chapter seven applications using arena mcgraw-hill/irwin © 2005 the mcgraw-hill companies, inc. all...
DESCRIPTION
Chapter Seven Learning Objectives Ability to model manufacturing cells using Arena Ability to incorporate inspection and rework into manufacturing cells models Ability to use Arena's advanced transfer template panel to model material handling processes Ability to develop a preliminary simulation model design using a design checklistTRANSCRIPT
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Chapter Seven
Applications Using Arena
McGraw-Hill/Irwin © 2005 The McGraw-Hill Companies, Inc. All rights reserved.
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Chapter Seven Learning Objectives
Ability to model manufacturing cells using Arena
Ability to incorporate inspection and rework into manufacturing cells models
Ability to use Arena's advanced transfer template panel to model material handling processes
Ability to develop a preliminary simulation model design using a design checklist
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Chapter Seven Worksheet MenuChapter 7 Exhibits
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worksheet
Process Analysis and Improvement: Tools and Techniques Copyright ©2005 by The McGraw-Hill Companies, Inc.
Filename Sheet / Page Name Exhibit Number Application / Caption
Drawings.vsd Manufacturing Cell Models 1 Manufacturing Cell Models
Drawings.vsd Manufacturing Cell Flow 2 Manufacturing Cell Flow Chart
Drawings.vsd Two-Product Flow 70 Two-Product Flowchart
Worksheets.xls Static Analysis 3 Manufacturing Cell Static Analysis
Worksheets.xls Manufacturing Cell Models 12 Manufacturing Cell Model Part A
Worksheets.xls Manufacturing Cell Models 13 Manufacturing Cell Model Part B
Worksheets.xls Resources 14 Resource Definitions for Manufacturing Cell Models
Worksheets.xls Failures 24 Failure/Repair Cycle Calculations
Worksheets.xls DensityFunctions 25 Failure/Repair Cycle Density Functions
Input.xls Input 31 Workbook Input.xls
Output.xls Output 34 Workbook Output.xls
Worksheets.xls Attributes 35 Entity Attributes for Manufacturing Cell Models
Worksheets.xls Simulation Analysis 38 Manufacturing Cell Simulation Analysis Results
Worksheets.xls Simulation Analysis 39 Manufacturing Cell Simulated Daily Production
Worksheets.xls Simulation Analysis 40 Manufacturing Cell Simulated Process Utilization
Worksheets.xls Academic Limits 78 Arena Academic Edition Limits
Worksheets.xls Model Design Checklist 85 Simulation Model Design Checklist
Worksheets.xls Modules Advanced Process Panel Advanced Process Panel Modules
Worksheets.xls Modules Advanced Transfer Panel Advanced Transfer Panel Modules
View Selected Worksheet or Drawing
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Chapter Seven FilesCD File Description
Chapter 7 Drawings.vsd Chapter 7 Drawings
Chapter 7 Presentation.ppt Chapter 7 PowerPoint Presentation
Chapter 7 Worksheets.xls Chapter 7 Worksheets
Conveyor.doe Manufacturing Cell 2.doe with Conveyor
Input.xls Manufacturing Cell 5.doe input data
Large Accumulator Hold.doe Academic Limits Work Around
Large Accumulator.doe Academic Limits Work Around
Limit Entities.doe Academic Limits Work Around
Manufacturing Cell 1.doe Basic Manufacturing Cell Model
Manufacturing Cell 2.doe Extended Manufacturing Cell Model
Manufacturing Cell 3.doe Extended Manufacturing Cell Model
Manufacturing Cell 4.doe Extended Manufacturing Cell Model
Manufacturing Cell 5.doe Extended Manufacturing Cell Model
Manufacturing Cell 6.doe Extended Manufacturing Cell Model
Output.xls Manufacturing Cell 5.doe output data
Products Combined.doe Products Combined
Products Separate.doe Products Separate
Products Sequence.doe Products Sequence
