April 24, 2002
Nathan Copenhaver
Sikorsky Aircraft
Simulation Modeling and Analysis
Final Project
Modified Case Study of Material Handling
At California Steel Industries, Inc.1
Introduction
California Steel Industries (CSI), founded in 1984, is located in Fontana,
California and covers about 400 acres of land. CSI produces and ships over one million
tons of steel each year. The facility is comprised of the land formally owned by the
Kaiser steel plant and contains 8.5 miles of roads and a 22-mile rail system. The future
outlook for the California Steel Industry is promising. Production is expected to increase
which has led management to the decision to upgrade the facility. In order to remain
competitive, the company has decided to look into the material handling system used in
the current facility layout and to find ways to improve upon existing conditions. In order
to do this, management has decided to create computer-simulated models to measure the
efficiency of their current system based on the work-in-progress inventory and the cycle
time of their products. Once these metrics are calculated CSI can begin to produce
alternative methods and measure their performance against existing conditions. The goal
of the company is to have a material handling system that minimizes both work-inprogress inventory and cycle time for their products. By achieving this goal, CSI will be
able to increase productivity at a faster rate and a cheaper cost allowing them to stay
competitive in the steel industry.
Problem statement and Project Plan
The problem statement that CSI wishes to address is: What will be the material
handling system that will maximize our productivity and minimize our time and money?
In addition: How can we use our existing facility infrastructure to best suit our needs and
what will we have to add/replace? In order to tackle these issues, the company decided to
use computer simulation models. In addition to their existing setup, two other models
will be proposed and analyzed. To be able to compare the three models, some consistent
1
Original case study written by Hary Herho, David Hong, Genghis Kuo, and Ka Hsing Loi at California
State Polytechnic University-Ponoma. This paper represents a modified version of their case study.
metrics will be proposed to measure the efficiency of the handling systems. The two
main metrics include:


Work-in-progress (WIP)
Cycle time of individual products
It was decided that work-in-progress (WIP) would be a measure of the money that the
company could save. The more items in inventory, the more money that is sitting around.
By decreasing the WIP while maintaining the output CSI could realize a cost savings.
The cycle time would show management how long it took to produce a product from its
initial inception into the system to the completed product. The smaller the cycle time, the
more product that, ideally, could be produced in the same amount of time as current
production.
Part of the problem statement involved using existing infrastructure such as the
railways in new setups. This is taken into consideration in the two alternative models.
New additions to the facility (such as more cranes) are also considered in the alternative
models. Other possibilities for the alternative models include moving machines to
different buildings, faster/more powerful material moving equipment, sharing of
resources, and changes in downtime/reliability of various equipment.
Models
Existing layout
The current layout of the California Steel Industry material handling system
follows from the case study provided by Hary Herho, David Hong, Genghis Kuo, and Ka
Hsing Loi in the text Simulation using ProModel.
The locations of the model consist of 3 main buildings: the Tin Mill (TM), Cold Sheet
Mill (CSM), and Galvanize Mill. Within each location, there are numerous machines.
For the layout of the original model (See Appendix A) the TM box annealing machine, 5stand, and #2 galvinizing machines are located in the Tin mill. The cleaning, upender,
and CSM annealing box are in the cold sheet mill and the #1 galvanizing machine is in
the galvanize mill. As one notices in the model layout, each location has its own storage
bay in the original configuration. In addition, there is a arrivals location where the work
comes into. The arrivals, and storage bays all are assumed to have an infinite capacity.
Otherwise, all of the machines have a capacity of 1 with the exception
of the
annealing
Figure
taken
from Simulation
boxes, which have a capacity of 12 (TM annealing) and 3 (CSM annealing).
using ProModel pg. 388
The materials at CSI consist of three different types of steel coils: Full-hard,
galvanized, and cold rolled. Each of these types of coils arrive at the Stand-5 and weigh
between 2 and 32 tons. This is modeled by assigning them weights (an attribute)
triangularly distributed with a mode of 16 tons. This value is valuable as it determines
Galvanized coils
shipped
the annealing time when the coils reach the annealing stations. The different coils are
broken down as follows:
Coil Type
Galvanized
Cold Rolled
Full-Hard
Percentage of Coils
60%
35%
5%
In addition to the 3 different types of coils, 60% of all the coils produced are heavy-gauge
and the other 40% are light-gauge coils. Once the coils have run their course through the
system, they are sent to the shipping location designated for the type of coil that they are.
