FlexSim

So Flexible and
Powerful
 What is FlexSim?

FlexSim is a powerful analysis tool that helps engineers

and planners make intelligent decisions in the design
and operation of a system. With FlexSim, you can build
a 3-dimensional computer model of a real- life system,
then study that system in a shorter time frame and for
less cost than with the actual system.
 Flexsim Advantages
Affordable & Cost effective
Provides managers the opportunity to:
Visualize different scenarios
accurately in 3d
Analyze mathematically
Optimize and experiment before
implementation
Easy to communicate the solution
Animation, custom reports and
graphics

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 Application Areas

Manufacturing
Logistics, Transportation and Supply Chain
Packaging
Mining
Container and Bulk Port Handling
Healthcare
Banking
Retail
Defense and Security

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More than 3000 Customers

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 Use in Manufacturing
Run production schedule to determine the progress made in a
week, month or quarter.

Plan for new product models

Evaluate purchases of new machines to determine the impact on

throughput via simulation to get a better measurement of ROI

Use the 3D model to train your engineers and staff

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 Uses in Warehouse design
Improve retail / warehouse space utilization
Reduce stock-out and excess inventory problems
Analyze picking process efficiencies
Resolve material handling issues.

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3d Model of a Warehouse

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 Course Outline

Introduction
FlexSim Use and Terminology
Modelling with FlexSim
Model building
 Introduction

Simulation Basics
What is Simulation?
Discrete Event
Statistics
 What is Simulation?
Simulation is nothing but the problem
solving, we can solve the problems by
observing behaviour of the parts and whole
system.

It provides virtual environment to

experiment on our process.

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 What is a Simulation Model?

A purposeful and imitation of a real life

system, which can be used to answer
questions or solve problems.
It contains only those elements of reality that
are needed to answer the question or solve
the problem.

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 Discrete-Event Simulation
- Used to model the systems which change states at
discrete points in time as a result of specific events.
Examples of system EVENTS:
part arrivals
product movement
machine process start/finish
machine breakdown/repair
Examples of STATES:
Machines: idle, setup, processing, dwell
Queues: empty, full
Operators: on-shift, off-shift
Transports: travelling, loading, unloading

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 Inputs and Outputs:
Know the difference

Model Outputs
Modeling Inputs
Arrival Rates Throughput
Number of Workers
Process Times Utilization Rates
States
FlexSim Concepts & Terminology
Model
Objects
- Fixed Resources
- Mobile Resources (task executors)
- Flowitems
- Ports
- Triggers
- Task Sequences
Libraries
Model Views

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 Models, Objects and Flowitems
Model A collection of FlexSim objects
representing an actual system with just enough
detail to answer the questions you are
concerned with!

Object A building block with user-definable

attributes, variables, and visual properties.

Flowitem the entities that flow through a model,

such as products, customers, paperwork, phone calls,
etc.

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 Model

Objects

Flowitems
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 FlexSim Model
A FlexSim model is a system of queues,
processes, and transportation.
Queues develop naturally in a model when
upstream arrival rates exceed the downstream
processing rates.

Processing is simply a time delay on the object

being processed.

Transportation is the physical movement of an

entity from one resource to another.

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 Library

Library a list of class objects

to be used in building a model.
User customizable/expandable
for specific modelling needs.

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 FlexSim Standard Objects
FlexSim currently has 25 objects in
its discrete object library.
The three main superclasses:
Fixed Resource
Task Executer
Dispatcher
Extensive coverage of the FlexSim
Object Library is found in the
FlexSim Users Manual.

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 Object Classification
FixedResources objects which send
and/or receive flowitems.
ex.

TaskExecuters mobile resources that

perform assigned tasks.
ex.

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 FixedResource Superclass
FixedResource objects are the backbone of a simulation
model. Theyre used to define the product flow.

FixedResources can:
push or pull flowitems
process flowitems
queue up flowitems (accumulate up to a max content)
call for an operator to be utilized (for process / setup)

There is no transfer time between FixedResource

objects unless a TaskExecuter is called to transport the
flowitems.
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Tasks and Tasksequences
Task a single instruction or action to be
performed by a TaskExecuter object.
ex. LOAD flowitem

Tasksequence a series of tasks to be

performed in sequence.
ex. TRAVEL to queue
LOAD flowitem
TRAVEL to processor
UNLOAD flowitem
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 TaskExecuter Superclass
Task Executers execute task sequences.

When a Task Executer receives a tasksequence, it will start

executing the tasks, one after another, until the tasksequence
is either finished or preempted by a preempting tasksequence
of higher priority.

Tasksequences are created and dispatched automatically when

the Use Transport or Use Operator boxes are checked on
a FixedResource.

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 Dispatcher Superclass
The Dispatcher receives tasksequences and either queues them up
or dispatches the tasksequences immediately to other Dispatchers
and/or TaskExecuters connected to its output ports.

