modeling high mix processes in process ... - promodel.com · 3 job shops represent production...
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2/2018 Version 9.3PCS Visio Tips & Features Webinar
For Software Version: 9.3Copyright © 2018 ProModel Corporation
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801-223-4600
This publication may not be reproduced in whole or in part in any form or by any means, electronic or mechanical, including photocopying, recording, or otherwise, without prior written permission of ProModel Corporation. ProModel and MedModel are registered trademarks of ProModel Corporation.
Instructor Info:
Bruce Gladwin, PMP, 6σBB
SVP, Commercial Products
Office: 801.223.4639
Modeling High Mix processes in Process Simulator
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Explore characteristics of “Job Shop” production systems
Methods for modeling job shop-like processes in
Process Simulator.
Examples◦ Intuitive or “Brut Force” method for modeling a job shop.
◦ Generic template you can use for any high mix batch processing model
◦ Specific example of a job shop-like model in the food processing
industry
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Job shops represent production systems that produce a high mix
of products that can be made using the machines and equipment
available on the shop floor.
Even large flow manufacturing facilities may have their own job
shops for making special tooling that is needed on the flow lines.
Job shops typically run batches of products through their work
centers due to the long setup times required to perform each
operation.
Job shops typically use common or generic equipment rather than
specialized machines that excel in performing a single operation.
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Supplier
A
Supplier
B
Raw
Materials
Inventory
Production Work Centers
Finished
Goods
Inventory
Customer
X
Customer
Y
Turning Center
Drilling / Boring
Milling Center
Heat Treat / Anneal
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This model represents
the “brut force” method
of job shop modeling.
It contains:
- 2 Product Types
- 4 Work Centers
You can see that with
only 2 product types
and 4 work centers the
Routings are getting messy.
If you tried to do this with
20 product types it would
likely be impractical.
RM1
RM2
RM1 Inv
RM2 Inv
Mill 1 Mill 2 Mill 3
Milling Center
Heat Treat / Anneal
Oven 1 Oven 2 Oven 3
Oven 4 Oven 5 Oven 6
Typical Job Shop Environment
Lathe 1 Lathe 2
Lathe 3 Lathe 4
Turning Center
HBM1 HBM 2
HBM 3
FG1 Store
Mill Out
TC In
DB In
Drilling / Boring
FG2 Store
Cust X
Cust Y
65%
35%
Batch Size = 15
Batch Size = 20
0000
Prod 1
0000
Prod 2
0000
Prod 2
MC Op
TC Op
DB Op
MH
FG1
FG2
FG2
0000
WIP P1
0000
WIP P2
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Product 1
Product 2
Product 3
Product 4
Product 5
Product 6
Product 7
Product 8
Product 9
Product
10
Product
11
Product
12
Product
13
Product
14
Product
15
Product
16
Product
17
Product
18
Product
19
Product
20
Product
21
Product
22
Product
23
Product
24
Product
25
Product
26
Product
27
Product
28
Product
29
Product
30
Product
31
Product
32
Product
33
Product
34
Product
35
Product
36
Product
37
Product
38
Product
39
Product
40
Product
41
Product
42
Product
43
Product
44
Product
45
Product
46
Product
47
Product
48
Product
49
Product
50
Product
51
Product
52
Product
53
Product
54
Product
55
Product
56
Product
57
Product
58
Product
59
Product
60
Product 61
Product 62
Product 63
Product 64
Product 65
Product 66
Product 67
Product 68
Product 69
Product 70
Product 71
Product 72
Product 73
Product 74
Product 75
Product 76
Product 77
Product 78
Product 79
Product 80
Product 81
Product 82
Product 83
Product 84
Product 85
Product 86
Product 87
Product 88
Product 89
Product
90
Product 91
Product 92
Product 93
Product 94
Product 95
Product 96
Product 97
Product 98
Product 99
Product
100
Job Shop Demo – High Mix, Low Volume
Release
Wk Stn 1 Wk Stn 2 Wk Stn 3 Wk Stn 4 Wk Stn 5
