Discrete Event Simulation of Dept. 110/114
by
Robert Griffiths
2nd Draft
Simulation Modeling and Analysis
12/7/99
Problem Definition
The resources of two manufacturing cells are to be combined due to reduced load in both
departments. In addition, other areas of the shop have declared “needs” for both manpower and
equipment. Early voluntary retirement will have (has had) an impact on available manpower and
skills. The layout of the new department will therefore be impacted by both availability of
machines and machinists to staff the cell. A preliminary design of the layout of the department
projects costs of approximately $850,000 for the proposed restructuring effort.
The initial work to develop a layout has been based on “tribal knowledge” and basic
consideration of machine loading in light of projected schedule. A simulation of the proposed
new department is to be developed, producing the proposed part numbers and utilizing
machinists with known skill sets.
Introduction
The resources of large manufacturing facilities were organized several years ago as
“villages”. Like machines were frequently grouped together giving shop floor control the
“flexibility” of routing parts to whatever machines were available. Redundancy in machines and
machinists was a common occurrence, organizing machines and operators in “villages” was a
perceived effective method for flowing parts though the shop. Those were days when inventory
levels were high, floor space to accommodate the large machining groups was amble, and there
was an abundance of labor.
The shop floor continues to evolve today. Over the past decade, the drive has been to
reduce inventory levels by moving parts more efficiently through the shop. To accomplish this,
“machining cells” were setup. Each cell / department would contain the minimum required
equipment to produce their product. In addition, the departments were arranged into “U-shaped
flowlines”- this served a many goals, among them:
1) reduced the floor space of the department
2) allowed for one machinist to perform multiple tasks
3) aided in the development of the “visual factory” in which department personnel as well as
customers could easily understand the part ”flow” and where the problems were
If the parts running in a department change to a degree that causes the cell in its current
configuration not to run as efficiently, it is time to change the part mix or reorganize the cell.
This is often a challenge in the current environment where men and machines are in limited
supply. The planner must reconcile the requirements for capacity that the schedule demands to
the availability of resources.
Another point to note concerning “lean-manufacturing” systems. These are “engineered
systems”, that is, cells should be designed such that the inputs to the cell will result in predictable
outputs. This is required without large redundancies built-in (recall the minimalist approach).
Therefore, unplanned events such as machine downtime, absenteeism, large schedule surges,
etc., can have a severe impact on the cell’s performance.
Statement of Objectives

Develop a 5 machinist, 1st shift model of the proposed department. The department should
produce two assemblies and two detail part numbers- a total of four entities

Simulation should highlight any bottlenecks in terms of operators and / or equipment

Simulation should verify cells capability to maintain schedule through mid-2002
Model Planning
The proposed layout CAD file was utilized in the model development to aid in
determination of locations. All the relevant machines in the department were captured in the
model:

2 N/C VTL (Vertical Turning Lathe)

1 Layout table

1 4-axis horizontal milling center

1 5-axis horizontal milling center

1 Vertical milling center (3axis)

1 Manual vertical drill press

1 Alkali washer

1 Deburr booth

1 Power Washer

1 Assembly table

1 inspection bench

2 material incoming / outgoing areas

1 outside processing location
Graphic 1
The resources utilized were five machinists with different skills / responsibilities:

VTL operator- operates the two VTLs

HMC operator- operates the 4-axis and / or 5-axis HMC

VMC operator- operates the 3-axis VMC and the manual drill

Deburr operator- performs manual deburr as well as washing part and various layout
functions