A tasksequence may preempt the current tasksequence part way

through the current list of tasks. The preemption can either
temporarily interrupt the current tasksequence or permanently
destroy the current tasksequence as well as any other tasksequences
waiting in the preempted TaskExecuters tasksequence queue.
Tasksequences can be sorted by their priority.
Because a TaskExecuter is a subclass of the Dispatcher, it too can act
as a Dispatcher and be connected through its output ports to other
TaskExecuters.

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 The Flowitem Bin
Sources create copies of
objects in the Flowitem
Bin.

Any changes made to

objects in the Bin affect
the flowitems that are
created by Sources.

Used to set size, color,

shape, etc.

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 Object Port Connections
Output/Input Ports Output-to-Input
port connections define possible flowitem
routes to/from Fixed Resources.

Input
Output

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 Port Connections

Objects can have an unlimited number of ports.

A port connection is needed for each possible routing choice

in the model.

The actual port that a flowitem passes through depends on the

selected rule for the object that is either doing the pushing or
the pulling.

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 The Send to Port Field

Located On the Flow tab for all Fixed

Resource Objects.
Use the editable Template Code to determine a
rule for sending flowitems downstream.
May be a static number or dynamically derived
by a statistical distribution.
 Object Port Connections
Center Ports for referencing purposes, typically
used to point to a TaskExecuter to be called for the
processing or transportation of a flowitem.

Center

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 Port Connection Modes

Different modes
available from the
menu bar.

Press ESC key to

return to regular
cursor mode.
Select object properties that can use the sampler tool
Can also make port connections for you
 Keyboard shortcuts used for
Port Connections

Outputs to Inputs Center to Center

Disconnect
Q W
Connect
A S
V C
View
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 Mouse Operations

View Window Navigation:

Translate: left click-drag
Tilt and Rotate: right click-drag
Zoom: left+right click-drag (or scroll wheel)
Object:
Translate in X and Y: left click-drag on object
Translate in Z: right+left click-drag on object

Highlighted = yellow box; left click

Selected = red box; shift-click or ctrl-click

select multiple objects by shift or ctrl click-dragging a
bounding box around a group of objects
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 Basic Steps of Modeling in FlexSim

1 - Create a layout using library objects

2 - Make port connections
3 - Edit the look and behaviour of objects
4 - Run the simulation
5 - View the results

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Model 1 Layout

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 Source

The Source is used to

introduce flowitems into
the model.
The arrival rate of
flowitems will be based on
an Inter-Arrival Time,
Arrival Schedule or
Sequence.
Most models will start
with a Source.

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 Sink
The Sink is used as an
exit point for
flowitems.
FlowItems can only
exit the model via the
Sink.

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 Queue
The Queue is used to
stage FlowItems for
downstream operations.
Queues are used in the
model wherever work-in-
process (WIP) exists
between process steps.
A Queue may be a table,
basket, line, or waiting
room.

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 Processor

A Processor is used anytime an operation is performed on a FlowItem.

A Processor can be any kind of machine or station; anything that would take
time to manipulate a FlowItem.
The FlowItems must stay in the Processor for the sum of the Setup Time and
the Process Time plus any Blocked Time.
 Step 1. Create a Layout
Drag objects from the Library (icon grid) and drop them into the
Orthographic Model View window using your mouse.
Reposition, resize, or rotate objects as desired using the mouse.

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 Flowitem Flow
Flowitems are passed from one object to the
next object.
To create time delay in the flowitem flow, add
conveyors or task executers for transport.
Convey time depends on the conveyors length and
speed.
Transport time between objects depends on the
distance between the objects, plus the task executers
speed, acceleration, & deceleration.

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 Step 2. Make Port Connections
Using either the keyboard shortcuts or the connections modes
from the toolbar, click-and-drag port connections between
the objects.
Direction is important! Drag from the sending object to
the receiving object. The sending object will have a heavy
yellow border and when you mouse over the receiving object, it
will gain a lighter yellow border.

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 Step 3. Edit the Objects

Properties Window
Double click (or right click then choose Properties)
Used to edit object specific behaviour and view
general info on all objects
Visual shape, size, orientation, location
Port connections
Labels
Statistics

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 Properties Window
Each object class has its
own Properties Window.

Properties affect the time

that FlowItems stay in an
object and arrival,
processing , dwell times.

Apply will accept

changes.
OK will accept changes
and close the window.
Cancel will close the
window without
accepting changes.
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 Properties Tabs
Properties are grouped into tab pages by category.
Every fixed resource object will have a Flow tab
and a Triggers tab.

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 Labels, General, and Statistics Tabs

Labels (taught later)

User defined attributes
General Tab
Look and size
Port connections
Display switches
Statistics
Throughput, states,
queuing, and stay times
Graphs, charts, readings
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 Object Size and Rotation
Objects can be repositioned, resized,
and reoriented from the General Tab
or Quick Properties.
Additionally, objects can be
manipulated from within the model
view.
Reposition an object by left-click dragging
the object to a new location.
Edit > Resize and Rotate Object must
be checked
Left-click drag on the arrows to resize.
Up and right are larger
Down and left are smaller
Right-click drag on the arrows to rotate.

