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Altiok / Melamed Simulation Modeling and Analysis with ArenaChapter 12
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SIMULATION MODELING AND ANALYSIS SIMULATION MODELING AND ANALYSIS WITH ARENAWITH ARENA
T. Altiok and B. MelamedT. Altiok and B. Melamed
Chapter 12Chapter 12
Modeling Transportation SystemsModeling Transportation Systems
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• Examples of simulation modeling and analysis projects for transportation systems include
• designing new traffic routes and alternate routes to satisfy demand for additional road capacity• eliminating bottlenecks and congestion points in existing routes by appropriate placement of traffic lights and tollbooths• designing traffic patterns on the factory floor, including transporters and conveyors, for efficient movement of raw material and product• designing port facilities, such as berths and piers, and allocating vessels to berths, where such designs include material handling systems (loaders/unloaders, transporters, conveyors and others) for containers and bulk material transport• designing new airports or adding runways to existing ones to satisfy demand for additional flight capacity, where such designs include air traffic patterns and routing, runway scheduling and planning cargo operations
Examples of Transportation Systems
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• The panel supports modules that provide additional mechanisms of time-lapse transfer of Arena entities among Station modules or geographic locations
• Route modules may be used as dispatch points, and Station modules as destination points
• Transporter and Conveyor modules may be used for material transport
• the Enter and Leave modules may be used to transfer entities into and out of physical or logical locations
• the PickStation module allows entities to select a destination Station module using a selection criterion, such as the minimum or maximum of queue size, number of busy resource units, or an arbitrary expression
• alternatively, an entity can be endowed with an itinerary using the Sequence module to specify a sequence of Station modules (referred to in Arena as Step objects)
Advanced Transfer Template Panel
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• A Station module is used to designate a physical location or a logical location in the model
• example: a physical location might be a milling station that physically houses milling machines• example: a logical location might be a dummy station at a model site close to a cluster of related modules
• A Route module is used to route (transfer) entities to Station modules at various locations in the model
• the destination Station module may be specified in an entity attribute as an expression, as a Station module name, or as part of an itinerary defined in a Sequence module• Route modules are not graphically connected to destination Station modules
Station and Route Modules
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• The Advanced Transfer template panel also provides specialized transportation facilities for material handling in manufacturing-related systems
• a Transporter module is used to model transporters (vehicles, such as trucks, forklifts, container carriers , etc.), which move material in discrete parcels
• a Conveyor module is used to model conveyors (continuous-mode conveyance facilities, such as conveyor belts)
Transporter and Conveyor Modules
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• In order to implement transporters or conveyors, the modeler specifies a transportation network consisting of
• locations (Station modules) • topology (distances among locations)
• Network topology is specified in
• Distance (data) modules (for transporters) • Segment (data) modules (for conveyors)
• Once the velocities of transports and conveyors are known, Arena will automatically compute the corresponding travel times
The Arena Transportation Network
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• When an Arena entity gets hold of a transporter, • the entity enters a Transport module for the duration of the transportation activity• the entity and the transporter move as a group
• When the group (entity and transporter) arrives at its destination Station module,
• the entity frees the transporter (possibly after a delay for unloading), and exits the Transport module• the transporter will stay at that Station module until requested again
• when an entity accesses a conveyor• the entity enters a Convey module for the duration of the conveyance activity• during the conveyance activity, the entity occupies a number of cells on the conveyor
• On arrival at its conveyance destination Station module, • the entity exits the conveyor and releases the conveyor cells it had occupied before, and exits the Convey module.
Transportation Rules of Operation
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• A number of additional modules regulate the operation of transporters and conveyors
• the Free module is used to release a transporter engaged by an entity• the Exit module is used to release a conveyor engaged by an entity• the Activate module is used to start transporters • the Halt module is used to stop transporters • the Start module is used to start conveyors• the Stop module is used to stop conveyors
• the Move module is used to advance a transporter among stations
Additional Transportation Modules
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• The Animate Transfer toolbar supports visualization and animation of various transportation devices, such as transporters and conveyors
• This toolbar’s buttons are shown below
Animate Transfer Toolbar
The Arena Animate Transfer toolbar
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• The Animate Transfer toolbar buttons are (left to right):1. The Storage button is used to animate the contents of a storage, similarly to the Queue button of the Animate toolbar. Internally, the Store and Unstore modules (from the Advanced Process template panel) provide the functionality of entities entering and departing a storage, while the number of entities in storage is accessible in the SIMAN variable NSTO(storage)
