2. Improve Module Roadmap Define 1D – Define VOC, VOB, and CTQ’s 2D – Define Project Boundaries 3D – Quantify Project Value 4D – Develop Project Mgmt. Plan Measure 5M – Document Process 6M – Prioritize List of X’s 7M – Create Data Collection Plan 8M – Validate Measurement System 9M – Establish Baseline Process Cap. Analyze 10A – Determine Critical X’s Improve 12I – Prioritized List of Solutions 13I – Pilot Best Solution Control 14C – Create Control System 15C – Finalize Project Documentation Green 11G – Identify Root Cause Relationships +1 +1 -1 -1 +1 -1
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7. Computer Simulation Concept A computer simulation models the process by simulating it’s performance. Real Process Inputs Outputs Model Outputs Inputs Modeling Parameters
8. Basic Steps in Computer Simulation (1) Define problem (2) Map Process (3) Define inputs (4) Build model using software (5) Validate model (6) Perform simulations (7) Interpret results (8) Recommend and document
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10. Step 2 - Map the Process WW Flow (GPM) Additional Feeder Lines P1 P2 P4 P3 Data reflects peak use periods. P25 P24
11. Step 3 - Define the Inputs WW Flow (GPM) Additional Feeder Lines P1 = operates 26% of time @ 400GPM P2 = operates 44% of time @ 300GPM P4 = operates 40% of time @ 800GPM P3 = operates 50% of time @ 1000GPM Data reflects peak use periods. P25 = operates 25% of time @ 300GPM P24 = operates 25% of time @ 800GPM
12. Step 4 - Build the Model Let’s take a closer look!
13. Step 4 - Build the Model (Modeling Parameters)
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15. Step 5 - Validate the Model Note that main line does not need to be sized for all 15 pumps to run simultaneously.
16. Steps 6 & 7. Perform Experiments & Interpret Results Future GPM is expected to average ~6250GPM and peak at ~9800GPM
17. Steps 6 & 7. Perform Experiments & Interpret Results Future Max No. of Pumps = 17 (of 25)
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Editor's Notes
Mimic the major elements of a process, not every detail.
Don’t put 100% confidence in the model. Use it to make decisions.
Used modeling to find O ring crack on the Challenger explosion (reconstruct incident).