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 Quick Properties

The Panel to the right side of the 3D grid

Gives you the option to edit certain
commonly used properties of the currently
highlighted object.
 Step 4. Run the Simulation
Reset, Run, Stop, Step
Control run speed with the slide
control (has no effect on the
simulation results)

The drop triangle shows other

time options
The Execute menu has access
to these functions as well

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 Step 5. View the Results
Create a Full, Summary or State
Report using the Statistics
menu
Other reporting features to be
discussed later:
Dashboards
Object Properties Statistics Tab
Triggers writing to GlobalTables

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 Summary Report
Display a tabular report for all
objects in model (or just those
that are red-selected).

Choose from a list of standard

system variables to include in
the report.

Add user-selected attributes to

the report.

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Summary Report View

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 FlexSim State Report
State profile is listed for all
objects in the model (or just
those that are red-
selected).

Displays the amount of time

or percentage of total
simulation time an object
was in each of its states.

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State Report View

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 Concept of Triggers
When key events occur on an object, a trigger
is fired.
The user may specify a variety of things to
happen when a trigger fires (trigger logic).
There are triggers when a flowitem enters or
exits an object. There are triggers when a process
time finishes or a repair time is complete.
Each type of object has a unique set of triggers.

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 Triggers
Define and customize system
behavior at a specific event
occurrence.
Write/read information to/from a
flowitem.
Change visual properties of
flowitems or objects.
Send Messages to other objects.
Change behavior of other objects.
And much more

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 Editing Selected Objects
Group editing can be performed on selected objects using
the Edit Selected Objects menu in the views sidebar.
Only one object can be highlighted (YELLOW box) in a
given view window.
Multiple objects can be selected (RED box).

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 Using TaskExecuters

Requirements:
Add a TaskExecuter object to carry tested parts to their
destination.

Concepts:
The Operator object
Centerport object connections
Use Transport picklist options
 Forming a TaskExecuter Team
Center

Output

Input

Dispatcher
TaskExecuters

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 NetworkNodes

NetworkNodes are used to define the path a TaskExecutor

will follow when executing its travel tasks.
A network path is made up of a group of interconnected
NetworkNodes.
A TaskExecuter is assigned to move on the network by
connecting it to any NetworkNode in the path. The
connected node becomes the TaskExecuters home node.
If a FixedResource is visited by a task executor assigned to
travel on the network, that FR must be connected to at least
one NetworkNode, making it accessible via the network.

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 Connecting NetworkNodes
Click-and-drag a
connection while
pressing the A key.

When connected, you

will see a black line
between the nodes.
Two green direction
indicators show that
travel is allowed in
both directions.

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 Connecting a Fixed Resource
to the Network

Click-and-drag a connection,
while holding the A key,
between a NetworkNode and the
object where the load takes
place.

A blue line will show the

connection. The line does not
connect to any port.

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 Connecting a TaskExecutor
to the Network

Click-and-drag a connection
between the TaskExecutor and a
NetworkNode while pressing the
A key.

A red line will indicate that the

connection has been made. The
line does not connect to any port.

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 Single Direction Paths
A path can be restricted to travel in a
single direction by pressing the Q
key and click-dragging in the
direction you want to disallow travel.

The green direction indicator turns

red, showing the restricted direction.

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 Non-Passing Paths

A non-passing path can be toggled by

using the A key and click-and-
dragging between two nodes that are
already connected.

The direction indicator turns yellow,

showing a non-passing direction.
No
A dragging a red or yellow travelling
direction will toggle back to green.
Travel but no passing

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 Direction Indicator Context Menu

Rather than A dragging the path to toggle

path type, you can right click a direction
indicator and choose from a context menu.

X clicking a direction indicator with the

left mouse button will also toggle through
the different direction modes.

Use the Travel Networks section

of the view sidebar to set
connection defaults and increase
the size of the network nodes.

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 Spline Control Points
To create a curved path, select
Curved from the direction
indicator context menu.

Spline control points will appear

on the path.

Drag the spline control points to

create a curved path.

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 NetworkNode View Modes
The display options for the network can be toggled by holding
down the X key and then clicking on any NetworkNode.

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 Paths Tab
Each path from a NetworkNode can be
edited in many ways.
Different direction modes can be set using
the Connection Type dropdown list.
Minimum spacing between travellers can be
defined.
A maximum speed can be set for this path
connection.
A Virtual Distance can be set. Virtual
distance is a forced distance value. Using
virtual distance, you can give a path an
artificial length.
When might a virtual distance be
useful?

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 MultiProcessor

The MultiProcessor allows you to perform

several operation steps at one location.
Each operation can have a different process
time, and use a different number of operators.
A MultiProcessor is a good object to use when
you have large flowitems that move to a spot
where several operations are performed before
it moves again.
Only 1 flowitem at a time is allowed in the
MultiProcessor.

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 Rack
The Rack is used to store flowitems in a specific column
and row (bay and level).
You can toggle between three different visual displays of
the Rack by holding the X key and clicking on the
Rack.
The physical configuration is defined by the Rack layout
size table.

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Rack Tabs

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