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Procedia CIRP 61 (2017) 122 – 127

The 24th CIRP Conference on Life Cycle Engineering

Procedure model for efficient simulation studies which consider the flows
of materials and energy simultaneously
Johannes Stoldta,*, Matthias Putza
a
Fraunhofer Institute for Machine Tools and Forming Technology IWU, Reichenhainer Straße 88, 09126 Chemnitz, Germany
* Corresponding author. Tel.: +49 371 5397-1372; fax: +49 371 5397-61372. E-mail address: [email protected]

Abstract

The premise of this work is that more guidance is required for the application of the simultaneous simulation of material flows and energy
flows. This assumption is supported by the findings of a systematic review which showed great diversity in earlier published case studies. Yet,
other existing procedure models provide little advice regarding the manifestations of specific details of a simulation study. This paper presents
a novel procedure model that is meant to increase the efficiency in simulation projects by providing detailed and consistent guidance for design
choices in a simulation study. Selected results of its application are shown exemplarily.
©©2017
2017TheTheAuthors. Published
Authors. by Elsevier
Published B.V. This
by Elsevier B.V.is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 24th CIRP Conference on Life Cycle Engineering.
Peer-review under responsibility of the scientific committee of the 24th CIRP Conference on Life Cycle Engineering
Keywords: Simulation, Energy efficiency, Decision making, Procedure model, Discrete event simulation

1. Introduction only offers limited insight on the relevant criteria for deciding
which characteristics should be selected for investigating
Fuelled by economic pressure and societal change, the specific problems.
awareness of production companies for matters of energy and More guidance can be provided in the design and execution
resource efficiency has risen in recent years. In response, of efficient simulation studies for investigating the implemen-
engineers developed, implemented and tested a myriad of tation of energy efficiency (EE) measures. Thus, a detailed
approaches to eliminate energy waste by means of techno- procedure model is suggested to guide simulation engineers
logical and organisational improvements [1]. These efforts are with respect to their particular task. In preparation to its
usually expected to achieve an economic advantage quickly introduction, section 2 clarifies some terminology used in this
without adverse effects on the fulfilment of production targets. paper. The starting point for the procedure model was an
The combined simulation of material and energy flows has extensive systematic review on the characteristics of case
become a tool of choice for investigating approaches, which studies in the field, which have been published so far. Its
concern production system planning or operational aspects quantified results as well as a critical review of existing
(see reviews in [2,3]). A review of earlier published works on procedure models are presented in section 3. A description of
the subject shows that individual simulation studies vary the proposed model and its steps is provided in section 4. At
significantly in their respective characteristics. This can be last, a brief example is introduced to clarify which details are
exemplified considering the consumption model (energy considered and to illustrate the results of its application.
model) for electricity (ranging from operating state average
demand to actor-based physical simulations) or the employed
simulator’s architecture (ranging from offline spreadsheet 2. Terminology
calculations to online coupling of multiple simulators).
Some general work on the structured implementation of Characteristics of a simulation study describe how spe-
simulation studies, which consider the flows of both materials cific aspects are designed in the execution of the study, e.g.
and energy, has already been published [2–4]. However, it which approach/method to experiment design was chosen.

2212-8271 © 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 24th CIRP Conference on Life Cycle Engineering
doi:10.1016/j.procir.2016.11.195
 Johannes Stoldt and Matthias Putz / Procedia CIRP 61 (2017) 122 – 127 123

The Characteristics vector comprises all characteristics 2%

and defines the overall design of a study, i.e. includes the
7% 9%
experiment design, the simulator architecture, the energy
11%
model and other characteristics’ respective manifestation. 1%
25%
Case study is used, especially in the following section, in
the sense of a singular execution of a simulation study to 20%
investigate a specific system with a certain aim. Accordingly, 17% 8%
multiple investigations with different aims on the same
system or vice versa are considered as multiple case studies. PPC: Scheduling PPC: Lot size planning
PPC: Capacity planning PPC: Control strategies
SD: Infrastructure planning SD: Machine control changes
SD: Process / system design SD: Lifecycle assesment/costing
3. Literature review Supply Chain Management

