Delmia DPM M2 - Create the Process Plan

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Create the Working Environment

Create the Process Plan

3 Create the Simulation

4 5

Analyze the Movements

Enhance the Simulation

6 Create Output files

7 Conduct Tool Validation

Module 2

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Create the Process

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Create the Process

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.

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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

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Workbenches and Toolbars used in this Module Workbenches

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Toolbars

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Create the Process Create a Process Library

A

B Create a Process Plan

Create Activity Types Create Activity Subtypes

Attach Process Library Insert Activities Insert Subtype Activities D

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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E Verify the Process Prepare Verification Dialog Box View Disassembly and Assembly

3 hours

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A

Create a Process Library

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Create Activity Types Create Activity Subtypes

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Create a Process Library

Create the Process About Process Libraries

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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.

More about Process Libraries can be found in the On-Line documentation. 6

Create the Process

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Create a Process Library

Create a Process Library– Procedure 1

To create a new Process Library, click File / New…

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From the New dialog box select ProcessLibrary. Click OK.

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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.

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Create the Process

Create a Process Library

Create a Process Library– Procedure 4

The New Type dialog box will appear. From this dialog box the Activity will be named. Notice that the option to link this library to a previously established library is available through the “Inheritance from another library” drop down menu. Attaching an already established library and manipulating it to suit the project needs can save time. The screen will show an activity icon with the activity name printed twice at the top of the screen.

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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.

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Create the Process

Create a Process Library

Create a Process Library– Procedure

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Highlight the subtype activity just created, and select the Create new activity subtype icon.

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Name the new subtype activity then click OK.

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This is an example of a process library.

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Create A Process Library – Exercise

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Master Exercise – 3.5 HP Engine 3.5 HP Engine (Step 5): Create a Process Library 20 min.

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:

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Create a process library Create an activity Create subtype activities

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Do It Yourself (1/4)

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Starting point

Ending point

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Do It Yourself (2/4)

1. Start by creating a new process library.

2. To build the process library for the 3.5 hp engine project, you will need the ProcLibCreation Toolbar.

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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 engine’s subassemblies.

5. 6. 7.

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.

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8.

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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Do It Yourself (4/4)

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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,

Your process library should look like this.

SAVE AS: R16 DPM Assembly / Project Data / ProcessLib1 15

B

Create a Process Plan

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Attach the Process Library Insert Activities Insert Subtype Activities

Inst. Inst. 16

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Create the Process Plan

Create a Process Plan

About the Process Plan

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A process plan is a collection of activities that occur in a certain order to achieve a specific outcome or product. A process plan is created by pulling activities from a process library into the process. Once activities become part of the process plan they can be edited to meet specific needs. When completed, the process plan is a visual representation of the process’s critical path.

More about Process Planning can be found in the On-Line documentation. 17

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Create the Process Plan

Create a Process Plan

Insert Library - Procedure 1

The first step in creating a process plan is to attach a process library to the project.

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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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Create the Process Plan

Create a Process Plan

Insert Library - Procedure 4

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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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Create the Process Plan

Create a Process Plan

Add Activities - Procedure After Insert Activity has been clicked, the Insert Activity dialog box will display.

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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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Create a Process Plan

Create the Process Plan

Add Activities - Procedure 2

To complete the process plan, continue inserting activities and assigning their relationships as either Child or Successor until there is a process activity that will represent everything that must be accomplished for the project. Subtype activities can be added depending on the amount of hierarchical detail needed.

3 The procedure for assigning subtype activities is the 1. 2.

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3. 4.

same as assigning activities: Click on the Insert Activity icon. Select the item to be attached from the Insert Activity dialog box. Choose the relationship, as child or successor. Select the item in the process node to which the subtype activity will be assigned.

Reassigning the child or successor relationship can be done by dragging and dropping the activity to another level on the PPR tree.

A CHILD of an activity is inserted one level beneath its parent activity and will automatically generate a start and stop function.

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. 21

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Create a Process Plan

Create the Process Plan Rename Activities – Procedure

Once the initial activities of the process have been assigned, they can be modified to reflect the specifics of the current project.

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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.