Inspector- performs visual in-process and final inspection of parts
The entities in the simulation were defined as the four parts numbers scheduled to be produced
by the department.
The JT8 inlet case- this is received to the department as a weldment. The cell is
responsible for some light machining early in the process and then the part spends a
majority of its lead-time outside the cell at braze, paint, and various nondestructive
testing activities.
The F119 inner and outer shrouds. These parts are machined by the cell in detail,
are brazed together with struts to form an inlet assembly. Machining is then performed
by the cell on the assembly.
External files are utilized which contain arrival information (dependant on schedule), and
shift definition. In accordance with the objectives, the model is first simulated using only a 1st
shift defined for all locations. A 15-minute break is defined mid-morning and a 30 minute lunch
break starts at 12:15pm.
No machine downtime has been modeled. This is an acceptable omission based on the
premise that this will be a limited shift operation (1 or 2 shifts). It is envisioned that one could
take advantage of off-shift time to perform preventative maintenance and necessary repairs.
Therefore machine downtime should have at minimal impact on production. This is also a
realistic expectation in practice. Many “disciplined” shops do schedule regular maintenance
activities on the off-shifts.
The model file is located in Appendix II.
Data Collection
Arrival Schedule
Raw material arrival to the cell can be modeled as deterministic in nature, that is, the part
scheduler’s task is to insure that material is available for processing based on delivery dates.
Material must arrive early enough to account for the processing lead-time to insure on-time
delivery. Lead-times for the parts produced through the department are diagrammed below:
outer case [3 wks]
F119_Assembly [8wks]
inner shroud [2]
JT8_Assembly [2.5wks]
So, if a F119_Assembly were due for delivery on 2/28, an outer case detail should be started no
later than 11 weeks prior. Actual delivery dates for the hardware is charted below:
JT8 Delivery Schedule
1
Cut date
7/26/02
5/26/02
3/26/02
1/26/02
11/26/01
9/26/01
7/26/01
5/26/01
3/26/01
1/26/01
11/26/00
9/26/00
7/26/00
5/26/00
3/26/00
0
1/26/00
Quanitity
2
F119 Delivery Schedule
Quanitity
4
3
2
1
Ja
n00
M
ar
-0
0
M
ay
-0
0
Ju
l-0
0
Se
p00
No
v00
Ja
n01
M
ar
-0
1
M
ay
-0
1
Ju
l-0
1
Se
p01
No
v01
Ja
n02
M
ar
-0
2
M
ay
-0
2
Ju
l-0
2
Se
p02
0
Cut Date
Based on delivery requirements, the simulation is determined to start on October 28
1999, with the arrival of raw material for an outer shroud. To implement an arrival schedule in
ProModel, it is necessary to develop interarrival times which are tabulated and read in as an
external file.
Note that while the F119 delivery schedule is fairly well distributed (with the exception
of the 2002 ramp-up), the JT8 exhibits “clustering” early during 2000. We referred to this as a
schedule (or demand) that is “front loaded”. The Unit manager has options: he/she could
attempt to have the department continue to function as normal, absorbing the increased load
(which will have to be accommodated in terms of increased overtime). A second option would
be to instruct the part scheduler to “level load” the schedule for the department. The scheduler
would attempt to adjust the arrival of raw material to provide a more uniform flow of material
through the department. As this simulation will initially assume the cell operates first shift only,
this may be necessary.
Processing
Data for operation processing time was obtained. The data largely contained “engineered
time standards”, that is, the time given per operation is an average of observations. Appendix I
has tabulated operations and the times associated with them. Column F of this table contains the
total time at that operation.
Obtaining variation data on these time standards is a difficult and a somewhat inaccurate
task based on current practices. It has been decided (based in experience) to assume the
following distributions:
Task
Distribution
Setup of machines or inspection tasks
Normal – s.d. approx 20% of engineered times
processing (outside processing, deburr,
Triangular
inspection, etc.,)
Normal- small deviation from mean <1.5
n/c machining
Simulation Results / Validation
The model was created by adding one part number at a time and visually verifying
correct routing and resource behaviors. Allowance for shifts was not initially taken into accountthat is, the cell operated 24 hours per day, 7 days per week. At this point, model results were