The premise of this paper is that the efficient application of Fig. 1. Shares of use cases, which consider certain planning tasks.
simulation which simultaneously considers material flows and
energy flows requires more guidance than current approaches At about 71 %, the vast majority of the case studies utilised
can provide. The following section introduces a review of discrete event simulation (DES; e.g. [3–6,9–11]). Tools that
documented case studies (see section 2) to show the current combine DES with continuous simulation approaches, such as
diversity in such studies. Afterwards, existing procedure AnyLogic®, were also used fairly frequently (16 %; e.g.
models are discussed and the need for action is outlined. [2,14,15]). Another 6 % employed only a solver or alternative
simulation approaches and some 7 % of the documented case
3.1. Systematic review of documented case studies studies included no statement on the applied tools.
Documented solutions for enhancing material flow simula-
Recent years saw tremendous development in the field of tions with energy considerations differ primarily in which
simultaneous simulation of material flows and energy flows, energy-related target figures are measured and in how the
much of which has been documented in specific case studies. energy flows are modelled. In most cases, at 43 % each,
To provide an overview on the aims of these simulation electricity (e.g. [10,12,13]) or electricity along with other
studies and their respective characteristics, an extensive process media, such as compressed air, (e.g. [2,11,14]) were
literature review has been completed. In total, 75 publications included in the investigation. 6 % of the case studies focused
from 2005 onward have been identified that presented 104 on a total energy equivalent (e.g. [8]) and further 6 % were
case studies (see section 2). These were classified regarding primarily concerned with the CO2 equivalent or similar
their primary goal, planning task, type of tool, energy-related lifecycle inventory indicators (e.g. [16]). Only 2 % used costs
target figures, energy models, and experiment design method. as the main target figure (e.g. [9,17]).
In the following, the results of this systematic review are Fig. 2 shows the shares of case studies that applied the
discussed with selected citations. For purposes of conciseness, various identified energy models. The results show that most
the entire list of reviewed papers had to be omitted here. implementations used an average consumption for multiple
When material flow simulation is extended with energy, operating states (OS) (e.g. [3,11]). Some works also utilised
three different primary goals are relevant. 13 % of all case spline curves (e.g. [18]) or artificial models (e.g. [13])
studies aimed to verify or validate that a certain change (see abstracted from real measured profiles for selected OSs
planning task below) could improve the system’s energy (especially for producing or warm-up/cool-down states). The
efficiency. These put lower emphasis on quantifying the use of continuous or physical models is also found in some
actual effects on the energy consumption (e.g. [5]). The case studies, most of which also employed combined
majority of 74 % primarily tried to quantify the utilisation of simulation tools (e.g. [15]). Historic measurements or just
energy-related target figures (e.g. [2,3,6–8]) and another 13 % time-shares of OSs are used in only a few case studies.
aimed to optimise certain parameters/aspects (e.g. [9,10]).
Fig. 1 gives an overview on the planning tasks that were
5% 5% 2%
investigated using energy-enhanced simulation. Three basic 1%
7% 12% 3%
groups of tasks could be identified: supply chain management,
system design (SD), and production planning and control
(PPC). The latter two have been differentiated further to give
some insight on which particular aspect was adjusted to raise
energy efficiency. From the numbers it becomes apparent that 65%
both SD and PPC have been investigated in about equal
numbers, while only very few studies on supply chains (2 %)
Equivalent Historic measurements
could be found. In most cases, the simulations focused on Only OS OS-related averages
improved production control strategies (changes to the OS-related splines OS-related artif. models
Cont./physical models n/a
production flow; e.g. [2,4,5,10,11]) or efficient process or
system design (selection and dimensioning of material flow
system elements or similar; e.g. [2,3,6–8,12,13]). Fig. 2. Shares of use cases, which apply certain energy models.
124 Johannes Stoldt and Matthias Putz / Procedia CIRP 61 (2017) 122 – 127

