process node at this time.
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A CHILD of an activity is inserted one level beneath its parent activity and will automatically generate a start and stop function.
Reassigning the child or successor relationship can be done by dragging and dropping the activity to another level on the PPR tree.
A SUCCESSOR of an activity is inserted into the process as the next logical activity and will be automatically linked to the next action.
Inst. Inst.
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Once the initial activities of the process have been assigned, they can be modified to reflect the specifics of the current project.
Access the Properties dialog box by highlighting an activity in the PPR tree and right clicking on it. This brings up the Properties dialog box. Activity names, cycle times, descriptions, as well as many other aspects associated with this activity, can be reassigned from this dialog box. Icons can also be reassigned by clicking on the icon next to the Icon Path dialog box. The Icon file dialog box will appear with the icons in the Current location.
Inst. Inst.
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Scope: In this exercise you will create a process plan using the library created in the previous exercise and attaching it to Environment2 . You will then insert activities and subtype activities into the process node. Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R16 DPM Assembly / PROJECT DATA
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Do It Yourself (1/3)
Starting point
Ending point
Do It Yourself (2/3)
This process plan will begin as a disassembly process. After the sequence has been validated, it will be reversed into an assembly sequence.
1. 2.
Open environment_2 from the Process Folder In Project Data. The process library you created in previous exercise will need to be linked in order to insert its activities into the process node of Environment3. You will do this by using the Insert Activity Library icon.
A. B. C.
Click on the Insert Activity Library icon. Click on the process node from the PPR tree. Locate and select the ProcessLib1 that was created.
Remember that although the environment still appears the same, the process library is now linked to the process node.
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Do It Yourself (3/3)
To populate the process node with the activity and subtype Activities, use the Insert Activity icon. 3. From the Insert Activity dialog box, click on the Engine Assembly, then click the process node. Engine Assembly.1 will appear under the process node. 4. Since you are building an engine disassembly, the remaining subtype activities will be added in the reverse order that they appear in the process library. 5. With the dialog box still open, click on the Block Assy subtype. With the Add As Child selection made, click on the Engine Assembly. 6. Add all of the remaining subtypes with the Add As Successor option.
Remember that the Successor must be linked to the previous sub assembly and not to the engine.
Order Activities with PERT Chart Manipulate the PERT Chart Link Activities Modify Process
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From the standard view, the process plan can be seen in the PPR tree. However, when modifications need to take place or a portion of the process needs a closer look, using the Pert Chart is more appropriate.
Highlight the process node, an activity, or a subtype activity. The PERT chart is able focus on only the specific level of the process plan that needs modification. After the appropriate level has been selected, click on the Open PERT Chart icon from the Data Views Toolbar.
The portion selected from the Process plan is now available in the PERT chart.
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When you display the Pert Chart, you will see a row of Process Activity icons. This is an example of how the PERT Chart might look from the Process Node level. Notice that the entire Engine Assembly is one icon.
A + sign in the upper right corner of an icon indicates that the process contains sub processes
Display sub-processes by clicking on the + sign. The block will expand to show the sub-processes.
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The blocks hold icons for activities that were created as children of another activity. The block represents the hierarchical position of a group of activities.
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On the PERT Chart, activity icons can be moved around the for the purpose of organization and sequencing.
Left click and hold to move icons to any square that permits you to visualize the sequence. Icons within a blocked process will remain inside the block because the process is part of a parent-child relationship. For that reason, the block changes shape to accommodate all of the icons in that sub-assembly.
Inst. Inst.
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To link the steps together, click on the Link the selected activities icon on the Activity Management toolbar. Make sure the icon is highlighted orange. Select the activity to link, then select the second activity to link. After clicking the second activity, a link arrow will appear between the two to indicate the linkage.
To unlink a box, click the arrow so that it turns orange, then press the delete key. 34
Create a flow from a blocked process to an activity or another block by adding links. This will create a start and stop icon inside the block. The start icon can then be moved to the front of the activity and linked together.
There must be a start and stop logical activity for the entire process.
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Click and drag activities to a different area of the PERT Chart as necessary to view hidden boxes.
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Click the Open PERT Chart button to display the PERT Chart view. Click the 3D Standard Viewer button to display the 3D View.
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After the PERT Chart has been created, start and stop activities can also be inserted into the 3D Standard Viewer using the Logical Activity Creation toolbar.
Add a Start activity: This creates the basic start and stop icons. Add a Switch activity: When creating forks there is an option to create switches.
Add a Stop activity: This creates the basic start and stop icons.
Add an OrIn activity: When linking to more than one activity this can create a 2nd option for the switch.
Add an AndIn activity: This command gives the option of creating more than one activity to connect to the next activity.
Add an AndOut activity: This command gives the option of creating more than one way to connect to the next activities.
The Logical Activity Creation toolbar provides methods for modifying the process by inserting extra Logical Activities in addition to the Start and Stop icons that come with the relationship linkage.
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Scope: In this exercise you will use the PERT chart to examine the process. After considering the order in which the activities have been placed, you may wish to manipulate the process and add the appropriate links. Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R16 DPM Assembly / PROJECT DATA.
In this exercise you will: Use a PERT chart Link blocks and activities Manipulate the process
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Do It Yourself (1/4)
Starting point
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Ending point
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Do It Yourself (2/4)
Now that your process plan contains the activities needed to disassemble the 3.5 hp engine, you will take a closer look at it using the Pert chart.