encouraging. Each part spent about 50 – 60% of its anticipated lead-time in the system. In
addition, the number of exits for the F119 assembly confirmed that logic for combining inner and
outer details was working correctly. Parts did not appear to be excessively “blocked”. These
results confirmed the interactions and routings were somewhat reasonable.
Appendix III contains the results file .
Experimentation and recommendations
Several experiments are currently underway. After verifying the basic “behavior” of the
system, shift assignments were then added. Recall the goal of the study is determine the
capability of this cell operating with a 1st shift only. The results (not included in this paper)
showed the cell incapable of absorbing the increased workload generated by the JT8 schedule.
Investigations will occur (results to be placed in FINAL paper) as to the cause and potential
fixes. Preliminary results appear to show the deburr resource over-taxed. This in and of itself
seems to make sense as most of the deburr tasks are manual in nature and require a captive
resource. However, another issue could be at work. The model does not include “incoming
queues” for the workstations (would exceed ProModel- Student capability). Therefore, a part is
required to have its next location clear before vacating its current workstation. This dynamic
interaction may be the reason the cell fails to produce hardware with only one shift.
This is not necessarily a failure of the model. In fact, one could argue that in the ideal
flowline / pull system, the parts “never hit the floor”. Individual queues at workstations represent
inventory that is not producing hours for the shop, hence, high inventory is bad. Until further
investigation proofs otherwise, I would suggest that this model reflects an ideal flowline.
It demonstrates the need to either:
1) level-load the schedule, or,
2) additional capacity (maybe a 2nd shift deburr?) is required
Senstivity experiments, results of which will be available in the FINAL paper, may shed
light on this issue.
Appendix I- Processing time detail
A
B
F119_ass'y
0010
F119_ass'y
0020
F119_ass'y
0050
F119_ass'y
0070
F119_ass'y
0100
F119_ass'y
0110
F119_ass'y
0130
F119_ass'y
0140
F119_ass'y
0170
F119_ass'y
0190
F119_ass'y
0200
F119_ass'y
0220
F119_ass'y
0230
F119_ass'y
0240
F119_ass'y
0250
F119_ass'y
0260
F119_ass'y
0265
F119_ass'y
0270
F119_ass'y
0290
F119_ass'y
0470
F119_ass'y
0570
F119_ass'y
0590
F119_ass'y
0600
F119_ass'y
0610
F119_ass'y
0625
F119_ass'y
0630
F119_ass'y
0640
F119_ass'y
0650
F119_ass'y
0660
F119_ass'y
0670
C
D
10
210
396
462
0.001
66
0.001
34.5
19.8
66
6.6
4
20
47.4
300
100
5
90
0.001
0.001
19.8
0.001
55
60
0
38
100
100
11.37
200
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
0680
0685
0690
0700
0705
0707
0710
0712
0715
0720
0725
0740
100
20.45
70
70
0
60
100
9.5
24
360
16.91
0.001
F119_ass'y
F119_ass'y
0750
0755
9.5
210
E
F
0 REQUISITION DETAILS
0 DRY STACK OPERATION
0 SET UP FOR TACK WELD
0 APPLY BRAZE ALLOY TO OD OF
0 INSPECT FOR BRAZE COVERAGE
0 APPLY BRAZE MATERIAL
0 INSPECT FOR BRAZE COVERAGE
0 LOAD STRESS RELIEVE FIXTURE
0 UNLOAD STRESS RELIEVE FIXTURE
0 LAYOUT CASE FOR MACHINING
0 LOAD STRESS RELIEVE FIXTURE
0 UNLOAD STRESS RELIEVE FIXTURE
0 LAYOUT CASE FOR MACHINING
17.48 MACHINE REAR OUTER FLANGE AND I.D.
666 MACHINE ANTI-ICE CAVITY & WELD PRE
164 MILL PS2 CAVITY AND WELD PREP. INS
40 ROUGH DRILL (21) HOLES IN ANTI-ICE
30 POWER WASH AND DEBURR PART
0 RECEIVING INSPECTION FOR OP 280
0 WELD JTS #2,#3,#6,#7,#8,#9,#10
0 UNLOAD STRESS RELIEVE FIXTURE
0 WELD JOINT #4
0 LAYOUT CASE FOR MACHINING
64 FINISH MACHINE INNER AND OUTER REA
0 INSTALL DIA. -C- ON REAR SIDE OF O
30 FINISH MACHINE INNER AND OUTER FRO
230 FINISH MILL FLANGE SURFACES AT BOT
230 ROUGH AND FINISH STRUT ENDS, BOSS
55.54 SEMI-FINISH AND FINSH MACHINE EYEL
262 ROUGH, AND FINSH FORWARD FLANGE
FA
120 FACE MILL PS2 BOSSES,DRILL AND TAP
23.66 DRILL (21) HOLES ON FORWARD FLANGE
70 ROUGH, AND FINSH SCALLOPS ON
71 FACE MILL MANIFOLD BOSS AND (4) MO
0 DRILL, REAM AND TAP INNER AND OUTE
0 TAP (18) HOLES IN OUTER AFT FLANGE
50 MOUNTS FOR BUSHING INSTALLATION. I
24.8 WASH PART
0 BACK SPOTFACE (4) HOLES IN GOOSENE
0 DEBURR ALL HOLES, BOSSES
35.43 FLUSH
0 RECEIVING INSPECTION FOR
OPERATION
24.8 ALKALI CLEAN PER POP 384
0 BENCH
10.8
210
396
462
0.001
66
0.001
33
19.8
66
9.9
5.94
21.6
70.07
966
264
45
90
0.001
0.001
20
0.001
55
124
0
68
330
330
132
462
220
30
132
165
0
64.8
150
64.8
24
360
12
0.001
36.976
