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Original Date: 06/05/2006
Revision Date: / /
Best Practice : Factory Flow Modeling
Rockwell Collins has implemented the Arena simulation software package that provides process/flow simulation for small- and large-scale systems. The simulation tool has resulted in large-dollar cost avoidance on major programs throughout the company.
The previous process of digital simulation of manufacturing processes and flow modeling performed manually or by spreadsheet was highly complex and error prone. The older digital simulation process failed to provide objective analysis of the data, and results were often challenged because it was too complex for the average person to follow.
Rockwell Collins implemented Arena simulation software, a new software simulation package that provides process/flow simulation for small- and large-scale systems giving representative inputs, process metrics, and resources that can accurately define the current-state process and identify problem areas. Arena has the ability to quickly vary inputs, process metrics, and resource availability that assist in evaluating the impact to related processes as well as the overall system. The software provides the ability to automate through the use of Visual Basic and animate for intuitive understanding, which allows process flow changes and performance changes to define future- state process changes and flows.
Tactical applications using Arena software allow comprehensive evaluations that include analysis of inputs, metrics, resources, and change-variation effects on the overall production system. The improved modeling tool provides “peel-the-onion” foresight and a deeper understanding of the overall system and its sensitivities. Comparative analysis can be realistically performed between existing and proposed systems with metrics and flows that reflect the current-state system. It is much less costly to experiment or make mistakes in the simulation system than it is in the real system.
Strategic applications of Arena software in the design and development process help determine resource requirements earlier, objectively establishing assembly and test requirements and providing faster analysis to identify the impact of missed productivity goals on output performance.
Rockwell Collins’ use of Arena software for process/flow simulation has provided the following cost savings and improvements:
A $1 million cost avoidance for the F-22 program by using production-flow simulation to identify the labor capacity needs for additional repair labor rather than purchasing costly new acceptance test equipment
A $200,000 cost avoidance for the JAGR-S program, identifying needs met by adding additional automated test equipment rather than a diagnostic station
The ability to forecast delivery dates and resource needs and proactively evaluate accurate strategy changes for the Selective Availability Anti-Spoofing Module and host application equipment-production effort
Validate production targets through implementation of advanced process analysis improvements, identifying lower-cost and risk solutions to convert the tuning test station for the Data Links program
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