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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. 22

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Create A Process Plan – Exercise

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Master Exercise – 3.5 HP Engine 3.5 HP Engine (Step 6): Create a Process Plan 20 min.

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.

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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: ƒ Attach a process library ƒ Insert activities

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Do It Yourself (1/3)

Starting point

Ending point

Load: R16 DPM Assembly / Project Data / Process / Environment2 25

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.

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Open environment_2 from the Process Folder In Project Data.

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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.

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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.

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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.

Save As: R16 DPM Assembly / Project Data / Process / Dissassembly1 27

C

Order Activities with PERT Chart

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Manipulate the PERT Chart Link Activities Modify Process

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Create the Process Plan

Order Activities with PERT Chart

About the PERT Chart

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The PERT chart is a graphical representation of the process flow. It allows for modification of the process plan in a dynamic and friendly manner. It is a useful tool for visualizing and re-structuring the sequence of operation of the process. Since simulation is a 3D representation of the manufacturing process, the PERT chart can easily re-sequence the process. The order in which the activities are linked will be reflected in the PPR Tree.

More about PERT Charts can be found in the On-Line documentation. 29

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Create the Process Plan

Order Activities with PERT Chart

Access the Pert Chart – Procedure 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.

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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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Order Activities with PERT Chart

Create the Process Plan Access the PERT Chart– Procedure

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

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Display sub-processes by clicking on the + sign. The block will expand to show the sub-processes.

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Create the Process Plan

Order Activities with PERT Chart

Access the PERT Chart– Procedure Sub-processes are activities that are subordinate to a main activity. For example, assembling a muffler might require that several sub-steps, or subprocesses, be performed.

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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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Create the Process Plan

Order Activities with PERT Chart

Move PERT Chart Icons – Procedure On the PERT Chart, activity icons can be moved around the for the purpose of organization and sequencing.

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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. 33

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Order Activities with PERT Chart

Create the Process Plan Link and Unlink Activities– Procedure There may already be arrows on some of the boxes. This is the result of selecting the Add as Successor option when creating the new process.

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Activities can be linked to multiple activities when necessary.

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

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Create the Process Plan

Order Activities with PERT Chart

Link and Unlink Icons – Procedure An activity inside of a blocked process can NOT be linked to an activity outside the block. Activity icons can link to another process by clicking on its surrounding block. Doing so creates another stop activity inside the block.

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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.

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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. 35

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Create the Process Plan

Order Activities with PERT Chart

Move Between Pert Chart and 3D View – Procedure

To return to the 3D view use the Data Views toolbar.

Click the Open PERT Chart button to display the PERT Chart view.

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Click the 3D Standard Viewer button to display the 3D View.

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Order Activities with PERT Chart

Create the Process Plan Insert Logical Activities – Procedure

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.

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Add a Stop activity: This creates the basic start and stop icons.

Add a Switch activity: When creating forks there is an option to create switches.

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. 37

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Pert Chart – Exercise

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Master Exercise – 3.5 HP Engine 3.5 HP Engine (Step 7 ): Use the Pert Chart 20 min.

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.

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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: ƒ Use a PERT chart ƒ Link blocks and activities ƒ Manipulate the process

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Do It Yourself (1/4)

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Starting point

Ending point

Load: R16 DPM Assembly / Project Data / Process / Disassembly1

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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.

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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.

Link the engine assembly to its start and stop operations.

4.

Examine all of the links and delete any that seem wrong.

5.

Assign any missing links so that every box of the process is linked in a flow that makes sense.

6.

To create the links you need, click on the Link Selected Activities icon.

7.

Select the box from which the link starts followed by the box you wish to link.

8.

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.

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Your Pert chart should look similar to this. NOTE: With your instructor’s help, you may choose to create parallel processes or insert other logical activities. However, the subsequent exercises will assume that the sequential state described here is present.

Save As: R16 DPM Assembly / Project Data / Process / Disassembly1 42

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Link Product Data to the Process

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Link Product Data to Activity

Inst. Inst. 43

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Link Product Data to the Process

Create the Process Plan

About Linking the Product Data to the Process

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After the process is built and it has been sequenced using the Pert Chart, the next step is to associate the product data to the process activities. Prior to linking the data, the process has been given the instructions needed to carry out the task. By associating the product (parts or assemblies), to the process activities, the process is being assigned products on which to perform its tasks.