210
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_ass'y
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_inner
JT8
0760
0780
0800
0810
0820
0830
0010
0020
0030
0040
0045
0050
0055
0070
0080
0090
0105
0110
0120
0130
0150
0170
0090
0010
16.91
0.001
16.91
26
39
0.001
60
60
20
200
4.75
42
4.75
50.75
70
20
90
300
300
400
138
0.001
16.56
85.03
JT8
JT8
JT8
JT8
JT8
JT8
JT8
JT8
0020
0030
0040
0050
0060
0070
0080
0090
358.72
122.6
140.54
28
8.5
27.83
9.29
271.2
JT8
0100
9.29
JT8
JT8
0150
0160
0.001
20.5
JT8
JT8
JT8
JT8
JT8
JT8
JT8
JT8
JT8
JT8
JT8
JT8
0168
0170
0180
0200
0210
0220
0230
0250
0260
0270
0280
0300
5.8
37.92
7.22
31.54
51.72
6.95
5.9
16.4
4.1
13.3
2.7
42.99
35.43 FLUSH
0
35.43 FLUSH
0 AND PIN-SD,HEADLESS
0 FINISH BURR AND CORRECT
0 FINAL INSPECTION
0 FACE AND TURN
60 ROUGH I.D. FLOW PATH.
28 MILL KEY SLOT
250 ROUGH POCKETS
12.4 WASH
0 BREAK EDGES
12.4 WASH
42.96 FACE TO CLEAN
70 FINISH TURN I.D. FLOW PATH
28 MILL KEY SLOT
0 DEBURR SHARP EDGES
438 ROUGH AND FINISH POCKET FLOOR
536 FINISH POCKET SIDE WALLS
524 R. MILL BUTTRESS SLOTSINSTALL (21)
0 BREAK EDGES
0 FINAL INSPECTION
0
0 MASK VANE & BOSS OPENINGS LAYOUT
I
0 ROUGH AND FINISH MACHING L.E. OF
214.7 ROUGH & FINISH MACHINE T.E. OF
101.03 DRILL, CHAM., TAP, AND MILL INNER
254.9 DRILL, CHAM.,TAP & MILL INNER & O
0 DRILL (2) HOLES THRU CONNECTOR & I
0 COUNTERSINK RIVET HOLES IN INNER F
35 FLUSH CASE AND VANES
0 DEBURR & INSPECT OUTER FRONT
FLAN
35 FLUSH INLET CASE VANE AND SHROUD
P
0 DETAIL INSPECT. (QAI)
0 ABRASIVE CLEAN MAS TUBE ASSY
CONNE
0 FLUX, ASSEM, BRAZE MAS TUBE ASSY
0 FLUX, ASSEM, BRAZE MAS TUBE ASSY
18.99 REMOVE FLUX
0 RIVET CONNECTOR & MAS TUBE ASSY
0 FLUX, ASSEMBLE & BRAZE MAS TUBE A
18.99 CLEAN BRAZED AREA TO REMOVE FLUX
0 CHECK FOR FLOURIDES
0 REBRAZE JOINTS AT INNER SHROUD
0 REMOVE FLUX (1782) AS REQ'D
0 BRAZED JOINTS
0 (2) WIRES TO PASS FREELY THRU I.D.
12 PRESSURE TEST TUBES BF,BG,BH,&BJ
30
0.001
14
26
39
0.001
60
116
48
450
12
42
12
50
116
48
90
738
836
924
138
0.001
16.56
61.6
347.6
312.4
174.323
304.7
27.5
30.06
10.033
275
46.753
0.001
22.14
6.264
40.954
28.307
11
55.858
19.8
15.66
17.712
3.3
3.672
2.916
62.532
JT8
JT8
JT8
JT8
JT8
JT8
F119_inner
F119_inner
F119_inner
F119_inner
F119_inner
F119_inner
F119_inner
F119_inner
0380
0385
0390
120.78
0
9.29
0410
0415
0450
0010
0020
0035
0045
0047
0080
0100
0130
0.001
4.6
0.001
228.26
108
18
200
45
0.001
23.4
0.001
0 ASSEMBLE HELICAL COIL INSERTS IN I
0 SCOPE PART, CHECK FOR AND
35 FLUSH VANE AND SHROUD ASSEMBLY
PAS
0 INSPECT (FINAL). (QAI)
0 ASSEMBLE TUBE (BAKE TOOL)
0 FINAL INSPECT (SURFACE TREAT)
100 ROUGH FACE & TURN REAR SIDE &
100 ROUGH FACE & TURN FRONT SIDE & OD
0 MILL TIMING SLOT
403 MILL BUTTRESS SLOTS
0 DEBURR BUTTRESS SLOTS & O.D.
0 VERIFY ACCEPTANCE OF OP. 30, 40, 5
0
0
66
0
10.033
0.001
8.132
0.001
228.26
208.06
18
603
45
0.001
16.9
0.001
Appendix II- Model file
********************************************************************************
*
Formatted Listing of Model:
*
*
C:\My Documents\grad_school\sma\termproj1.mod
*
********************************************************************************
Time Units:
Minutes
Distance Units:
Feet
********************************************************************************
*
Locations
*
********************************************************************************
Name
Cap
Units Stats
Rules
Cost
------------------ -------- ----- ----------- ---------- -----------NC_VTL_BT538472 1
1 Time Series Oldest, ,
NC_VTL_BT538471 1
1 Time Series Oldest, ,
LAYOUT_TABLE
1
1 Time Series Oldest, ,
TOYODA_4AX
1
1 Time Series Oldest, ,
HBM_5AX
1
1 Time Series Oldest, ,
VMC_BT540991
1
1 Time Series Oldest, ,
RADIAL_ARM_DRILL 1
1 Time Series Oldest, ,
DEBURR_BOOTH
1
1 Time Series Oldest, ,
INSPECTION_AREA 1
1 Time Series Oldest, ,
ALKALI_WASH
1
1 Time Series Oldest, ,
POWER_WASH
1
1 Time Series Oldest, ,
ASSEMBLY_BENCH 1
1 Time Series Oldest, ,
INCOMING
infinite 1 Time Series Oldest, ,
Outside_processing INFINITE 1 Time Series Oldest, ,
OUTGOING
infinite 1 Time Series Oldest, ,
********************************************************************************
*
Entities
*
********************************************************************************
Name
Speed (fpm) Stats
Cost
------------- ------------ ----------- -----------F119_inner 10
Time Series
F119_Assembly 50
Time Series
F119_outer 50
Time Series
JT8_Assembly 50
Time Series
********************************************************************************
*
Path Networks
*
********************************************************************************
Name Type