Lastly, the experiment design methods documented in the 4. Procedure model

identified case studies provides some insight into the diversity
found in the execution of simulation studies. In the order of Simulation of production systems is generally used in the
their frequency, the following approaches were identified: factory’s lifecycle phases: planning, realising, and operation
scenario analysis (54 %), optimization (12 %), factorial [19]. The previously discussed case studies and procedure
design (12 %), sensitivity analysis (10 %), and design of models show that simultaneous simulation of material flows
experiments (1 %). Another 11 % included no statement. and energy flows is usually intended to investigate the effect
of certain changes in the system design, in both the physical
3.2. Discussion of existing procedure models structure and the organisation of processes. In fact, most
reviewed work concerned existing production systems, where
The previously discussed results of the systematic review energy data could be acquired directly from existing equip-
show considerable diversity in the application of simultaneous ment. A major reason for this appears to be the lack of data
simulation. Considering this result, existing procedure models provided by machine manufacturers. Accordingly, the scope
were reviewed regarding the assistance they provide in of the proposed procedure model shall be re-planning pro-
defining a study’s characteristics vector (see section 2). jects, which aim to foster energy efficiency (EE) and require
As of 2016, the relevant standard VDI 3633 Part 1 does not the simultaneous consideration of the material flows (MF) and
explicitly mention the inclusion of energy considerations in its energy flows (EF). It is understood that the model could po-
procedure model [19]. The associated ASIM professional tentially also be applied when planning entirely new systems,
group Simulation in Production and Logistics recognized this however, such cases are not in the scope of the current work.
deficit and has formed a work group dedicated to energy- The suggested procedure model comprises 12 steps (Fig. 3:
enhanced DES in 2014, i.a. to investigate possible needs. steps left, results right). These are supplemented with aids for
In his dissertation, Khalaf built on the VDI procedure deciding on characteristics. Similar to Sproedt et al. [3], the
model to provide guidance specifically for the development of steps of the actual simulation study are preceded by preparato-
energy efficient PPC strategies [4]. This work includes mostly ry steps intended to define a suitable project scope. While this
considerations on the data acquisition, pre-processing and is mostly a creative process, possible solutions can be classi-
data management. More differentiated insights on the efficient fied according to their principals. Müller and Löffler suggest-
design of simulation studies (i.e. when to choose which ed a set of heuristics for this purposes [20]. The preselection
characteristic) were not included. of one of these for a specific system requires a focus area, an
Sproedt et al. presented a more holistic procedure model, EE-related objective (EE focus), and potential for change.
explicitly aiming to “provide guidance in the general process Accordingly, the earlier two are defined in step 1. This
of identifying possible measures to improve its eco-efficiency, follows the logic that any re-planning project will be initiated
regardless of if simulation is intended to be used” [3]. The after preliminary analyses, which consider a company-specific
model itself provides no insight on the possible manifestations EE focus, were made to identify untapped potential (compare
the various characteristics of a simulation study may have, as to planning procedure model in [20]). These, again, will point
the scope is not primarily set on the simulation. Hence, also to a specific subsystem within the factory (focus area). The
no specific directions on the design of the characteristics EE focus is a management defined change driver like greater
vector (as introduced in section 2) are provided. ecologic efficiency (e.g. product per emission), better
Thiede’s procedure model combines three fundamental resource utilisation (e.g. less scrap), lower costs, or similar.
systemisations for fostering energy efficiency, for energy Considering the focus area in existing factories along with
management systems, and for simulation studies [2]. The so- other restrictions (e.g. process criticality), many aspects of the
called application cycle gives some methodical advice on how system may not change. In the style of [21], three coefficients
to make certain decisions in the simulation study. For in- of determination (COD) were specified for the procedure
stance, an “energy portfolio” is suggested to identify the most model in Fig. 3. These measure the most relevant aspects of a
relevant energy consumers. The author also introduced a factory: production flow (PF), MF system, and EF systems.
modelling approach, which narrows down some choices from The lower their value is estimated in step 2, the more room or
the beginning, e.g. the characteristic energy model. Due to the possibilities for system changes exist. The combination of
explicit focus on simulation, the application cycle is possibly high and low values for any of the three yields 8 fundamental
the most advanced guide on the design of simulation studies, planning cases. Depending on the project-specific COD, the
which consider both material and energy flows. Yet, many relevant planning case is determined as a result of this step.
decisions on important characteristics are still barely aided. In [22] Müller et al. expand on the heuristics presented in
Concluding the literature review, none of the cited works [20], exemplarily describing fundamental EE measures which
provides satisfactory assistance in the efficient design of a relate to the former. For step 3, these were associated with the
simulation study’s characteristics vector for a specific previously identified planning cases according to their
problem. This is understandable because simulation projects respective applicability (which depends directly on the COD).
require a high degree of creativity in the modelling process, For instance, if no fundamental changes can be made to the
which complicates the development of generally applicable PF, MF and EF the heuristic “reduction of waste energy” and
aids. However, systematic guidance can be provided in a specifically the measure “reduction of idle machine availabili-
narrow field of application. The following section presents ty” (shutdown control) is feasible. Thus, an EE approach that
some preliminary results on this. suites the project’s specifics may be identified easily in step 3.
 Johannes Stoldt and Matthias Putz / Procedia CIRP 61 (2017) 122 – 127 125

Table 1. Exemplary partial suggestion table for simulation worthiness check.

beginn of
focus area Planning case Production and equipment control
re-planning project

Pursued EE approach Opt. prod. ctrl. Shutdown ctrl.