Reject Batch.doe Manufacturing Cell 2.doe with Inspection
Reject Single.doe Manufacturing Cell 2.doe with Inspection
Rework Batch.doe Manufacturing Cell 2.doe with Inspection
Rework Single.doe Manufacturing Cell 2.doe with Inspection
Route PickStation.doe Manufacturing Cell 2.doe with Stations
Route Sequence.doe Manufacturing Cell 2.doe with Stations
Route Set.doe Manufacturing Cell 2.doe with Stations
Route.doe Manufacturing Cell 2.doe with Stations
Transporter Set.doe Manufacturing Cell 2.doe with Transporter
Transporter.doe Manufacturing Cell 2.doe with Transporter
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Chapter Seven Outline
Manufacturing Simulation Models Modeling Inspection – Rejection – Rework Modeling Material Handling Equipment Modeling Multiple Product Flows Arena Academic Edition Limits Process Simulation Model Design
Checklist
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Manufacturing Simulation Models
Exhibit 7-1 p. 186Page: Manufacturing Cell Models
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Manufacturing Cell Flow
Exhibit 7-2 p. 187Page: Manufacturing Cell Flow
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Manufacturing Cell Models
Exhibit 7-3 p. 187 Sheet: Static Analysis
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Manufacturing Cell Models
Single Item Base Model Manufacturing Cell 1.doe Batch Mode Base Model Manufacturing Cell
2.doe Manufacturing Cell 3.doe Operator in SubModel Manufacturing Cell 4.doe Scheduled Operators Manufacturing Cell 5.doe Input/Output Manufacturing Cell 6.doe Variables Comparison of Expected Verses Simulated
Results
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Manufacturing Cell ModelsProcess Times in Minutes
# Model DescriptionTime Between Order Arrivals
Batch Size
Tally Batch Sizes
Sub Model
Operator Resource
Automatic Process Operator
Manual Process Operator
Operator Schedules
Process Failures
Arena Variables
1 Basic Model UNIF (0.5, 1.5, 1)
1
2 Batching of Orders UNIF (5, 15, 1)
3 Operators and SubModel
Yes Yes
4 Scheduled Operators, Operator Set, and Tally
Yes Yes Yes Yes
5 Resource Failures, Reads Batch.Size from Worksheet, and Writes Output Worksheet
Gap
Rea
d fr
om
Inpu
t.xls Yes Yes Yes Yes
6 Arena Variables
UN
IF (B
atch
.Mea
n,
Bat
ch.S
tdev
, 1)
Nor
mal
(Bat
ch.M
ean,
B
atch
.Ste
dev,
2)
Yes Yes
Ope
rato
r.Lev
el.1
for
Load
and
Unl
oad Yes Yes Yes
Manufacturing Cell #.doe
Ope
rato
r.Lev
el.2
Nor
mal
(10,
3,
2)
Ope
rato
r.Lev
el.1
or
Ope
rato
r.Lev
el.2
for
Load
and
Unl
oad
Exhibit 7-4 p. 188 Sheet: Manufacturing Cell Models
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Manufacturing Cell Models
Exhibit 7-5 p. 188 Sheet: Manufacturing Cell Models
Process Times in Minutes Worksheet Input / Output Times in Minutes
# Model DescriptionInitial
Process TimeAutomatic Process
Time
Manual Process
Time Reads from Write to
Initial Process Down Time
(Failure Count)
Automatic Process Up Time
(Failure Time)1 Basic Model Normal (0.95,
0.1, 3)Normal (1.5, 0.01, 4) Normal
(2.0, 0.2, 6)
2 Batching of Orders BatchSize * Normal (1.5, 0.01, 4)
3 Operators and SubModel
4 Scheduled Operators, Operator Set, and Tally5 Resource Failures, Reads Batch.Size from Worksheet, and Writes Output Worksheet
Input.xls Output.xls Count = 20 Normal (15 , 3, 9) GAMM (81.429, 0.7, 10)
6 Arena Variables
Bat
ch.S
ize
* Nor
mal
(In
itial
.Mea
n,
Initi
al.S
tdev
, 3)
Nor
mal
(Loa
d.M
ean,
Lo
ad.S
tdev
, 4) +
B
atch
.Siz
e *
Aut
omat
ic.M
ean
+ N
orm
al (U
nloa
d.M
ean,
U
nloa
d.St
dev,
5)
Bat
ch.S
ize
* Nor
mal
(M
anua
l.Mea
n,
Man
ual.S
tdev
, 6)
Cou
nt =
Fai
lure
.Cou
nt
Nor
mal
(F
ailu
re.C
ount
.Mea
n ,
Failu
re.C
ount
.Std
ev, 9
)
GA
MM
(F
ailu
re.U
pTim
e.M
ean,
0.