T/S
From To
BI Dist/Time Speed Factor
-------- ----------- ---------------- -------- -------- ---- ---------- -----------net1 Passing Speed & Distance N1
N2
Bi 40.00
1
N2
N4
Bi 6.00
1
N4
N5
Bi 81.00
1
N5
N6
Bi 77.00
1
N6
N7
Bi 98.12
1
N7
N2
Bi 97.08
1
N5
N8
Bi 46.47
1
N8
N9
Bi 40.05
1
N9
N6
Bi 13.70
1
N3
N7
Bi 105.13 1
net2
Passing
N7
N11
Bi 67.35 1
N11
N10 Bi 15.00 1
N10
N1
Bi 23.83 1
N6
N13
Bi 30.30
1
N6
N14
Bi 10.04 1
N6
N15
Bi 19.72 1
N15
N13 Bi 9.68
1
N9
N16
Bi 20.00 1
Speed & Distance N1
N2
Bi 76.24
N2
N3
Bi 75.00
1
N3
N5
Bi 16.00
1
N5
N2
Bi 92.12
1
N5
N4
Bi 25.41
1
N4
N6
Bi 66.00
1
N4
N7
Bi 59.00
1
N6
N7
Bi 21.00
1
N7
N8
Bi 17.00
1
N8
N9
Bi 14.00
1
N9
N10
Bi 33.00 1
N10
N11 Bi 16.00 1
N6
N12
Bi 49.00 1
N13
N5
Bi 33.09 1
N4
N14
Bi 5.00
1
N15
N10 Bi 10.00 1
1
********************************************************************************
*
Interfaces
*
********************************************************************************
Net
Node
Location
---------- ---------- -----------------net1
N1
INCOMING
N2
NC_VTL_BT538472
N4
NC_VTL_BT538471
N5
TOYODA_4AX
N8
HBM_5AX
N9
ALKALI_WASH
N6
DEBURR_BOOTH
N11
INSPECTION_AREA
N7
Outside_processing
N10
OUTGOING
N13
LAYOUT_TABLE
N14
POWER_WASH
N15
ASSEMBLY_BENCH
N16
RADIAL_ARM_DRILL
net2
N1
INCOMING
N2
Outside_processing
N4
NC_VTL_BT538472
N6
HBM_5AX
N7
VMC_BT540991
N8
RADIAL_ARM_DRILL
N9
ALKALI_WASH
N10
ASSEMBLY_BENCH
N12
TOYODA_4AX
N5
LAYOUT_TABLE
N13
DEBURR_BOOTH
N14
NC_VTL_BT538471
N3
N15
INSPECTION_AREA
POWER_WASH
********************************************************************************
*
Resources
*
********************************************************************************
Res Ent
Name
Units Stats Search Search Path
Motion
Cost
-------------- ----- -------- ------- ------ ---------- -------------- -----------VTL_oper
1 By Unit Closest Oldest net1
Empty: 120 fpm
Home: N2 Full: 120 fpm
(Return)
HMC_oper
1
By Unit Closest Oldest net2
Empty: 150 fpm
Home: N6 Full: 150 fpm
(Return)
VMC_oper
1
By Unit Closest Oldest net2
Empty: 120 fpm
Home: N7 Full: 120 fpm
(Return)
DEBURR_oper
1
INSPECTOR_oper 1
By Unit Closest Oldest net1
Empty: 120 fpm
Home: N6 Full: 120 fpm
(Return)
By Unit Closest Oldest net1
Empty: 150 fpm
Home: N11 Full: 150 fpm
(Return)
********************************************************************************
*
Processing
*
********************************************************************************
Process
Routing
Entity
Location
Operation
Blk Output
Destination
Rule Move Logic
------------- ------------------ ------------------ ---- ------------- ------------------ ------- -----------F119_inner INCOMING
WAIT 0
1 F119_inner NC_VTL_BT538472 FIRST 1 MOVE ON
net1
F119_inner NC_VTL_BT538471 ALT
MOVE ON net1
F119_inner NC_VTL_BT538472 GET VTL_oper
WAIT N(128.26,4.5)
FREE VTL_oper
WAIT N(100,1.2) 1 F119_inner NC_VTL_BT538471 FIRST 1 MOVE ON net1
F119_inner NC_VTL_BT538471 GET VTL_oper
WAIT N(108,4)
FREE VTL_oper
WAIT N(100,1.2) 1 F119_inner TOYODA_4AX
FIRST 1 MOVE ON net1
F119_inner TOYODA_4AX
GET HMC_oper
WAIT N(218,3)
FREE HMC_oper
WAIT N(403,10)
1 F119_inner DEBURR_BOOTH
FIRST 1 MOVE ON net1
F119_inner DEBURR_BOOTH
GET DEBURR_oper
WAIT T(30,45.00,120)
FREE DEBURR_OPER
1 F119_inner Outside_processing FIRST 1 MOVE ON net1
F119_inner Outside_processing WAIT T(2880,6000,14400)
F119_inner
F119_inner
F119_inner
F119_inner
F119_inner
F119_inner
F119_outer
net1
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
F119_outer
1 F119_inner INSPECTION_AREA FIRST 1 MOVE ON net1
INSPECTION_AREA GET INSPECTOR_oper
WAIT T(15,30,60)
FREE INSPECTOR_OPER
1 F119_inner ALKALI_WASH
FIRST 1 MOVE ON net1
ALKALI_WASH
GET DEBURR_oper
WAIT N(3,.5)
FREE DEBURR_oper
WAIT 15
GET DEBURR_OPER
WAIT N(5,.2)
FREE DEBURR_oper 1 F119_inner DEBURR_BOOTH
FIRST 1 MOVE ON net1
DEBURR_BOOTH
GET DEBURR_oper
WAIT T(10,16.9,50)
FREE DEBURR_oper 1 F119_inner Outside_processing FIRST 1 MOVE ON net1
Outside_processing WAIT T(60,180,240)
1 F119_inner INSPECTION_AREA FIRST 1 MOVE ON net1
INSPECTION_AREA GET INSPECTOR_oper
WAIT T(20,30,60)
FREE INSPECTOR_oper
INC inner_detail 1 F119_inner OUTGOING
FIRST 1 MOVE FOR 0
OUTGOING
WAIT UNTIL outer_detail>=1
COMBINE 1 AS F119_Assembly
1 F119_inner EXIT
FIRST 1 MOVE FOR 0
INCOMING
WAIT 0
1 F119_outer NC_VTL_BT538472 FIRST 1 MOVE ON
F119_outer NC_VTL_BT538471 ALT
MOVE ON net1
NC_VTL_BT538472 GET VTL_oper
WAIT N(10,2.5)
FREE VTL_oper
WAIT N(60,.87)
1 F119_outer NC_VTL_BT538471 FIRST 1 MOVE ON net1
NC_VTL_BT538471 GET VTL_oper
WAIT N(15,1.5)
FREE VTL_oper
WAIT N(116,.9)
1 F119_outer TOYODA_4AX