The processing of the coils will not be discussed in detail here but follow the main path
shown in the above layout of the plant. A couple routings of note include the 2 annealing
boxes in different locations. The original model has one annealing machine in the tin
mill while the other annealing machine is in the cold sheet mill. Before each coil enters
the annealing boxes they must be upended (routed through the upender). For the cold
rolled coils, 70% of the coils go through the cleaning and the other 30 % are left alone
because of additional treating at the 5-stand. 66% of all cold rolled coils are annealed in
the tin mill while the remaining are only annealed in the cold sheet mill.
One of the most important parts of the model are the resources which are used to
transport materials. In the original configuration there are two internal diesel haulers.
One is located in the tin mill while the other is located in the cold sheet mill. These
haulers move the coils around from location to location within the buildings in which
they are based. There are also 2 large diesel haulers, which move material between the
buildings. The final resource that is used in this model is the 5-stand crane. The crane
moves material from the 5-stand to the 5-stand storage. The crane is modeled as never
having downtime. The 4 haulers, on the other hand, have their downtime modeled as if
one of them was down at all times. In order to achieve this, each hauler went down every
40 minutes for 10 minutes. The downtimes were staggered so that the first hauler went
down at time 0, the second one started at time 10 min, etc. This enabled the model to
have one down at all times. Even though there was a pattern, it achieved the goal of the
downtime simulation.
The process times taken at the various locations are as follows:
Location
5-stand
#1 Galvanizing Line
#2 Galvanizing Line
Cleaning
Annealing
Time (in ProModel logic)
N(8,2) min
N(30,8) min
N(25,4) min
N(15,3) min
5 min/ton
It should be noted that the annealing time given here differs from the one proposed in the
case study in Simulation using ProModel. The problem that was realized was that by
having an annealing time of 5 hr/ton, the batched anneal of 12 items at an average of
about 16 tons, took approximately 960 hours to anneal. This came out to about 40 days
for one batch to anneal. As a result, the WIP would just continue to increase no matter
what the arrival interval. In addition, if the arrival interval was made to be very long ( a
week or so), then the production of the plant became extremely small for 1 year. The
original statement was made that the company produces over 1 million tons a year. This
information was contradictory. It was decided upon to use 5 min/ton in order to get
logical numbers for the simulation.
Alternative Layout # 1
The alternative layouts in the case study are the portion of the study that begins to
deviate from the proposed study in Simulation using ProModel. The reason for this is the
restrictive nature of the ProModel Student package software. The proposed alternative
layout includes adding multiple cranes and utilizing the rail system of the existing
facility. This alternative could not be realized using the student version software because
of the restrictions on the amount of resources and locations. The locations are restricted
to 20 and the resources are restricted to 5. As a result, the case study had to change
slightly with the same problem statement still in mind and another restriction imposed.
As a result of these difficulties, the alternative #1 system (Appendix A) was designed as
follows:
5-stand
Upender
#2
Galvanizing
Galvanized coils
shipped
Cleaning
Full hard coils
shipped
#1 Galvanizing
CSM box
annealing
TM box
annealing
Cold rolled coils
shipped
The first main difference in the setup of the alternative material handling system is that of
the TM annealing box being moved to the cold sheet mill. This move eliminates the
transportation of coils back and forth between the tin mill and cold sheet mill. Other than
that, the locations stay virtually the same from the original layout. In order to try and
simulate the rail car system, conveyors were used from the #1 and #2 galvanizing stations
to the galvanizing shipping location. The location “arrivals” and “galvanizing #2
storage”are eliminated from this model. This was required to accommodate the rails that
were simulated in this model. The arriving coils now go to the 5-stand machine. Due to
the arrival frequency (which will be expanded on in the analysis portion) and the process
time of the 5-machine, there were no arrival failures and the “arrivals” location could be
eliminated.
The resources were changed in this model. The tin mill now consists of 2 cranes. The 5stand crane still exists but another crane has been installed which moves coils from the 5stand storage area to the galvanizing #2 machine, and the #2 rail which leaves the tin mill
and meets up with the galvanize #1 rail which takes the completed coils to the galvanized
coils shipping area. The addition of the crane eliminated the internal diesel hauler for the
tin mill. By moving the TM annealing box to the cold sheet mill, the amount of uses of
the external hauler is also reduced significantly.
In general, the methods of processing the coils remains the same as does the distribution
of types of coils.
Alternative Layout #2
The second layout really takes the alternative layout 1 and expands on it. The
layout itself is the same as alternative 1. The difference of this alternative is that the cold
sheet mill now has 1 crane that does all of the maneuvering for that building. Although
massive, the crane eliminates the need for the internal diesel hauler. In addition, a new
location named “CSM_ARRIVALS” is created so that the external diesel hauler no
longer has to go to each individual machine but rather delivers the coils between
buildings to one location. From the “CSM_ARRIVALS” area, the crane in the cold sheet
mill building can move the coils. The layout and code for alternative layout #2 can be
found in Appendix A.