7, 1
0)
Manufacturing Cell #.doeInitial
Process Up Time
(Failure Count)
Bat
chSi
ze *
Nor
mal
(0.9
5,
0.1,
3)
Bat
chSi
ze *
Nor
mal
(2.0
, 0.2
, 6)
Normal (1.0, 0.2, 4) + BatchSize * 1.5 +
Normal (1.0, 0.2, 5)
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Manufacturing Cell Models Resources
Exhibit 7-6 p. 189 Sheet: Resources
Arena Resource Name
Capacity / Schedule
Busy Cost / Hour
Idle Cost / Hour
Cost / Use
Used in Models
Failures Used in
Models 5 - 6
R.Initial 1 $25.00 $25.00 $0.00 1 - 6 Failure Count
R.Automatic 1 $50.00 $25.00 $0.00 1 - 6 Failure Time
R.Manual 1 $35.00 $25.00 $0.00 1 - 6
Operator.Level.1 Schedule.1 $10.00 $10.00 $0.00 3 - 6
Operator.Level.2 Schedule.2 $20.00 $20.00 $0.00 3 - 6
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Manufacturing Cell Models Attributes
Exhibit 7-35 p. 198 Sheet: Attributes
Arena Attribute Initial ValueModels where used
Entity.Picture Picture.Envelope All
Entity.Type Work.Order All
BatchSize 2 - 6
Batch.Start.Time 5
Entity.Index 4 - 5
Gap 5
OperatorNumber 4 - 6
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Single Item Base Model Manufacturing Cell 1.doe
Exhibit 7-7 p. 198 Model Manufacturing Cell 1.doe @ 8 Hours
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Manufacturing Cell 1.doe
Exhibit 7-8 p. 198Automatic Process has Space Decide Module Dialog
NQ (Automatic Process.Queue) < NQ (Manual Process.Queue) + 2
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Manufacturing Cell 1.doe
Exhibit 7-11 p. 190Resource Spreadsheet
Exhibit 7-9 p. 190
Crystal Reports Cost Summary
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Batch Mode Base Model Manufacturing Cell 2.doe
Exhibit 7-12 p. 191Model Manufacturing Cell 2.doe @ 8 Hours
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Manufacturing Cell 2.doe
Exhibit 7-14 p. 191Process Spreadsheet View
Initial Process Time: Batch.Size * Normal (0.95, 0.10, 3)Automatic Process Time: Batch.Size * Normal (1.50, 0.05, 4)Manual Process Time: Batch.Size * Normal (2.00, 0.10, 6)
Mean, Std Dev, StreamEntity Attribute
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Manufacturing Cell 2.doe
Exhibit 7-13 p. 191 Assign Batch Size Dialog
Batch.Size= MAX (ANINT (Normal (10, 3, 2)), 1)Positive Integer with mean of 10 units
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Manufacturing Cell 3.doe Operator in SubModel
Exhibit 7-15 p. 192Model Manufacturing Cell 3.doe Automatic Process Submodel
Exhibit 7-16 p. 192 Queue Spreadsheet
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Manufacturing Cell 4.doe Scheduled Operators
Exhibit 7-17 p. 193Model Manufacturing Cell 4.doe Schedule.1
Exhibit 7-18 p. 193Model Manufacturing Cell 4.doe Resource Spreadsheet
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Manufacturing Cell 4.doe Operator Set
Exhibit 7-19 p. 193Set Spreadsheet Exhibit 7-20 p. 194
Load Batch Process Module Dialog
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Manufacturing Cell 4.doe Tally
Exhibit 7-21 p. 194Record Module Dialog
Exhibit 7-22 p. 194User Specified Crystal Report
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Manufacturing Cell 5.doe Worksheet Input.xls
Exhibit 7-28 p. 196Model Manufacturing Cell 5.doe Input Cycle
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Manufacturing Cell 5.doe Worksheet Input.xls
Exhibit 7-29 p. 196Read Input File Module Dialog
Exhibit 7-30 p. 196File Spreadsheet
Exhibit 7-31 p. 197Workbook Input.xls
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Manufacturing Cell 5.doe Assign Batch Start Time Module
Exhibit 7-32 p. 197Assign Batch Start Time Module
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Manufacturing Cell 5.doe Worksheet Output.xls
Exhibit 7-33 p. 197Write Output File Module Dialog
Exhibit 7-34 p. 198Workbook Output.xls
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Manufacturing Cell 5.doe Resource Failures