FIRST 1 MOVE ON net1
TOYODA_4AX
GET HMC_oper
WAIT N(65,3.8)
FREE HMC_oper
WAIT N(450,.1)
1 F119_outer ALKALI_WASH
FIRST 1 MOVE ON net1
ALKALI_WASH
GET DEBURR_oper
WAIT N(3,1)
FREE DEBURR_oper
WAIT 15
GET DEBURR_oper
WAIT N(5,.3)
FREE DEBURR_oper 1 F119_outer DEBURR_BOOTH
FIRST 1 MOVE ON net1
DEBURR_BOOTH
GET DEBURR_oper
WAIT T(100,187,240)
FREE DEBURR_oper 1 F119_outer Outside_processing FIRST 1 MOVE ON net1
Outside_processing WAIT T(700,1440,5000)
1 F119_outer NC_VTL_BT538472 FIRST 1 MOVE ON net1
NC_VTL_BT538472 GET VTL_oper
WAIT N(20,4)
FREE VTL_oper
WAIT N(50.75,.7) 1 F119_outer NC_VTL_BT538471 FIRST 1 MOVE ON net1
NC_VTL_BT538471 GET VTL_oper
F119_outer
F119_outer
F119_outer
F119_outer
net1
F119_outer
F119_outer
ON net1
F119_outer
WAIT N(30,6)
FREE VTL_oper
WAIT N(95,.8)
1 F119_outer Outside_processing FIRST 1 MOVE ON net1
Outside_processing WAIT T(1000,1997,5760)
1 F119_outer TOYODA_4AX
FIRST 1 MOVE ON net1
TOYODA_4AX
GET HMC_oper
WAIT N(120,5)
FREE HMC_oper
WAIT N(600,1)
1 F119_outer HBM_5AX
FIRST 1 MOVE ON net1
HBM_5AX
GET HMC_oper
WAIT N(300,19)
FREE HMC_oper
WAIT N(500,3)
GET HMC_oper
WAIT N(100,11)
FREE HMC_oper
WAIT N(400,2)
1 F119_outer ALKALI_WASH
FIRST 1 MOVE ON net1
ALKALI_WASH
GET DEBURR_oper
WAIT 3
FREE DEBURR_oper
WAIT 15
GET DEBURR_oper
WAIT 5
FREE DEBURR_OPER 1 F119_outer DEBURR_BOOTH
FIRST 1 MOVE ON
DEBURR_BOOTH
GET DEBURR_oper
WAIT 138
FREE DEBURR_oper 1 F119_outer Outside_processing FIRST 1 MOVE ON net1
Outside_processing WAIT 180
1 F119_outer INSPECTION_AREA FIRST 1 MOVE
INSPECTION_AREA GET INSPECTOR_oper
WAIT 60
FREE INSPECTOR_oper
INC outer_detail 1 F119_outer OUTGOING
FIRST 1
F119_outer OUTGOING
WAIT UNTIL inner_detail>=1
COMBINE 1 AS F119_Assembly
1 F119_outer EXIT
FIRST 1 MOVE FOR 0
JT8_Assembly INCOMING
WAIT 0
1 JT8_Assembly LAYOUT_TABLE
FIRST 1 MOVE
JT8_Assembly LAYOUT_TABLE
GET DEBURR_oper
WAIT n(90,22.3)
FREE DEBURR_oper 1 JT8_Assembly NC_VTL_BT538472 FIRST 1 MOVE ON
net2
JT8_Assembly NC_VTL_BT538472 GET VTL_oper
WAIT N(58.7,10)
FREE VTL_oper
WAIT N(300,2)
1 JT8_Assembly NC_VTL_BT538471 FIRST 1 MOVE
JT8_Assembly NC_VTL_BT538471 GET VTL_oper
WAIT N(122,10)
FREE VTL_OPER
WAIT N(214.7,2) 1 JT8_Assembly HBM_5AX
FIRST 1 MOVE
JT8_Assembly HBM_5AX
GET HMC_oper
WAIT N(101.03,9)
FREE HMC_oper
WAIT N(70,.4)
JT8_Assembly
JT8_Assembly
JT8_Assembly
JT8_Assembly
GET HMC_oper
WAIT N(28,2)
FREE HMC_OPER
WAIT N(254,3)
1 JT8_Assembly RADIAL_ARM_DRILL FIRST 1
RADIAL_ARM_DRILL GET VMC_oper
WAIT 35
FREE VMC_oper
1 JT8_Assembly POWER_WASH
FIRST 1
POWER_WASH
GET DEBURR_oper
WAIT 10
FREE DEBURR_oper
WAIT 35
GET DEBURR_oper
WAIT 10
FREE DEBURR_oper 1 JT8_Assembly DEBURR_BOOTH
FIRST 1
DEBURR_BOOTH
GET DEBURR_oper
WAIT T(100,271,300)
FREE DEBURR_oper 1 JT8_Assembly POWER_WASH
FIRST 1
POWER_WASH
GET DEBURR_oper
WAIT 10
FREE DEBURR_oper
WAIT 35
GET DEBURR_oper
WAIT 10
FREE DEBURR_oper 1 JT8_Assembly Outside_processing FIRST 1
Outside_processing WAIT 240
1 JT8_Assembly INSPECTION_AREA FIRST 1
JT8_Assembly
MOVE ON net1
JT8_Assembly INSPECTION_AREA GET INSPECTOR_oper
WAIT 40
FREE INSPECTOR_oper
1 JT8_Assembly Outside_processing FIRST 1
JT8_Assembly Outside_processing WAIT 4500
1 JT8_Assembly ASSEMBLY_BENCH FIRST 1
JT8_Assembly ASSEMBLY_BENCH GET DEBURR_oper
WAIT T(35,120.78,195)
FREE DEBURR_oper 1 JT8_Assembly DEBURR_BOOTH
FIRST 1
JT8_Assembly DEBURR_BOOTH
GET DEBURR_oper
WAIT 20
FREE DEBURR_oper 1 JT8_Assembly POWER_WASH
FIRST 1
JT8_Assembly POWER_WASH
GET DEBURR_oper
WAIT 9.29
FREE DEBURR_oper
WAIT 35
GET DEBURR_oper
WAIT 10
FREE DEBURR_oper 1 JT8_Assembly INSPECTION_AREA FIRST 1
JT8_Assembly INSPECTION_AREA GET INSPECTOR_oper
WAIT 40
FREE INSPECTOR_oper
1 JT8_Assembly EXIT
FIRST 1
F119_Assembly OUTGOING
DEC inner_detail
DEC outer_detail 1 F119_Assembly Outside_processing FIRST 1 MOVE FOR 0
F119_Assembly Outside_processing WAIT T(2000,3600,6000)
1 F119_Assembly INSPECTION_AREA FIRST 1 MOVE FOR 0
F119_Assembly INSPECTION_AREA GET INSPECTOR_oper
WAIT 150
FREE INSPECTOR_oper
1 F119_Assembly LAYOUT_TABLE
FIRST 1 MOVE FOR 0
F119_Assembly LAYOUT_TABLE
GET DEBURR_oper
WAIT 40
FREE DEBURR_oper 1 F119_Assembly Outside_processing FIRST 1 MOVE FOR 0
F119_Assembly Outside_processing WAIT 1440
1 F119_Assembly LAYOUT_TABLE
FIRST 1
F119_Assembly LAYOUT_TABLE
GET DEBURR_oper
WAIT 90
FREE DEBURR_oper 1 F119_Assembly NC_VTL_BT538472 FIRST 1
F119_Assembly NC_VTL_BT538472 GET VTL_oper
WAIT 17.48
FREE VTL_oper
WAIT 47.4
1 F119_Assembly NC_VTL_BT538471 FIRST 1 MOVE ON net1
F119_Assembly NC_VTL_BT538471 GET VTL_oper
WAIT 180
FREE VTL_oper
WAIT 500
1 F119_Assembly HBM_5AX
FIRST 1 MOVE ON net2
F119_Assembly HBM_5AX