2. The Seize button allows the modeler to define a so-called seize area to animate entities seizing a resource.
3. The Parking button allows the modeler to define a so-called parking area to animate parking area for transporters.
4. The Transporter button allows the modeler to design a visual representation (picture) for a transporter.
5. The Station button permits the specification an icon for Station module.
Animate Transfer Buttons
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6. the Intersection button permits the specification of an intersection in a network of automated guided vehicles (AGVs), which are transporter- type objects that must keep track of their positions to avoid collisions
7. The Route button is used to specify the animation path for moving entities in the system
8. The Segment button is used to specify the animation path of a conveyor
9. The Distance button is used to specify the animation path of a transporter
10. The Network button is used to specify the animation path of an AGV
11. The Promote Path button is used to promote a visual line to an animation path of a desired object
Animate Transfer Buttons (Cont.)
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• This example models bulk port operations, using the notions of• station• entity routing among stations• entity pick-up and drop-off by another entity • the control of entity movements using logical gating
• The example models a bulk port, called Port Tamsar, where• the port operates continually 24 hours a day and 365 days a year• it has a single berth where the vessels dock, and a single ship loader • cargo vessel movements in the port are governed by tugboats
• We wish to simulate Port Tamsar for 1 year (8760 hours) and to estimate
• berth and ship-loader utilization• expected port time per ship
• Modeling accuracy of operations at Port Tamsar• a number of operating details have been omitted to simplify modeling• still, the foregoing description is quite realistic and applicable to many bulk-material ports and container ports around the world
Example: A Bulk Port Model
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TugboatStation
0.5 hour
Tugboat
OffshoreShip
Anchorage
1 hour
Coal-LoadingBerth
ShipLoader
CoalPile
1 hour
Layout of Port Tamsar
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• Ship arrivals are governed by the following rules of operation:• while the annual coal production plan calls for nominal deterministic ship arrivals at the rate of 1 ship every 28 hours, ships usually do not arrive on time due to weather conditions, rough seas, or other reasons, and consequently, each ship is given a 5-day grace period commonly referred to as the lay period • ships are assumed to arrive uniformly in their lay periods• arriving ships queue up FIFO (if necessary) at an offshore anchorage location, whence they are towed into port by a single tugboat as soon as the berth becomes available
Port Tamsar Ship Arrivals
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• Tugboats are governed by the following rules of operation:• the tugboat is stationed at a tug station located at a distance of 1/2 hour away
from the offshore anchorage
• travel between the offshore anchorage and the berth takes 1 hour
• it is assumed that there is an uninterrupted coal supply to the ship loader at
the coal-loading berth
• it is assumed that ship loading times are uniformly distributed between
14 and 18 hours
• once a ship is loaded at the berth, the tugboat tows it away to the offshore
anchorage, whence the boat departs with its coal for its destination
• higher priority is given to departing vessels in seizing the tugboat
Port Tamsar Tugboat operations
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• An important environmental factor in many port locations around the world is tidal dynamics
• cargo ships are usually quite large and need deep waters to get into and out
of port
• water depth increases with high tide and decreases with low (ebb) tide
• the time between two consecutive high tides is precisely 12 hours
• assume that ships can go in and come out of port safely only during
tidal window consisting of the middle 4 hours of high tide
• thus, every 12 hours, the tidal window at the port is closed for 8 hours
and open for 4 hours
Port Tamsar Tide Dynamics
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Arena model segment implementing ship arrivals at Port Tamsar
Vessel Arrivals
Check Tide_1for Tug BoatInbound WaitGet Berth
Lay PeriodTime
Mark Arrival
0
Modeling Ship Arrivals
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• The Arena model segment implementing ship arrivals has the following logic:
• ship arrivals are generated deterministically by the Create module, called Vessel Arrivals, one ship every 28 hours• on creation, a ship entity immediately proceeds to the Delay module, called Lay Period, where it is delayed uniformly between 0 and 120 hours to model an actual arrival within its lay period• in due time, the ship entity enters the Assign module, called Mark Arrival Time, where its (actual) arrival time is stored in its
ArrTime attribute
Modeling Ship Arrivals (Cont.)
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Ship Arrivals Modules
Dialog box of the Seize module Get Berth
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Dialog box of the Hold module Check Tide_1
Ship Arrivals Modules (Cont.)