1
EE focus
definition of
(eco. eff. ↑,
Energy part of task specification? Yes Yes
objective for
res. util. ↑, Dynamic energy calc. necessary? Likely No
re-planning project
preparatory steps to specify EE-related planning task

costs ↓, …)
Complex dependence between system Possibly Possibly
2 states and EF?
definition of
planning case via MF control to energy indicators? Possibly No
planning case
coefficient of
determination

3 With this, the preparatory steps are complete and the actual
identification of
relevant EE pursued EE simulation study following VDI 3633 Part 1 [19] and Wenzel
approaches and approach at al. [23] may commence. The structure closely follows these
selection thereof
works, as they reflect a well-accepted standard for DES in
4
deduction of
production and logistics. It needs to be clear that steps 8/10
specific planning planning task occur in parallel and are closely tied to steps 7/9/11 in an
task for studied specification
production system iterative procedure. All simulation-related steps were analysed
for implications on the characteristics vector. To guide deci-
study using other
sions efficiently, aids like decision flow charts with sugges-
Worth simulating No
5
MF along with EF?
means (no simult. tion tables, suitability matrices, etc. were developed to accom-
simulation MF-EF)
pany the procedure model. Thus, overviews on design choices
Yes for the characteristics are provided along with the means to
6
target system identify the most suitable alternative (bearing previous deci-
task definition (for and initial
simulation study) experiment sions in mind). The procedure model focusses on energy-
plan
related aspects; other aspects are omitted but remain relevant.
7 Whether the simultaneous simulation of MF and EF should
simulation study according to procedure model of VDI 3633 Part 1

sys. borders,
energy model, be applied at all is the result of step 5. For this purpose, a
system analysis
architecture, decision flow chart was developed. Considering the pursued
tool
EE approach, suggestions on how to decide at different
8 decision points were devised. An exemplary aid, a partial
verification and validation of datas and models

data collection
raw data for suggestion table, for two EE approaches of one planning case
MF and EF
and for a part of the flow chart is shown in Table 1. If, for
example, any of the last three decisions is answered as “yes”
9 formal model,
seq. structure
in a project, simultaneous simulation is advised. Suggestions
model formalisation MF-EF, are provided to guide the simulation engineer on how likely a
infrastructure
model
“yes” or “no” is for the particular problem. Yet, these sugges-
10
tions are not absolute and require a critical review, each time.
prepared If the problem is worth simulating, a specific target system
data preparation data for MF for the simulation study needs to be defined. This work may
and EF
follow, for instance, the schematic presented in [24].
11 Additionally, an initial experiment plan has to be prepared.
executable
model In step 7, a number of decisions need to be taken to define
implementation
including MF the system borders of the EF system(s) and to identify
and EF
relevant elements within these (e.g. using an energy portfolio
12 [2]). Furthermore, the most appropriate energy model and a
Assessed
experiments and
simulation
suitable simulator architecture as well as software package(s)
analysis
results are selected. Lastly, a list of necessary information is
compiled and the necessary simulation effort estimated.
realisation in the
The results are used in parallel to define which energy data
production system has to be collected by which means. For this purpose, known
data acquisition methods were associated with and evaluated
considering possible energy models in a suitability matrix.
Fig. 3. Suggested procedure model for efficient simulation studies.
Thus, a quick overview of efficient combinations can aid
decision-making. Further guidance, especially on metering,
Creatively combining the focus area and the pursued EE
will be integrated from other works (e.g. [2,4]). The collection
approach again in step 4 yields a concrete specification of the
of data unrelated to the EF is naturally also a part of step 8.
planning task. This is essentially a non-formalised description,
Drawing from the results of the previous steps, a formal
which summarises intended changes and targeted improve-
model should be created before the actual model is simulated
ments, e.g. altered PF through energy-sensitive production
(see [23]). Sproedt et al. suggested Energy Value Stream
control to lower energy costs in the turning department.
126 Johannes Stoldt and Matthias Putz / Procedia CIRP 61 (2017) 122 – 127