GET HMC_oper
WAIT 60
FREE HMC_oper
WAIT 120
GET HMC_oper
WAIT 60
FREE HMC_oper
WAIT 180
1 F119_Assembly DEBURR_BOOTH
FIRST 1 MOVE FOR 0
F119_Assembly DEBURR_BOOTH
GET DEBURR_oper
WAIT 5
FREE DEBURR_oper
WAIT 20
GET DEBURR_oper
WAIT 90
FREE DEBURR_oper 1 F119_Assembly Outside_processing FIRST 1 MOVE FOR 0
F119_Assembly Outside_processing WAIT 5000
1 F119_Assembly INSPECTION_AREA FIRST 1
MOVE ON net2
F119_Assembly INSPECTION_AREA GET INSPECTOR_oper
WAIT 35
FREE INSPECTOR_oper
1 F119_Assembly Outside_processing FIRST 1 MOVE ON net1
F119_Assembly Outside_processing WAIT 7200
1 F119_Assembly LAYOUT_TABLE
FIRST 1
MOVE ON net2
F119_Assembly LAYOUT_TABLE
GET DEBURR_oper
WAIT T(60,90,240)
FREE DEBURR_oper 1 F119_Assembly NC_VTL_BT538472 FIRST 1 MOVE ON
net2
F119_Assembly NC_VTL_BT538472 GET VTL_oper
WAIT N(90,12)
FREE VTL_oper
WAIT N(220,2)
1 F119_Assembly VMC_BT540991
FIRST 1 MOVE ON net2
F119_Assembly VMC_BT540991
GET VMC_oper
WAIT N(150,13.9)
FREE VMC_oper
WAIT N(40,.3)
1 F119_Assembly NC_VTL_BT538472 FIRST 1 MOVE ON net2
F119_Assembly NC_VTL_BT538471 ALT
MOVE FOR 0
F119_Assembly NC_VTL_BT538472 GET VTL_oper
WAIT N(60,5)
FREE VTL_oper
WAIT N(90,.4)
1 F119_Assembly HBM_5AX
FIRST 1 MOVE ON net2
F119_Assembly HBM_5AX
GET HMC_oper
WAIT N(480,21)
FREE HMC_oper
WAIT N(1600,4.9) 1 F119_Assembly VMC_BT540991
FIRST 1 MOVE ON net2
F119_Assembly VMC_BT540991
GET VMC_oper
WAIT 60
FREE VMC_oper
WAIT 180
1 F119_Assembly Outside_processing FIRST 1 MOVE FOR 0
F119_Assembly Outside_processing WAIT T(540,1440,2200)
1 F119_Assembly RADIAL_ARM_DRILL FIRST 1 MOVE FOR 0
F119_Assembly RADIAL_ARM_DRILL GET DEBURR_oper
WAIT 30
FREE DEBURR_oper 1 F119_Assembly ALKALI_WASH
FIRST 1 MOVE ON
net2
F119_Assembly ALKALI_WASH
GET DEBURR_oper
WAIT 5
FREE DEBURR_oper
WAIT 20
GET DEBURR_oper
WAIT 10
FREE DEBURR_oper 1 F119_Assembly DEBURR_BOOTH
FIRST 1 MOVE ON
net2
F119_Assembly DEBURR_BOOTH
GET DEBURR_oper
WAIT 300
FREE DEBURR_oper 1 F119_Assembly Outside_processing FIRST 1 MOVE FOR 0
F119_Assembly Outside_processing WAIT 5760
1 F119_Assembly INSPECTION_AREA FIRST 1
MOVE ON net2
F119_Assembly INSPECTION_AREA GET INSPECTOR_oper
WAIT T(20,30,60)
FREE INSPECTOR_oper
1 F119_Assembly ALKALI_WASH
FIRST 1 MOVE ON net2
F119_Assembly ALKALI_WASH
GET DEBURR_oper
WAIT 5
FREE DEBURR_oper
WAIT 20
GET DEBURR_oper
WAIT 10
FREE DEBURR_oper 1 F119_Assembly Outside_processing FIRST 1 MOVE FOR 0
F119_Assembly Outside_processing WAIT T(480,1440,2880)
1 F119_Assembly POWER_WASH
FIRST 1 MOVE ON net2
F119_Assembly POWER_WASH
GET DEBURR_oper
WAIT 10
FREE DEBURR_oper
WAIT 30
GET DEBURR_OPER
WAIT 30
FREE DEBURR_oper 1 F119_Assembly ASSEMBLY_BENCH FIRST 1 MOVE ON
net2
F119_Assembly ASSEMBLY_BENCH GET DEBURR_oper
WAIT T(45,90,120)
FREE DEBURR_oper 1 F119_Assembly INSPECTION_AREA FIRST 1 MOVE ON
net2
F119_Assembly INSPECTION_AREA GET INSPECTOR_oper
WAIT T(120,240,300)
FREE INSPECTOR_oper
1 F119_Assembly EXIT
FIRST 1 MOVE FOR 0
********************************************************************************
*
Shift Assignments
*
********************************************************************************
Locations Resources Shift Files
Priorities Disable Logic
---------- ---------- ------------------------------ ------------ ------- -----------------C:\My Documents\grad_school\sm 99,99,99,99 No
********************************************************************************
*
Variables (global)
*
********************************************************************************
ID
Type
Initial value Stats
------------ ------------ ------------- ----------inner_detail Integer
0
Time Series
outer_detail Integer
0
Time Series
********************************************************************************
*
External Files
*
********************************************************************************
ID
Type
File Name
Prompt
------------ ----------------- -------------------------------------------------- ---------INNER_ARRIVE Arrival
C:\My Documents\grad_school\sma\inner_arrivals.wk1
OUTER_ARRIVE Arrival
C:\My Documents\grad_school\sma\outer_arrivals.wk1
(null)
Shift
C:\My Documents\grad_school\sma\termproj.sft
JT8_ARRIVE Arrival
C:\My Documents\grad_school\sma\JT8_arrivals.wk1
Appendix III- Results Output (24/7 operation)
--------------------------------------------------General Report
-------------------------------------------------------------------------------Scenario
: Normal Run
Replication : 1 of 1
Simulation Time : 25072.98333 hr
-------------------------------------------------------------------------------LOCATIONS
Average
Location