Average Average Minutes
Gamma Distribution
Shape Parameter Arena Expressions in Minutes
# Equipment LabelOperating
PercentFailures /
HourOperating
MTBFRepair MTTR Operating Repair Operating (Up Time) Repair (Down Time)
1 Failure Time 95.00% 1.000 57.0 3.0 0.7 1.4 Gamma (81.429, 0.7, 10) Gamma (2.143, 1.4, 10)
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Exhibits Worksheet
Display DensityFunctions
Worksheet
Exhibit 7-24 p. 195Sheet: Failures
Exhibit 7-25 p. 195Sheet: DensityFunctions
Exhibit 7-23 p. 195Model Manufacturing Cell 5.doe Failure Spreadsheet
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Manufacturing Cell 5.doe Frequency Statistics
Exhibit 7-27 p. 196Frequency Statistics Replication 1
Exhibit 7-26 p. 195Statistic Spreadsheet
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Manufacturing Cell 6.doe Variables
Exhibit 7-36 p. 198Model Manufacturing Cell 6.doe Variable Spreadsheet
Exhibit 7-37 p. 199Model Manufacturing Cell 6.doe Failure Spreadsheet
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Manufacturing Cell 6.doe @ 8 Hours
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Comparison of Expected Verses Simulated Results
Exhibit 7-38 p. 199Sheet: Simulation Analysis
Exhibit 7-39 p. 199Sheet: Simulation Analysis
Exhibit 7-40 p. 199Sheet: Simulation Analysis
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Modeling Inspection – Rejection – Rework
Reject Batch.doeReject Single.doeRework Batch.doeRework Single.doe
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Reject Batch.doe
Exhibit 7-41 p. 200Reject Batch.doe Special Model Logic
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Reject Batch.doe
Exhibit 7-42 p. 200Separate Rejects
Exhibit 7-43 p. 201Separate Good
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Reject Single.doe
Exhibit 7-44 p. 201Special Model Logic
Exhibit 7-45 p. 201Decide Module Dialog
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Rework Batch.doe
Exhibit 7-46 p. 202Rework Batch.doe Special Model Logic
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Rework Single.doe
Exhibit 7-47 p. 202Rework Single.doe Special Model Logic
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Modeling Material Handling Equipment
Route.doe Route PickStation.doe Route Sequence.doe Conveyor.doe Transporter.doe AGV.doe
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Route.doe
Exhibit 7-48 p. 203Route.doe Special Model Logic
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Route.doe
Exhibit 7-49 p. 204Route.doe Enter Spreadsheet
Exhibit 7-50 p. 204Route.doe Leave Spreadsheet
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Route Set.doe
Exhibit 7-51 p. 204Route Set.doe Leave for Final Processing Station
Final Processing Stations (2 - (NQ (Automatic Process.Queue) < NQ (Manual Process.Queue) + 2))
Exhibit 7-52 p. 204Route Set.doe Advanced Set Spreadsheet
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Route PickStation.doe
Exhibit 7-53 p. 205Route PickStation.doe Special Model Logic
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Route Sequence.doe
Exhibit 7-54 p. 205Route Sequence.doe Special Model Logic
Entity.Sequence = Sequence Number (1+ (NQ (Automatic Process.Queue) > NQ (Manual Process.Queue) + 2))
Exhibit 7-57 p. 205Assign Sequence Module
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Route Sequence.doe
Exhibit 7-55 p. 205Sequence Spreadsheet
Exhibit 7-56 p. 206Advanced Set Spreadsheet
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Conveyor.doe
Exhibit 7-58 p. 206Conveyor.doe Special Model Logic
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Conveyor.doeExhibit 7-59 p. 207Segment Spreadsheet
Exhibit 7-60 p. 207Conveyor Spreadsheet
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Transporter.doe
Exhibit 7-61 p. 207Transporter.doe Special Model Logic
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Transporter.doe
