Chapter Seven

Applications Using Arena

McGraw-Hill/Irwin © 2005 The McGraw-Hill Companies, Inc. All rights reserved.

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

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

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

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

Manufacturing Simulation Models

Exhibit 7-1 p. 186Page: Manufacturing Cell Models

Manufacturing Cell Flow

Exhibit 7-2 p. 187Page: Manufacturing Cell Flow

Manufacturing Cell Models

Exhibit 7-3 p. 187 Sheet: Static Analysis

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

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

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)

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

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

Single Item Base Model Manufacturing Cell 1.doe

Exhibit 7-7 p. 198 Model Manufacturing Cell 1.doe @ 8 Hours

Manufacturing Cell 1.doe

Exhibit 7-8 p. 198Automatic Process has Space Decide Module Dialog

NQ (Automatic Process.Queue) < NQ (Manual Process.Queue) + 2

Manufacturing Cell 1.doe

Exhibit 7-11 p. 190Resource Spreadsheet

Exhibit 7-9 p. 190

Crystal Reports Cost Summary

Batch Mode Base Model Manufacturing Cell 2.doe

Exhibit 7-12 p. 191Model Manufacturing Cell 2.doe @ 8 Hours

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

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

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

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

Manufacturing Cell 4.doe Operator Set

Exhibit 7-19 p. 193Set Spreadsheet Exhibit 7-20 p. 194

Load Batch Process Module Dialog

Manufacturing Cell 4.doe Tally

Exhibit 7-21 p. 194Record Module Dialog

Exhibit 7-22 p. 194User Specified Crystal Report

Manufacturing Cell 5.doe Worksheet Input.xls

Exhibit 7-28 p. 196Model Manufacturing Cell 5.doe Input Cycle

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

Manufacturing Cell 5.doe Assign Batch Start Time Module

Exhibit 7-32 p. 197Assign Batch Start Time Module

Manufacturing Cell 5.doe Worksheet Output.xls

Exhibit 7-33 p. 197Write Output File Module Dialog

Exhibit 7-34 p. 198Workbook Output.xls

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

Manufacturing Cell 5.doe Frequency Statistics

Exhibit 7-27 p. 196Frequency Statistics Replication 1

Exhibit 7-26 p. 195Statistic Spreadsheet

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

Manufacturing Cell 6.doe @ 8 Hours

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

Modeling Inspection – Rejection – Rework

Reject Batch.doeReject Single.doeRework Batch.doeRework Single.doe

Reject Batch.doe

Exhibit 7-41 p. 200Reject Batch.doe Special Model Logic

Reject Batch.doe

Exhibit 7-42 p. 200Separate Rejects

Exhibit 7-43 p. 201Separate Good

Reject Single.doe

Exhibit 7-44 p. 201Special Model Logic

Exhibit 7-45 p. 201Decide Module Dialog

Rework Batch.doe

Exhibit 7-46 p. 202Rework Batch.doe Special Model Logic

Rework Single.doe

Exhibit 7-47 p. 202Rework Single.doe Special Model Logic

Modeling Material Handling Equipment

Route.doe Route PickStation.doe Route Sequence.doe Conveyor.doe Transporter.doe AGV.doe

Route.doe

Exhibit 7-48 p. 203Route.doe Special Model Logic

Route.doe

Exhibit 7-49 p. 204Route.doe Enter Spreadsheet

Exhibit 7-50 p. 204Route.doe Leave Spreadsheet

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

Route PickStation.doe

Exhibit 7-53 p. 205Route PickStation.doe Special Model Logic

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

Route Sequence.doe

Exhibit 7-55 p. 205Sequence Spreadsheet

Exhibit 7-56 p. 206Advanced Set Spreadsheet

Conveyor.doe

Exhibit 7-58 p. 206Conveyor.doe Special Model Logic

Conveyor.doeExhibit 7-59 p. 207Segment Spreadsheet

Exhibit 7-60 p. 207Conveyor Spreadsheet

Transporter.doe

Exhibit 7-61 p. 207Transporter.doe Special Model Logic

Transporter.doe

Exhibit 7-63 p. 207Distance Spreadsheet

Exhibit 7-62 p. 207Transporter Spreadsheet

AGV.doe

Exhibit 7-64 p. 208AGV.doe Special Model Logic

AGV.doe

Exhibit 7-66 p. 208Network Spreadsheet

Exhibit 7-65 p. 208Transporter Spreadsheet

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

Modeling Multiple Product Flows

Exhibit 7-70 p. 209Page: Two-Product Flow

Products Separate.doe Products Combined.doe Products Sequence.doe

Products Separate.doe

Exhibit 7-71 p. 210Products Separate.doe Model Logic

Exhibit 7-72 p. 210Process Module Spreadsheet

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

Products Sequence.doe

Exhibit 7-76 p. 211Products Sequence.doe Model Logic

Exhibit 7-77 p. 211Sequence Spreadsheet

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

Concurrent Entities

Exhibit 7-79 p. 212Arena Academic Edition 150 Entities Error Message

Limit Entities.doe

Exhibit 7-80 p. 212Model Limit Entities.doe

EntitiesWIP (Entity.Single) > Entity.Limit – 3

Large Accumulator.doe

Exhibit 7-81 p. 213 Large Accumulator.doe

Accumulator.Contents > Accumulator.Size - 1

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

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)

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

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