JAMES YUNG DSES-6620 Simulation Modeling and Analysis Project Description:

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JAMES YUNG
DSES-6620 Simulation Modeling and Analysis
Project Description:
1. ABSTRACT
This report discusses and examines the results from a ProModel software simulation model of a Chinese
Restaurance kitchen during the busy evening hours of Sunday night.
The report and model will analyze the kitchen throughput, in term of number of meals produce, from two
different workflow setup, and give suggestion for choosing the better one based on results of the
simulation model.
2. OBJECTIVES
The objective of this modeling exercise is to be able to simulate the operation of the Restaurance
kitchen during the busy hours.
The model simulation will allow examination of order received and flow process through the kitchen to
draw improvement to increase the throughput of meals and to minimize the waiting time of orders from
received to made for deliver.
3. SCOPE
The model is limited to modeling the continuous work flow of each chef and does not take into account of
the followings:

Worker break-time (rarely taken during busy hours)

Cost (fix pay per day work for every worker)

Wrong order cooked (no rework)
The limitations are legitimated based on a Chinese restaurance business model.
This simulation study objective only requires determining the throughput during busy hours (5pm to 8pm)
when maximum demand is required from the kitchen.
In a typical weekend, the orders can be divided into three different groups:
•Single queue with 3 different servers
•Three different queues to 3 different servers
Collect Data in 5 weeks period
WEEK 1
AP
SP
MN
4:00 PM
5
0
2
5:00 PM
7
2
3
6:00 PM
10
4
6
7:00 PM
10
4
6
8:00 PM
5
2
3
9:00 PM
5
2
3
10:00 PM 11:00 PM
5
5
0
0
0
0
6:00 PM
15
6
9
7:00 PM
12
6
7
8:00 PM
5
2
5
9:00 PM
5
0
1
10:00 PM 11:00 PM
5
5
0
0
1
0
6:00 PM
10
4
5
7:00 PM
10
4
6
8:00 PM
10
4
6
9:00 PM
5
0
0
10:00 PM 11:00 PM
5
5
0
0
0
0
6:00 PM
10
4
6
7:00 PM
10
4
6
8:00 PM
10
4
6
9:00 PM
5
0
0
10:00 PM 11:00 PM
5
5
0
0
0
0
WEEK 2
AP
SP
MN
4:00 PM
6
0
3
5:00 PM
12
3
9
AP
SP
MN
4:00 PM
5
1
1
AP
SP
MN
4:00 PM
3
1
1
AP
SP
MN
4:00 PM
2
0
1
5:00 PM
5
1
2
6:00 PM
12
5
6
7:00 PM
12
4
6
8:00 PM
5
2
3
9:00 PM
5
0
1
10:00 PM 11:00 PM
5
5
0
0
1
0
4:00 PM
21
2
8
5:00 PM
39
11
23
6:00 PM
57
23
32
7:00 PM
54
22
31
8:00 PM
35
14
23
9:00 PM
25
2
5
10:00 PM 11:00 PM
25
25
0
0
2
0
WEEK 3
5:00 PM
5
1
3
WEEK 4
5:00 PM
10
4
6
WEEK 5
Total
AP
SP
MN
Orders received from 5 to 8PM
AP
SP
MN
5:00 PM
39
11
23
6:00 PM
57
23
32
7:00 PM
54
22
31
8:00 PM
35
14
23
Total
Average
363 in 5 weeks
72.6 per week
Number of orders
5 weeks total orders (5 to 8 PM)
60
AP
40
SP
20
0
MN
5:00 PM
6:00 PM
7:00 PM
8:00 PM
AP
39
57
54
35
SP
11
23
22
14
MN
23
32
31
23
Time
Draw Input Conditions based on 5 weeks data collected from 5 pm to 8 pm:
4 hrs = 2400 min
2400 / 72.6 = 3.3 orders per min
P(AP)
= 55%
P(MN)
= 30%
P(SP)
= 15%
Input condition:
• Arrivals N ( 3.3,.3)
• 1 hour warm-up time
• 4 hrs run with 10 replications
• 5 min extra required to cook non-specialty meals
•Chef_A
AP: N(5,1)
•Chef_SP
AP: N(10,3) SP: N(15,1) MN: N(15,3)
SP: N(20,3) MN: N(15,2)
•Chef_MN AP: N(10,2) SP: N(20,2) MN: N(10,1)
Output:
REPLICATION ANALYSIS (Sample size 10)
Statistic
Avg
Low 95% CI
High 95% CI
------------------------
----
----------
-----------
AP - Total Changes
42.5
39.4793
45.5207
FIFO_AP - Total Changes
36
31.476
40.524
Main - Total Changes
19.2
17.3593
21.0407
FIFO_MN - Total Changes
18.7
16.0225
21.3775
QTY - Total Changes
71.8
70.4179
73.1821
FIFO_QTY - Total Changes
64.4
61.2875
67.5125
SP - Total Changes
10.1
8.23928
11.9607
FIFO_SP - Total Changes
9.7
7.79102
11.609
Corrected number of meals cooked are the Total change value of AP, SP, MN and QTY.
Chefs are busy all the time
FIFO_Kitchen Throughput from 5 pm – 8pm
REPLICATION ANALYSIS (Sample size 10)
Statistic
Avg
Min
Max
-------------------
----
---
---
AP -
35.6
26
50
MN -
18.3
11
22
QTY -
63.6
58
71
SP -
9.7
8
11