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Ship Arrivals Modules (Cont.)
Dialog box of the Hold module Inbound Wait for Tug Boat
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Tug Station
Create Tug
TugboatMonitor Need for
VesselPickup Inbound
VesselGo to Inbound
StationGo to Loading
Port Exit Station
Original
Members
Departing VesselDropoff
Dispose
Tally Port Time
Who Wants Tug BoatTrue
False
Vessel StationGo to Departing
0
0
0
0
Modeling Tugboat
Operation
Arena model segment implementing tugboat operations at Port Tamsar
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• The Arena model segment implementing tugboat operation has the following logic:
• at time 0, a single tugboat is created at the Create module, called
Create Tug• the tugboat then proceeds to the Station module, called Tug Station,
which merely serves as an entry point in the model• the tugboat immediately proceeds to the Hold module, called
Monitor Need for Tugboat, to monitor and wait for service “requests”• the ship entity waits in the queue Inbound Wait for Tug Boat.Queue
until the tugboat becomes available• the tugboat segment will ensure that the tugboat constantly monitors
the queue Inbound Wait for Tug Boat.Queue for ships waiting to be
towed into port
Modeling Tugboat Operation (Cont.)
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Tugboat Operation Modules
Dialog box of the Create module Create Tug
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Tugboat Operation Modules (Cont.)
Dialog box of the Station module Tug Station
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Tugboat Operation Modules (Cont.)
Dialog box of the Hold module Monitor Need for Tugboat
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• The logic of the Hold module, called Monitor Need for Tugboat, accomplishes the following functions:
• via the Condition field, the tugboat entity constantly monitors two queues,
Inbound Wait for TugBoat.Queue and Outbound Wait for
tugBoat.Queue,
for ships calling on its services • the monitored condition is the logical expression
NQ(Inbound Wait for Tug Boat.Queue) +
NQ(Outbound Wait for Tug Boat.Queue) > 0
which scans for ship entities waiting for the tugboat in either of the Hold
module’s queues housing inbound or outbound ships• once the scan condition becomes true, the tugboat will immediately
proceed to the Decide module, called Who Wants Tug Boat,
to find out if the request is from an inbound ship or a (high priority)
outbound ship
Tugboat Operation Modules (Cont.)
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Tugboat Operation Modules (Cont.)
Dialog box of the Decide module Who Wants Tug Boat
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Tugboat Operation Modules (Cont.)
Dialog box of the Route module Go to Departing Vessel Station
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Tugboat Operation Modules (Cont.)
Dialog box of the Pickup module Pickup Inbound Vessel
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• The logic of a Pickup module accomplishes the following functions:
• generally, a Pickup module is used by an incoming entity to pick up
other entities residing in a queue• the number of entities to be picked up is specified in the Quantity field,
starting from the queue position specified in the Starting Rank field• the queue itself is specified in the Queue Name field• the picking entity and the picked-up entities form a grouped entity,
where the picked-up members form an internal queue,
and are identified by their rank (position) in it• since the picking entity may make several pickups (at different times or
places), picked-up members of the group maintain their identity ID via
their rank• rank information may be used in entity drop-off
Tugboat Operation Modules (Cont.)
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Tugboat Operation Modules (Cont.)
Dialog box of the Route module Go to Loading Station
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Modeling Coal Loading
Arena model segment implementing coal loading at Port Tamsar
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Coal Loading Modules
Dialog box of the Station module Coal Loading Station
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Dialog box of the Dropoff module Dropoff Inbound Vessel
Coal Loading Modules (Cont.)
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Dialog box of the Seize module Seize Loader
Coal Loading Modules (Cont.)
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Dialog box of the Release module Release Loader and Berth
Coal Loading Modules (Cont.)
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Dialog box of the Pickup module Pickup Vessel
Coal Loading Modules (Cont.)
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Dialog box of the Hold module Check Tide_2
Coal Loading Modules (Cont.)
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Dialog box of the Record module Tally Port Time
Coal Loading Modules (Cont.)
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Modeling Tidal Windows
Arena model segment implementing tidal windows at Port Tamsar
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Tidal Windows Modules
Dialog box of the Create module Create Tidal Window
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Dialog box of the Assign module Close
Tidal Windows Modules (Cont.)
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Port Tamsar Simulation Results
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Port Tamsar Simulation Results (Cont.)