More about Linking Product Data can be found in the On-Line documentation. 44

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Create the Process Plan

Link Product Data to the Process

Link Product Data to the Process - Procedure 1

Open the Process Node of the PPR tree so that all of the activities in the process are visible.

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Open the Product node of the PPR tree so that the parts of the product are visible.

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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. 45

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Link Product Data to the Process

Create the Process Plan Link Product Data to the Process - Procedure

5 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.

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Example: The crankshaft gear must appear in each activity that calls for a crankshaft gear or it will not be visible in the simulation.

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.

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Create the Process Plan

Link Product Data to the Process

Link Product Data to the Process - Procedure

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You can use the View menu (or Toolbar) to check whether or not all assignments have been made by selecting List unassigned Products.

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Link the Data – Exercise

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Master Exercise – 3.5 HP Engine 3.5 HP Engine (Step 8 ): Link the Product Data to the Process Activities 20 min.

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.

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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)

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Starting point

Ending point

Load: R16 DPM Assembly / Project Data / Process / Disassembly1 50

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.

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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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Do It Yourself (3/3)

4. Repeat the steps until all of the engine parts and all of its subassemblies have been assigned to the appropriate activities.

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5. Use the List Unassigned Products icon to view the engine components without assignments. Correct any unassigned subassemblies.

SAVE AS: R16 DPM Assembly / Project Data / Process / Disassembly2 52

E

Verify the Process

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Prepare Verification Dialog Box View Disassembly and Assembly

Inst. Inst. 53

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Verify the Process

Create the Process Plan About Process Verification

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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.

More about Process Verification can be found in the On-Line documentation. 54

Create the Process

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Verify the Process

Process Verification - Procedure

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Select the Process node from the PPR tree. From the Simulation toolbar select the Process Verification Icon. The Process Verification dialog box will appear.

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From the dialog box, click on the More button to Activate more options. Set the options in the box to: • Check the Animation box

Go to next activity.

More details on the button functions are located on the next page.

• Show Activity’s Products • Show All Resources

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• Reframe OFF

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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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Verify the Process

Create the Process

Process Verification - Procedure The Process Verification dialog box contains selections that will control the viewing of the process.

Go to the beginning of process within level Go to the beginning of process

The animation check box will cause the process to proceed automatically

Go to previous activity

Go to parent activity

Go to the end of process within level

Go to the end of process

Applies user-defined descriptive statements

Shows part-specific descriptions

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Repositions view to enhance simulation Activates user-defined pauses Activates hyperlink activities

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Create the Process

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Verify the Process

Process Verification - Procedure As process verification occurs, the nodes will highlight and the parts will be displayed. This validates that links are established and that the process is ready for simulation. When working in manual mode, if you did NOT click through the entire Validation process you will need to restore the initial state to return to the beginning.

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The validation process can be followed on the PPR tree

Select the “Restore Initial State” icon on the Simulation Toolbar.

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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Create the Process

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Verify the Process

Reverse the Process - Procedure

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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.

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Select the Process node on the PPR Tree and then click on the Reverse the Process icon on the Activity Management toolbar

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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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Verify the Process – Exercise

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Master Exercise – 3.5 HP Engine 3.5 HP Engine (Step 9): Link the Product Data to the Process Activities 20 min.

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.

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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: ƒ Validate the process ƒ Watch the assemble process 60

Do It Yourself (1/2)

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Starting point

Ending point

LOAD: R16 DPM Assembly / Project Data / Process / Disassembly2

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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 Activity’s 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.

The validation process can be followed on the PPR tree

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3. Click OK to Revere the entire process. Notice that the PPR Tree reverses.

Make changes to the process by using the Pert Chart.

SAVE AS: R16 DPM Assembly / Project Data / Process / Disassembly3 62

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Create the Process – Module Summary

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.

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Coming Up Create the Simulation Build a Basic Simulation and Refine the Moves. 3 hours

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