Scheduled
Total
Minutes Average Maximum Current
Name
Hours Capacity Entries
Per Entry Contents Contents Contents % Util
------------------ ----------- -------- ------- ------------- ---------- -------- -------- -----NC VTL BT538472 25072.98333
1 324 227.096420 0.04891
1
0 4.89
NC VTL BT538471 25072.98333
1 242 361.371694 0.0581316
1
0 5.81
LAYOUT TABLE
25072.98333
1
192 104.374542 0.0133211
1
0 1.33
TOYODA 4AX
25072.98333
1
150 688.499240 0.0686495
1
0 6.86
HBM 5AX
25072.98333
1
192 1088.140557 0.138877
1
0 13.89
VMC BT540991
25072.98333
1
100 215.567110 0.0143293
1
0 1.43
RADIAL ARM DRILL 25072.98333
1
92
34.602185 0.00211609
1
0 0.21
DEBURR BOOTH
25072.98333
1
384 133.275820 0.0340193
1
0 3.40
INSPECTION AREA 25072.98333
1
434
73.503700 0.0212052
1
0 2.12
ALKALI WASH
25072.98333
1 250 32.051056 0.00532629
1
0 0.53
POWER WASH
25072.98333
1 176 66.422665 0.00777091
1
0 0.78
ASSEMBLY BENCH
25072.98333
1
92 101.442185 0.00620368
1
0 0.62
INCOMING
25072.98333 999999
142
23.085359 0.00217905
4
0 0.00
Outside processing 25072.98333 999999
684 3185.211406 1.44823
6
0 0.00
OUTGOING
25072.98333 999999
100 348605.015170 23.1727
50
50 0.00
LOCATION STATES BY PERCENTAGE (Multiple Capacity)
%
|
Location
Scheduled
% Partially % | %
Name
Hours Empty Occupied Full | Down
------------------ ----------- ----- --------- ---- | ---INCOMING
25072.98333 99.81
0.19 0.00 | 0.00
Outside processing 25072.98333 25.86
74.14 0.00 | 0.00
OUTGOING
25072.98333 0.54
99.46 0.00 | 0.00
LOCATION STATES BY PERCENTAGE (Single Capacity/Tanks)
Location
Scheduled
%
%
%
%
% %
Name
Hours Operation Setup Idle Waiting Blocked Down
---------------- ----------- --------- ----- ----- ------- ------- ---NC VTL BT538472 25072.98333
3.81 0.00 95.11 0.03 1.05 0.00
NC VTL BT538471 25072.98333
4.74 0.00 94.19 0.06 1.01 0.00
LAYOUT TABLE
25072.98333
1.12 0.00 98.67 0.03 0.18 0.00
TOYODA 4AX
25072.98333
6.17 0.00 93.14 0.17 0.52 0.00
HBM 5AX
25072.98333
13.89 0.00 86.11 0.00 0.00 0.00
VMC BT540991
25072.98333
1.43 0.00 98.57 0.00 0.00 0.00
RADIAL ARM DRILL 25072.98333
0.20 0.00 99.79 0.01 0.00 0.00
DEBURR BOOTH
25072.98333
3.40 0.00 96.60 0.00 0.00 0.00
INSPECTION AREA 25072.98333
2.12 0.00 97.88 0.00 0.00 0.00
ALKALI WASH
25072.98333
0.46 0.00 99.47 0.07 0.00 0.00
POWER WASH
25072.98333
0.69 0.00 99.22 0.09 0.00 0.00
ASSEMBLY BENCH 25072.98333
0.60 0.00 99.38 0.02 0.00 0.00
RESOURCES
Average Average Average
Number Minutes Minutes Minutes
Resource
Scheduled Of Times
Per Travel Travel % Blocked
Name
Units
Hours
Used
Usage To Use To Park In Travel % Util
-------------- ----- ----------- -------- ---------- -------- -------- --------- -----VTL oper
1 25072.98333
566 69.673714 0.022085 0.050000
0.00 2.62
HMC oper
1 25072.98333
484 155.753913 0.101707 0.326000
0.00 5.01
VMC oper
1 25072.98333
142 84.690761 0.041704 0.141000
0.00 0.80
DEBURR oper
1 25072.98333
1620 52.257656 0.108604 0.136944
0.00 5.64
INSPECTOR oper 1 25072.98333
434 73.503700 0.000000 0.000000
0.00 2.12
RESOURCE STATES BY PERCENTAGE
%
%
Resource
Scheduled
% Travel Travel
% %
Name
Hours In Use To Use To Park Idle Down
-------------- ----------- ------ ------ ------- ----- ---VTL oper
25072.98333 2.62 0.00 0.00 97.38 0.00
HMC oper
25072.98333 5.01 0.00 0.00 94.98 0.00
VMC oper
25072.98333 0.80 0.00 0.00 99.20 0.00
DEBURR oper 25072.98333 5.63 0.01 0.01 94.35 0.00
INSPECTOR oper 25072.98333 2.12 0.00 0.00 97.88 0.00
FAILED ARRIVALS
Entity
Location Total
Name
Name
Failed
------------ -------- -----F119 inner INCOMING
0
F119 outer INCOMING
0
JT8 Assembly INCOMING
0
ENTITY ACTIVITY
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 Blocked
------------- ----- --------- ------------ --------- ------------ ------------ ---------F119 inner
49
1 29349.266082 72.777000 19731.834714 9297.403918 247.250449
F119 Assembly 50
0 32104.554080 26.662000 38.944180 31743.334580 295.613320
F119 outer
1
49 17473.483000 19.443000 9289.986000 8164.054000 0.000000
JT8 Assembly 42
0 6745.820643 1.855000 32.620929 6619.224952 92.119762
ENTITY STATES BY PERCENTAGE
%
%
Entity
In Move Wait For
%
%
Name
Logic Res, etc. In Operation Blocked
------------- ------- --------- ------------ ------F119 inner
0.25
67.23
31.68 0.84
F119 Assembly 0.08
0.12
98.87 0.92
F119 outer
0.11
53.17
46.72 0.00
JT8 Assembly 0.03
0.48
98.12 1.37
VARIABLES
Average
Variable
Total
Minutes Minimum Maximum Current Average
Name
Changes Per Change Value Value Value
Value
------------ ------- ------------ ------- ------- ------- --------inner detail
100 14020.810510
-1
1
0 -0.278751
outer detail
100 13886.940870
0
3
0 0.0816856