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Port Tamsar Simulation ResultsFor model with a shorter lay periods
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• This example models a toll plaza system on the New Jersey Turnpike, consisting of
• 2 exact-change (EC) lanes• 2 cash-receipt (CR) lanes • 1 Easy Pass (EZP) lane
• The layout of the toll plaza is shown below
TollBooths
Exact
Ch
ang
e(E
C)
Lan
es
EZ Pass(EZP) Lane
Cash
R
eceipt
(CR
) L
anes
Inco
ming
Car
s to
Toll
Plaza
Example: A Toll Plaza Model
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• Arriving vehicles select lanes (no jokeying allowed) as follows:1) 50% of all arriving cars go to EC lanes, and their service time distribution is (only the non-negative values are used) 2) 30% of all arriving cars go to CR lanes, and their service time distribution is 3) 20% of all arriving cars go to the EZP lane, and their service time distribution is
• Traffic congestion is non-stationary (heavier during morning and evening rush hours and lighter during off-peak hours) as follows:
4.81,1.01Norm( )
5 4.67,2.26Logn( )+
1.18 4.29× 2.27,3.02Beta( )+
Toll Plaza Car Arrivals and Service
8 4.4, 4.12Gamm( )+
1.32, 1.57, 1.76Tria( )
2.64 0.82, 4.5Weib( )+
1.32, 1.57, 1.76Tria( )
4.2 0.87, 8.24Gamm( )+
Time Period(in hours)
Inter Arrival Time Distribution (in seconds)
0 AM– 6 AM
6 AM – 9 AM
9 AM – 16 PM
16 PM – 19 PM
19 PM – 24 PM
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• The number of operating cash-receipt booths varies over time as follows:
• since such booths must be manned, and therefore are expensive to operate,
one of them is closed during the off-peak hours• only during morning and evening rush hours do all cash-receipt booths remain open
Toll Plaza Cash-Receipt Booths
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• Performance analysis objectives for the toll plaza system address the following issues:
1. What would be the impact of additional traffic on car delays?2. Would adding another booth markedly reduce waiting times?3. Could some booths be closed during some light traffic hours without appreciably increasing waiting times?4. What would be the impact of converting some cash-receipt booths to exact-change booths or to easy pass booths? 5. How would waiting times be reduced if both cash-receipt booths were to be kept open at all times?
• We wish to address the last issue above, using the following performance metrics
• average time to pass through the system • booth utilization
Toll Plaza Performance Issues
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Modeling Car Arrivals
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Car Arrivals Modules
Dialog box of the Create module Cars Arriving
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Dialog box for specifying sampling distributions (top) for time-dependent inter-arrivals in vector Int_Times (bottom)
Car Arrivals Modules (Cont.)
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Dialog box of the Assign module Assign Type and Modify Congestion Period
Car Arrivals Modules (Cont.)
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Dialog box of the Decide module Which Type
Car Arrivals Modules (Cont.)
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Dialog box of the Station module set for EC tollbooths
Car Arrivals Modules (Cont.)
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Dialog box of the PickStation module Exact Change Cars
Car Arrivals Modules (Cont.)
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Dialog box of the PickStation module Cash Receipt Cars
Car Arrivals Modules (Cont.)
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• In the PickStation module, called Cash Receipt Cars,• while tollbooth CR_1 is open, then 1-MR(CRS_1) = 0, and the expression for CR_1 evaluates to NQ(CRSQ_1), so that the tollbooth selection will be made based on the minimum of NQ(CRSQ_1) and NQ(CRSQ_2), as required• conversely, while tollbooth CR_1 is closed, then 1-MR(CRS_1) = 1 and NQ(CRSQ_1) = 0, and the expression for CR_1 evaluates to 1000, and since this number exceeds NQ(CRSQ_2) by assumption, tollbooth CR_2 is sure to be selected, as required
Car Arrivals Modules (Cont.)
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Car Services Modules
Dialog box of the Seize module Proceed to EC Booth
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Dialog box of the resource set EC Servers
Car Services Modules (Cont.)
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Dialog box of the spreadsheet views of sets in the Set module (bottom) and of the members of resource set EC Servers (top)
Car Services Modules (Cont.)
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Dialog box of the spreadsheet views of sets in the Set module (bottom) and of the members of resource set EC Servers (top)
Car Services Modules (Cont.)
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Dialog box of the Delay module Pay Exact Change
Car Services Modules (Cont.)