Mapping for this but the approach developed by Hopf [25] is Table 2. Choices made in an exemplary application of the procedure model.
also a viable choice. Depending on the size and complexity of Step Result of step / Characteristic Choice made
the factory, other more lightweight approaches may still be 1 Focus area Assembly/finish area & supplying
preferable to these. Additionally, the sequence structure of the subsystems of a car body shop
MF-EF interaction needs to be conceived in step 9 (e.g., the 1 EE focus Greater sustainability (improved
energy consumption strictly follows the material flow states economics, greater ecologic
of an element). Keeping this as well as the decision on the efficiency, lower social impact)
system border of the EF in mind, a decision on exactly how to 2 Coefficients of determination All ≈ 1
model the energy-related infrastructure has to be taken. 2 Planning case Production and equipment control
Step 10 is mostly concerned with providing energy data in
3 Possible EE approaches Optimised production control,
a suitable format. Finding a data resolution, which matches optimised equipment control,
the requirements for the simulated data as well as regarding shutdown control
the simulator’s performance, is a primary concern. Hence, 3 Pursued EE approach Optimised production control
results from steps 6 and 7 provide major input.
4 Planning task specification Identify best control strategy and its
An executable model, which integrates both MF and EF, is most sustainable parameters to
developed in step 11. The necessary effort depends greatly on improve operation of subsystems
the selected energy model, architecture, software package(s), 5 Worth simulating MF along Yes (dynamic calculation of energy
etc. To decrease the effort for the concept development in this with EF? indicators necessary)
phase, an overview of other existing work will be compiled 6 Target system Maximisation of profit as well as
based on the systematic literature review (see section 3.1). minimisation of CO2 equivalent and
Lastly, final experiment plans have to be conceived, night work
executed and evaluated. A decision flow chart and sugges- 6 Initial experiment plan Optimisation with a multi-objective
tions for the decision nodes therein (similar to step 5) provide genetic algorithm
guidance on the selection of a suitable method for planning 7 System borders of EF Upstream: local infrastructure of all
the experiments. According to the analysis of the respective process prerequisites or media
results, further plans have to be investigated, possibly Downstream: MF elements (here:
entailing additional minor implementation efforts. multi-robot work groups)
While the process model was described as linear, the 7 EF elements All production equipment and all
accompanying verification and validation make iterations directly supporting infrastructure
between steps a necessity. If inconsistencies or problems are 7 Energy model OS-related averages for all elements
identified, the simulation engineer will need to revise the 7 Architecture and tool DES integrating discretised EF
results of previous steps to include any new insights. (Plant Simulation & eniBRIC [26])
8 Data acquisition method Production equipment: historic
measurements or comparison and
5. Exemplary application estimation
Infrastructure equipment:
In order to show which kinds of results can be generated manufacturer information or
by employing the suggested procedure model and to verify its proportion of rated power
applicability, it was used for the case study presented in [24]. 8 Raw energy data Power consumption profiles
The latter reports on an investigation into parameterising and (frequency ‫•ͳا‬ሻƒ†‘‹ƒŽ
’‘™‡” ‘•—’–‹‘’‡”
selecting different energy-sensitive PPC strategies for the
operation of eight subsystems that supply the assembly and 9 Formal model Simple Microsoft Visio® file with
accompanying documents
finish area of a car body shop (Fig. 4). The basic aim was to
increase the system’s sustainability by organisational means. 9 Sequence structure MF-EF Bi-directional link between MF- and
EF-related OSs (see [26])
Table 2 summarises most choices, which would have been
made, if the procedure model had been applied beforehand. A 9 Infrastructure model Limited suppliers had to be
considered, thus explicitly modelled
few selected ones are commented hereafter:
10 EF input data specification Average power consumption as
floating point input values per OS in
x Coefficient of determination: car body shops will remain
SI units or derivate thereof.
mostly unchanged and are intended to operate at their limit
11 Development requirements Low (eniBRIC was previously
unless products are being changed, i.e. only minor changes
developed for this exact model)

5 5 3 1 3 3 1 1 subsystems 12 Experiment design method Optimisation with multi-objective

(# of work
WG WG WG WG WG WG WG WG
groups [WG]) genetic algorithm NSGA-II (see
[24])
doors
doors bonnet / (three- light work 12 Experiment plan Two different setups, 100
(five-door tailgate door
wings tunnel stations
version) version) (finish) specifications generations with 60 individuals
each, 90 days of production and 5
independent runs per individual
Fig. 4. Structure of examined system for which PPC parameters were sought.
 Johannes Stoldt and Matthias Putz / Procedia CIRP 61 (2017) 122 – 127 127

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