A_CHEF - % Util
84.91
M_CHEF - % Util
77.77
S_CHEF - % Util
67.04
Distribute_Kitchen Throughput from 5 pm – 8pm
REPLICATION ANALYSIS (Sample size 10)
Statistic
Avg
Min
Max
--------------------
----
---
---
AP -
40.8
31
47
Main -
19.7
16
23
QTY -
72.1
69
74
SP -
11.6
9
15
ENTITY ACTIVITY (Time stall in the kitchen)
FIFO_Kitchen
Average
Average
Average
Average
Average
Current
Minutes
Minutes
Minutes
Minutes
Minutes
Entity
Total
Quantity
In
In Move
Wait For
In
Name
Exits
In System
System
Logic
Res, etc.
Operation
------
------- --------- ---------
--------
---------
---------
--------
Meal
0
1.4
-
-
-
-
-
(Average)
Meal
0
0.516398
-
-
-
-
-
(Std. Dev.)
Meal A
35.6
8
34.998543
0.166000
17.995812
13.197412
3.639319
(Average)
Meal A
7.07421
3.43188
7.884183
0.000000
7.371682
0.513169
0.314182
(Std. Dev.)
Meal S
9.7
2.3
40.613202
0.166000
13.214442
23.884894
3.347866
(Average)
Meal S
1.1595
1.63639
7.859942
0.000000
6.901122
0.881158
1.024611
(Std. Dev.)
Meal M
18.3
3.7
39.687849
0.166000
17.314115
18.312140
3.895594
(Average)
Meal M
3.62246
2.75076
7.278683
0.000000
6.943116
0.587160
0.520118
(Std. Dev.)
Blocked
DIS_Kitchen
Meal
0
3
-
-
-
-
-
(Average)
Meal
0
0.471405
-
-
-
-
-
(Std. Dev.)
Meal A
40.8
2.1
21.781616
0.295000
3.031991
15.099593
3.355032
(Average)
Meal A
4.93964
0.875595
3.455094
0.000000
2.603878
0.226648
0.928918
(Std. Dev.)
Meal S
11.6
1.3
35.650320
0.384000
3.143700
25.121059
7.001561
(Average)
Meal S
2.319
1.05935
6.388774
0.000000
3.768347
0.339092
2.996392
(Std. Dev.)
Meal M
19.7
1.5
29.671632
0.424000
3.863329
19.908107
5.476196
(Average)
Meal M
3.0203
1.17851
7.237355
0.000000
4.443849
0.320514
2.770553
(Std. Dev.)
1.
2.
3.
Chefs utilization output data shows the Dis_kitchen require less work from each
chef.
Number of meals throughput are also higher in DIS_KITCHEN than
FIFO_KITCHEN.
Entity Activity table shows average time meal wait for process is greater in the case
of FIFO_Kitchen setup.
Validation and Verification
DIS_KITCHEN Chefs Average Minute Per Entry
REPLICATION ANALYSIS (Sample size 10)
Statistic
Avg
Min
Max
----------------------------------
---------
---------
---------
A_CHEF - Average Minutes Per Entry
4.961354
4.707368
5.345344
M_CHEF - Average Minutes Per Entry
9.488253
9.098706
10.059947
S_CHEF - Average Minutes Per Entry
13.849531
12.730250
15.368300
1.
2.
Total change value of AP, SP, MN and QTY are the corrected number of dishes cooked
C.I. Calculate based on Min Max values after warm-up which is not true representation
of the actual system throughput from 5 pm to 8 pm .
Average
Variable
Total
Minutes
Minimum
Maximum
Current
Average
Name
Changes
Per Change
Value
Value
Value
Value
--------
--------
----------
--------
--------
--------
--------
FIFO QTY
64.4
3.699230
11.1
75.5
75.5
43.8272 (Average)
FIFO QTY
4.35125
0.221134
1.28668
3.92287
3.92287
2.47939 (Std. Dev.)
FIFO AP
36
6.650917
5.7
41.7
41.7
23.9937 (Average)
FIFO AP
6.32456
1.217403
2.31181
5.2504
5.2504
3.12299 (Std. Dev.)
FIFO SP
9.7
25.163349
1.7
11.4
11.4
6.5543 (Average)
FIFO SP
2.66875
9.988899
1.41814
3.33999
3.33999
2.92238 (Std. Dev.)
FIFO MN
18.7
12.805729
3.7
22.4
22.4
13.2793 (Average)
FIFO MN
3.74314
2.295091
1.82878
4.27395
4.27395
3.0619 (Std. Dev.)
FIFO Ml
73.2
3.255722
17.1
90.3
90.3
53.9124 (Average)
FIFO Ml
0.788811
0.037930
0.316228
0.823273
0.823273
0.435939 (Std. Dev.)
QTY
71.8
3.304031
11.6
83.4
83.4
47.336 (Average)
QTY
1.93218
0.086214
0.966092
1.50555
1.50555
0.971072 (Std. Dev.)
AP
42.5
5.614435
6.8
49.3
49.3
27.7098 (Average)
AP
4.22295
0.543032
1.8738
4.83161
4.83161
3.03304 (Std. Dev.)
SP
10.1
22.657472
1.4
11.5
11.5
6.46964 (Average)
SP
2.60128
4.950216
1.07497
3.02765
3.02765
1.97236 (Std. Dev.)
Main
19.2
12.302016
3.4
22.6
22.6
13.1566 (Average)
Main
2.57337
1.834326
1.26491
3.1693
3.1693
2.06287 (Std. Dev.)
ML
72.5
3.284489
17.4
89.9
89.9
53.7278 (Average)
ML
1.08012
0.039790
0.516398
1.19722
1.19722
0.667982 (Std. Dev.)
Questions ???????????????????
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