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Dialog box of the spreadsheet views of capacity schedules in the Schedule module (bottom)
and corresponding durations of server CRS_1 at the tollbooth CR_1 (top)
Car Services Modules (Cont.)
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Dialog box of the Release module Leave EC Booth
Car Services Modules (Cont.)
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Dialog box of the Record module Record Flow Times
Car Services Modules (Cont.)
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Toll Plaza Simulation Results
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Toll Plaza Simulation Results (Cont.)
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Toll Plaza Simulation Results (Cont.)
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• The dramatic impact of the closure of tollbooth CR_1 during off-peak hours leaves room for improvement
• to what extent would the flow times of CR cars be improved, if tollbooth CR_1 were to remain open at all times?
• It is easy to modify the tollbooth plaza Arena model to reflect this improved operating rule
• merely set the capacity of server resource CRS_1 to 1 at all times
• Simulation results show next the extent of the corresponding performance improvement
Improved Toll Plaza System
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Improved Toll Plaza Simulation Results
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Example: A Gear Job Shop Model• This example models a gear job shop consisting of
• an arrival dock• a milling station with 4 milling machines• a drilling station with 3 drilling machines• a paint shop with 2 spray booths• a polishing area with a single worker• a shop exit
• Gear types are G1, G2, G3 with distinct operations plans (sequences) • The layout of the job shop and gear sequences are shown below
DrillingStation
ArrivalDock
MillingStation
ShopExit
PaintingStation
PolishingStation
G1G2G3
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• The table below lists the job shop locations and their distances
Distances Among Job Shop Locations
FromLocation
ToLocation
Distance(in feet)
Arrival Dock Milling Station 100Arrival Dock Drilling Station 100
Milling Station Drilling Station 300Milling Station Paint Shop 400Milling Station Polishing Area 150
Paint Shop Polishing Area 300Drilling Station Paint Shop 150Drilling Station Polishing Area 400
Paint Shop Arrival Dock 250Polishing Area Arrival Dock 250Polishing Area Shop Exit 200
Shop Exit Arrival Dock 550Shop Exit Drilling Station 500Shop Exit Milling Station 300Shop Exit Paint Shop 400Shop Exit Polishing Area 200
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Gear Operations Plans• The table below lists the gear operations plans
GearType
OperationsSequence
Processing Times
(in minutes)
G1 Milling 35Drilling 20Painting 55Polishing 15
G2 Milling 25Painting 35Polishing 15
G3 Drilling 18Painting 35Polishing 15
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• The following statistics are of interest:• gear flow times (by type)• gear delays at production stations • machine utilizations
• To analyze the performance of the job shop, we plan to run a simulation over 1 year of operation
Gear Job Shop Performance Issues
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Gear Arrivals and Departures Models
Arena model segment implementing gear arrivals at the arrival dockand transport to the job shop floor
Arena model segment implementing gear transport from the job shop floor to the shop exit and flow time statistics collection
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Job Shop Floor Manufacturing Model
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Gear-Job Arrivals Modules
Dialog box of the Create module Create Jobs
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Gear-Job Arrivals Modules (Cont.)
Dialog box of the Assign module Assign Job Type and Sequence
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Gear-Job Arrivals Modules (Cont.)
Dialog boxes of spreadsheet views of sequences in a Sequence module (bottom), operations steps of type G1 gears (middle)
and milling time assignment of type G1 gears (top)
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Gear-Job Arrivals Modules (Cont.)
Dialog box of the Request module Request a Truck
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Gear-Job Arrivals Modules (Cont.)
Dialog box of the Transport module Transport to Shop Floor
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Gear-Job Arrivals Modules (Cont.)
Dialog box of the Free module Free Truck at Mill
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Gear-Job Service Modules
Dialog box of the Process module Milling
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Gear-Job Service Modules (Cont.)
Dialog box of the Request module Request Truck at Milling
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Gear-Job Service Modules (Cont.)
Dialog box of the Record module Tally Flow Time
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Gear-Job Service Modules (Cont.)
Dialog box of the Transporter spreadsheet module (bottom) and the dialog box of the Initial Position Status field (top)
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Gear-Job Service Modules (Cont.)
Dialog box of the Distance spreadsheet module (left) and the dialog box of its Stations field (right)
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Job Shop Simulation Results
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Job Shop Simulation Results (Cont.)
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• To reduce the wait at the paint shop, modify the job shop model by increasing the number of paint booths from 2 to 3
• The simulation results of the modified job shop are shown below
Modified Job Shop Model