Wednesday March 5 2014, 11am (Eastern) Due to the popularity of our recent whitepaper on factoring downtime in to your simulation, we're holding a FREE Webinar on how to factor downtime into your simulation. Led by Brian Harrington, former Ford Motor Company employee and SIMUL8 expert, Brian is passionate about this subject and is keen to share his knowledge and discuss any questions you may have. The Webinar will expand on the topics covered in the whitepaper including; questions to consider when working with downtime, capturing at station or line level, associated distributions and accounting for the lockout procedure. In addition, we'll look at simultaneous breakdowns, skill trades to handle your breakdown and more.

1. Breakdowns Happen:
How to Factor Downtime
into your Simulation
Simulation expert Brian Harrington explains the key learning points
simulation modelers should consider when working with downtime.

2. Introductions
Brian Harrington, CSSBB
- 20 years in simulation at
Ford Motor Company
- Experienced Six
Sigma Blackbelt and
SIMUL8 Manufacturing Consultant
- Director of MTN-SIM, a
simulation specialist consulting firm
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3. MTBF & MTTR
1. How often does a machine fail (MTBF)?
2. How long does it take to repair it (MTTR)?
These two questions may seem simple, however
are often abstracted within the forest of machinery
and clouded by human behavior.
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4. One of the most debatable pieces of data
that goes into a simulation is the stochastic
behavior of machine downtime.
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Introducing new equipment
Collecting downtime data
Summarizing downtime data
Catastrophic downtimes
Lock-out procedures
Time to react, travel, and repair
Distributions to represent downtimes
Limited skilled trades
Simultaneous faults
Protective capacity
Equations (MTBF, MTTF, MTBC, MTTR, etc…)
Plants perspective
Designer’s
perspective
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5. Availability
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6. SIMUL8 Efficiency… Prove it
MTBF
Availability
MTTR
Efficiency
Go to MTBF MTTR Defined.S8
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7. Capture downtime at station or line level?
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8. Math behind the Spreadsheet
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9. Equivalent Results
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10. Advantages of Aggregate Values
• Used for predicting station/cell level
downtime based on components
• Reduces large data files
• Ease of communicating downtime figures
• Aligned with scope of model
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11. Distributions for MTBF & MTTR?
Exponential
Erlang
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12. Stat::Fit (View your data!)
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Data tables (Input data)
Input Graph
Descriptive Statistics
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Auto::Fit
Distribution Viewer
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Go to View Dist.S8

13. Time to React & Travel?
Named Distributions and the Combination
Distribution can capture some of this behavior.
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14. Lock-out Procedure
A safety protocol which protects skilled trades
when entering a station or work cell. Each skilled
trade will have a named-lock, which will be
“locked” on an electrical panel before entering a
work cell for a repair. The protocol will have
several required steps to assure that all power is
off, assuring no machinery, robot, etc. movement.
A typical lock-out procedure might take 3 to 7 minutes to complete!
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15. How do we account for the Lockout
Procedure?
A lockout procedure might be assumed
to be followed on the lengthier repairs
such as repair times that take 10
minutes or more.
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16. VL for creating a Bimodal Distribution
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17. Skilled Trades on Repairs
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18. TimeView
Improve Performance
Downtimes cause
Performance issues!
(Wait & Blocks)
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19. Design Facilities to Absorb Downtime
• Protective Capacity
– Resides in an over-speed (Push)
– Resides in buffers
– Preventative maintenance
– Skilled trades available
– Material handling systems
• Power & Free
• Electric Monorail Systems
• Power Friction
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20. Questions
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