1. Click on the Process node, then the Open Pert Chart icon.
2. Examine the Pert chart for the engine process created earlier. It should look like this once you have expanded it by clicking on the + in the upper right corner of the engine assembly box.
The arrows connecting the boxes represent a link from one action to the next. Remember that the links were established by choosing either a child or successor relationship while being inserted to the process.
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Do It Yourself (3/4)
3. 4. 5. 6. 7. 8. Link the engine assembly to its start and stop operations. Examine all of the links and delete any that seem wrong. Assign any missing links so that every box of the process is linked in a flow that makes sense. To create the links you need, click on the Link Selected Activities icon. Select the box from which the link starts followed by the box you wish to link. Notice that when you linked the engine assembly to its start and stop boxes, new start and stop boxes appeared. These will also need to be repositioned and linked.
Inst. Inst.
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More about Linking Product Data can be found in the On-Line documentation.
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Open the Process Node of the PPR tree so that all of the activities in the process are visible. Open the Product node of the PPR tree so that the parts of the product are visible. Collapse the rest of the Product nodes (if needed) until they are at a discreet part level. Look for the BLUE gear icon to identify a part, and the PINK gear icon to identify a product assembly. Go to the Activity Management toolbar and find the Assign an item icon.
Select the drop down arrow to see the additional features behind this icon. ERROR RECOVERY: Note the Unassign an item icon.
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Each item in the product list should be assigned to a Process activity. Use the Assign an Item icon to link product nodes (assemblies or parts) to process activities. a. Click on the Product item. b. Click on Assign an Item icon. c. Click on the process activity to which the product should be assigned. Make linkages at the same hierarchical level. For example, link product assemblies to process assemblies and product parts to assembly components.
Example: The crankshaft gear must appear in each activity that calls for a crankshaft gear or it will not be visible in the simulation.
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Scope: In this exercise you will link the product subassemblies to the subtype activities in the process node. Further, you will find any unassigned product components and decide if a link is needed. Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R16 DPM Assembly / PROJECT DATA.
In this exercise you will: Link the process to the product Find unassigned products
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Do It Yourself (1/3)
Starting point
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Ending point
Do It Yourself (2/3)
The Engine assembly does not get linked
Now that the process is In order, Link the process to the product.
1. Start by expanding both the Processlist and Productlist nodes in the PPR tree. 2. From the Activity Management Toolbar, use the Assign An Item icon to create the link between process and product. Assign the pink Assembly icon to the subassembly level of the process.
3. Click on the product. Find and click on the Assign an item icon. Click on the activity from the process node with which the product corresponds.
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4. Repeat the steps until all of the engine parts and all of its subassemblies have been assigned to the appropriate activities.
5. Use the List Unassigned Products icon to view the engine components without assignments. Correct any unassigned subassemblies.
Verify the Process Prepare Verification Dialog Box View Disassembly and Assembly
Inst. Inst.
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Process Verification is a visual representation of the process and product link. The Process Verification function permits the user to validate the product flow according to the sequence of the process plan. Running this procedure allows for the viewing of the parts and assemblies as each process activity calls for them. It is a method to validate the process prior to constructing a simulation.
Select the Process node from the PPR tree. From the Simulation toolbar select the Process Verification Icon. The Process Verification dialog box will appear.
Go to next activity.
From the dialog box, click on the More button to Activate more options. Set the options in the box to: Check the Animation box Show Activitys Products Show All Resources Reframe OFF
More details on the button functions are located on the next page.
After the options have been set, click on the Go to next activity button. The Process Verification will follow the process plan. Notice the time box keeps the overall cycle time.
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The animation check box will cause the process to proceed automatically
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Click OK in the Restore Initial Condition box to restore the original condition of the world for all products and resources and all of their attributes.
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It is sometimes easier to see the verification of the process in reverse order. For example, a disassembly sequence may be easier to follow if product items appear in the assembly order. For these situations, it is simple to reverse the process and then run the verification.
Select the Process node on the PPR Tree and then click on the Reverse the Process icon on the Activity Management toolbar
When the dialog box comes up select the Reverse the entire process option. Notice that you can reverse only certain segments of the process. This option is useful after the simulation has been constructed using move activities.
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Scope: Before the process can move on to the next step, you need to validate the process. During the validation process, you will observe the process node to see that all products are linked to their respective activities. Conditions: V5 and DPM Assembly Process Simulation workbench must be open. Access to the files in R16 DPM Assembly / PROJECT DATA.
In this exercise you will: Validate the process Watch the assemble process
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Do It Yourself (1/2)
Starting point
Ending point
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Do It Yourself (2/2)
1. You can verify the process after the products are linked to the processes. From the simulation toolbar, open the Process Verification dialog box. Set the following options: A. Animation on. B. Show Activitys products. C. Show all Resources. D. Reframe off. 2. Once the disassembly process has been established, it can be viewed in the assembly order. Use the Reverse the Process function to do this and then watch the engine assemble.
3. Click OK to Revere the entire process. Notice that the PPR Tree reverses.
Summary Whether it is done in DPM Assembly or in another software, such as Process Engineer, creating the process is the necessary first step to constructing a simulation. This module has demonstrated how to create and validate the process intention. As the simulation is built, modifications to the process are likely and can be easily accomplished using the techniques demonstrated here.
Coming Up Create the Simulation Build a Basic Simulation and Refine the Moves.
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3 hours
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