Wk Stn 6 Wk Stn 7 Wk Stn 8 Wk Stn 9 Wk Stn 10
Wk Stn 11 Wk Stn 12 Wk Stn 13 Wk Stn 14 Wk Stn 15
Wk Stn 16 Wk Stn 17 Wk Stn 18 Wk Stn 19 Wk Stn 20
Wk Stn 21 Wk Stn 22 Wk Stn 23 Wk Stn 24 Wk Stn 25
Inspection
Shop Floor
Tool 1 Tool 2 Tool 3 Tool 4 Tool 5 Tool 6 Tool 7 Tool 8 Tool 9 Tool 10
Tool 11 Tool 12 Tool 13 Tool 14 Tool 15 Tool 16 Tool 17 Tool 18 Tool 19 Tool 20
Tool 21 Tool 22 Tool 23 Tool 24 Tool 25 Tool 26 Tool 27 Tool 28 Tool 29 Tool 30
Tool 31 Tool 32 Tool 33 Tool 34 Tool 35 Tool 36 Tool 37 Tool 38 Tool 39 Tool 40
Tool 41 Tool 42 Tool 43 Tool 44 Tool 45 Tool 46 Tool 47 Tool 48 Tool 49 Tool 50
Tool Crib
Labor 1
Labor 2
Labor 3
Labor 4
Labor 5
Labor 1.2 Labor 1.3 Labor 1.4 Labor 1.5 Labor 1.6 Labor 1.7 Labor 1.8 Labor 1.9 Labor 1.10
Labor 2.2 Labor 2.3 Labor 2.4 Labor 2.5 Labor 2.6 Labor 2.7 Labor 2.8 Labor 2.9 Labor 2.10
Labor 3.2 Labor 3.3 Labor 3.4 Labor 3.5 Labor 3.6 Labor 3.7 Labor 3.8 Labor 3.9 Labor 3.10
Labor 4.2 Labor 4.3 Labor 4.4 Labor 4.5 Labor 4.6 Labor 4.7 Labor 4.8 Labor 4.9 Labor 4.10
Labor 5.2 Labor 5.3 Labor 5.4 Labor 5.5 Labor 5.6 Labor 5.7 Labor 5.8 Labor 5.9 Labor 5.10
Labor Pools
Packaging Shipping (Exit) ,
0000
WIP
0000
Cycle (min)
This model provides
a general template
for modeling job shops
of any size.
As built it contains:
- 100 Product Types
- 25 Process Stations
- 50 Tool Types
- 5 Labor Teams
It can be easily modified
To fit various job shop
modeling situations.
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Excel Tables◦ Routings
◦ Labor Types
◦ Tool Types
◦ Processing times
Arrays
Attributes
Macros
Variables
Flexible Route
Subroutines
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The Master Worksheet contains “n” rows for each product type. The
data elements are automatically copied to other worksheets that
contain just one type of data for each product at each process step.◦ The Routings worksheet contains only the routing data for each product
◦ The Labor worksheet contains only the Labor used at each step in the process
◦ The Tool worksheet contains only the Tool used for each product at each step
◦ The Op_Time worksheet contains only the operation times at each step
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Routing data (activity names) for each step in the process is
contained on a single row for each product type.
You can have multiple routing operations by modifying the Master!
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Process Simulator allows you to indirectly specify an Entity Name, an Activity name or a Resource name by using the Index Number of that Entity, Activity or Resource.
To see the Index Number of an object, look in the Object Explorer and click on the # symbol.
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Next, use Excel’s vLookup function to create an index number
table from the data with the Routing, Labor and Tooling
specifications.Activity List vLookup
Wk_Stn_1 1
Wk_Stn_2 2
Wk_Stn_3 3
Wk_Stn_4 4
Wk_Stn_5 5
Wk_Stn_6 6
Wk_Stn_7 7
Wk_Stn_8 8
Wk_Stn_9 9
Wk_Stn_10 10
Wk_Stn_11 11
Wk_Stn_12 12
Wk_Stn_13 13
Wk_Stn_14 14
Wk_Stn_15 15
Wk_Stn_16 16
Wk_Stn_17 17
Wk_Stn_18 18
Wk_Stn_19 19
Wk_Stn_20 20
Wk_Stn_21 21
Wk_Stn_22 22
Wk_Stn_23 23
Wk_Stn_24 24
Wk_Stn_25 25
Inspection 26
Packaging 27
Shipping 28
Release 29
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Labor used for each step in the process is contained on a single row
for each product type.
You could specify number of labor units by modifying the Master!
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A Tool or any other type of resource needed for each step in the
process is contained on a single row for each product type.
You could specify multiple tools or units by modifying the Master!
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Time spent at each activity is specified in this worksheet. This time
includes the use of the labor unit and the activity itself.
You could separate Operator & Run times by modifying the Master!