Exhibit 7-63 p. 207Distance Spreadsheet
Exhibit 7-62 p. 207Transporter Spreadsheet
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AGV.doe
Exhibit 7-64 p. 208AGV.doe Special Model Logic
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AGV.doe
Exhibit 7-66 p. 208Network Spreadsheet
Exhibit 7-65 p. 208Transporter Spreadsheet
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AGV.doe
Exhibit 7-67 p. 208Network Link Spreadsheet
Exhibit 7-69 p. 209Station Automatic and Manual Intersection Definitions
Exhibit 7-68 p. 209Station Initial Intersection Definition
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Modeling Multiple Product Flows
Exhibit 7-70 p. 209Page: Two-Product Flow
Products Separate.doe Products Combined.doe Products Sequence.doe
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Products Separate.doe
Exhibit 7-71 p. 210Products Separate.doe Model Logic
Exhibit 7-72 p. 210Process Module Spreadsheet
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Products Combined.doe
Exhibit 7-74 p. 211 Assign Dialog
Exhibit 7-75 p. 211 Process Spreadsheet
Exhibit 7-73 p. 210Products Combined.doe Model Logic
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Products Sequence.doe
Exhibit 7-76 p. 211Products Sequence.doe Model Logic
Exhibit 7-77 p. 211Sequence Spreadsheet
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Arena Academic Edition Limits
Limit Entities.doe Large Accumulator.doe
Model Component Academic Limit
Concurrent Entities 150
Siman Objects 300
Cinema Objects 150
Include Block/Elements 0
Exhibit 7-78 p. 212Sheet: Academic Limits
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Concurrent Entities
Exhibit 7-79 p. 212Arena Academic Edition 150 Entities Error Message
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Limit Entities.doe
Exhibit 7-80 p. 212Model Limit Entities.doe
EntitiesWIP (Entity.Single) > Entity.Limit – 3
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Large Accumulator.doe
Exhibit 7-81 p. 213 Large Accumulator.doe
Accumulator.Contents > Accumulator.Size - 1
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Large Accumulator.doeExhibit 7-82 p. 213Assign 1 Detail
Exhibit 7-83 p. 213 Assign to Accumulator Detail
Exhibit 7-84 p. 214 Assign from Accumulator Detail
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Process Simulation Model Design ChecklistProcess Description
What does this process do?What are the process inputs?What are the process outputs?What causes the process to not operate at 100% efficiency?What potential changes or features should be tested?
Simulation Model Objectives (Why build a simulation model)Questions to be addressed
Learn how Process OperatesEvaluate Potential ChangesEstimate Capacity
Types of Statistics RequiredQueues
Maximum LengthWaiting Time
ResourceUtilization
Production per PeriodFlow or Through Put TimeCostOthers?
EntitiesAttributes
Time of ArrivalPicture or IconColorSizeetc.
Grouping/SplittingCasesPallets
Maximum Number (150 academic version)
Exhibit 7-85 p. 213Sheet: Model Design Checklist
Arrival ProcessWhen
FrequencyStart time (1st arrival)
Entity TypeScheduled
Read from Excel WorkbookLimited Capacity Resources
How Many - (similar vs. different)Cycle Time (Variability)Operate/Repair Cycle
Fixed (Count)Random (Distribution)
SchedulesSet Up or Changeovers
Why they don’t always run at Maximum SpeedExperiment Plan
Validation & VerificationModel vs. Real World ProcessSensitivity Analysis
How will models be compared?Base Case ModelAlternative Models
Process Analyzer (PAN)Optimization (OptQuest)
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Summary
Applications Using Arena Manufacturing Simulation Models Modeling Inspection – Rejection – Rework Modeling Material Handling Equipment Modeling Multiple Product Flows Arena Academic Edition Limits Process Simulation Model Design Checklist
Next: VBA