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a_Product = Product Type (e.g. 1 = product type 1, 2 = type 2)
a_CycleStart = the entity’s arrival time to system
a_BatchSize = the batch size that is represented by the entity
a_Proc_Step = the entity’s current step in the process
a_Destination = the next Activity where the entity will be sent
a_Labor = the resource index number of the specified labor type
a_Tool = the resource index number of the specified tool type
a_OpTime = the operation time that will be taken at the current
step. This includes the use of any Labor and Tool elements that are
specified.
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Four arrays are used in the template◦ y_Routings reads the routing data from the Routings worksheet
◦ y_Labor reads the labor resource data from the Labor worksheet
◦ y_Tools reads the tool resource data from the Tools worksheet
◦ y_OpTimes reads the operation time data from the Op_Times worksheet
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This template uses Macros for global substitution parameters◦ m_MoveTime is a generic move time for entities moving from any Activity
to any other Activity.
◦ m_LaborAvail is a general resource availability setting that is used to specify
a PF&D (personal fatigue & delay) factor on each labor type. You could add
macros for each Labor type if you need specific factors for each Labor type.
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This template uses Variables to track Work in Process (WIP) and
Cycle Time of each entity from arrival to exit.
You can add any variables that you want to track whatever type of
information you need to track. Or, use them for decision making in
your subroutine.
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This template uses a Subroutine to apply common processing
logic to each entity at each step in the process.
Upon arrival at each Activity the Subroutine logic performs the
following steps…◦ Increment the Process Step attribute
◦ Set the Labor, Tooling and Operation Time attributes
◦ If a Tool is required, capture that resource
◦ If a Labor resource is required, use that resource for the Operation time,
otherwise remain at the Activity for the operation time (without a resource)
◦ Free all resources used
◦ If the process step is less than 25 then set the Destination attribute to the
next Activity.
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Food Processing Demo – High Mix, Low/High Volume
Receive
West Freezer West Trim West Inject West Massage West Dice West Grind West Stuff
West Chill West Cook West Inspect West Pack
Blend Tumble Breading Fryer
East Freezer East Trim East Inject East Massage East Dice East Grind East Stuff
East Chill East Cook East Inspect
R600
R800
R1000
R1200
R1400
Oven Racks
West Op
East Op
West Op.2 West Op.3 West Op.4 West Op.5 West Op.6 West Op.7 West Op.8
East Op.2 East Op.3 East Op.4 East Op.5 East Op.6 East Op.7 East Op.8
Labor Teams
(Exit)
(Exit) ,
0000
WIP
0000
Cycle (min)Beef 1 Beef 2
Pork 1 Pork 2
Lamb 2
Chix 1
Turk 2Turk 1
R600.2 R600.3 R600.4 R600.5 R600.6 R600.7 R600.8 R600.9 R600.10
R800.2 R800.3 R800.4 R800.5 R800.6 R800.7 R800.8 R800.9 R800.10
R1000.2 R1000.3 R1000.4 R1000.5 R1000.6 R1000.7 R1000.8
R1200.2 R1200.3 R1200.4 R1200.5
R1400.2 R1400.3 R1400.4 R1400.5
Chix 2
Cook Cook.2 Cook.3 Cook.4 Cook.5 Cook.6 Cook.7 Cook.8 Cook.9 Cook.10
Inspect Inspect.2 Inspect.3 Inspect.4 Inspect.5 Inspect.6
Lamb 1
West Op.9 West Op.10 West Op.11 West Op.12
East Op.9 East Op.10 East Op.11 East Op.12
West Ship
East ShipEast Pack
MH MH.2 MH.3 MH.4 MH.5 MH.6 MH.7 MH.8 MH.9 MH.10 MH.11 MH.12
West FG Store
East FG Store
R1200.6
R1400.6
This model is a
specific example
of using the Job Shop
Template to model a
high mix, high volume
batch production
system in the food
processing industry.
The Master worksheet
was modified to meet
the specific needs of
this system.
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This Master Worksheet contains 5 rows for each product type. The
additional data element specifies the number of labor units needed
for each product at each process step.◦ The Routings worksheet contains only the routing data for each product
◦ The Labor has two elements… Type & Quantity (number of units) at each step
◦ There are two time fields in this model… one for the time with the labor
unit(s) and the other for the automated machine time (e.g. time in the oven).
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Thanks for attending this “Job Shop Modeling with
Process Simulator” Webinar! We hope it was helpful.
Remember, help is only an email or phone call away.
Good luck and happy modeling!
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