Data Collection
In the problem statement, the key metrics that were to be traced in the models
were to be the work-in-progress (WIP) and the cycle time of the various products. In
order to achieve this, global variables were set up to track these metrics. The coils began
their cycle time the minute they arrived at the 5-stand and ended their journey when they
reached their respective shipping docks. This system of tracking remained consistent
throughout the 3 models.
Before the models could be run and compared, a number of key elements had to
be determined which were not suggested in the case study in Simulation using ProModel.
The distances between locations/machines were not given in the text. This was the first
thing that had to be determined and held constant throughout the simulations. This was
an important aspect of material handling comparisons since the distance that the material
must travel is a vital statistic. The distances were decided based on:
 The total acreage of the plant was 440 and the paths totaled 8.5 miles, which
gives one a general idea of how large the facility is.

Best guesses as to relative distances between facilities, machines, storage areas,
etc.
It was more important that the distances be relatively far (something further than 20 or
100 feet) and that they remain consistent throughout the models. The following table
shows the decided distances to some of the more important routes.
From
TM, CSM, or Galv #1
building
Any machine
Any machine in 1 building
Upender
5-Stand
5-Stand
To
External shipping dock
Distance
3000 ft
It’s own storage bay
Any machine in same
building
TM Annealing (in TM)
Upender
Cleaning
20 ft
500 ft
4000 ft
3500 ft
3000 ft
These distances remained constant throughout the models except in the case of the rails.
The rails were simulated as existing rails with corners and bends in them. In this case,
the distances from the galvanizing #1 building to the galvanizing coil shipping dock was
not 3000 ft but rather a little longer due to the jogs in the rail and its routing. These rail
systems were held consistent, however, between the 2 alternative models.
Another factor that had to be considered before data collection was the arrival time of the
coils into the system and their frequencies. This was another value that was not given in
the published case study but was left to the investigator. In order to look at this problem,
the original model was run for different arrival times and the WIP was observed. One
assumption made at this point was that the WIP of the system did not run to infinity for
the company. This was an assumption made on common sense. If the company had an
uncontrollable arrival frequency such that the system continuously built up inventory, the
company would not be in business. In order to get an idea for arrival times, the following
data was generated to experiment with the arrivals. The original model layout was
simulated for 1 week at 24 hours a day. The warmup period was 150 hours.
The graphs on the following page show the results of the runs:
From the graphs, one can see that the 40 min arrival time is the first time in which the
WIP begins to act somewhat constant. It is noticed that over this interval the WIP still
seems to be increasing. As a result, it was decided that the 45-minute arrival time would
be used. The larger arrival times did not seem to improve the steadiness of the WIP
unless time became much larger. If this happened, however, then the output of the
factory would not be very large and the model would not accurately represent a working
facility. The other graphs from this analysis can be found in Appendix B.
In summary, the main information that was needed was found through reverse
engineering the system to find values that were both reasonable and practical to the
simulation setup. For the comparison of alternatives, the same distances were used
except in noted cases and the arrival time was set to 45 minutes.
Model Validation
In order for the alternative models to be used, they had to be validated as being different
than the original model. Since each model contained almost the limit allotted for
locations and resources, the models could not be merged and ran together. As a result,
each model was run separately using the same values of numbers. In order to compare
the models with each other, the same stream was defined to run each simulation. The
stream used was the default stream (stream 1). The original model and the second
alternative were run by simulating 24 hours a day for 7 days (168 hours) and was
repeated 10 times. The following table shows the difference in total coils output for the
10 runs of the different models.
Original Model
Alternate Model
Total Coils Produced
182
178
182
167
185
182
185
194
189
201
Total Coils Produced
206
201
208
205
204
206
201
207
202
203
Difference
24
23
26
38
19
24
16
13
13
2
Computing the 95% confidence level resulted in:
D = 19.8
s(D) = 9.6586
N = 10
s(D) = 3.0543
h = (2.262)*(3.0543) = 6.9089
95% confidence interval = [12.8911,26.7089]
What this shows is that the model can assert with 95 % confidence that there is a
statistically significant difference between the two systems. Even though the arrivals,
streams, and runs were the same for both models, the alternative model resulted in more
produced coils. This was a direct result of the material handling system being able to get
more coils through the system quicker. The original model was also compared to the first
alternative model and the second alternative model was compared to the first alternative
model. All of the confidence levels were acceptable and can be seen in Appendix B.
As a quick check, the confidence intervals for WIP was also found using the 95% interval
calculation built into ProModel. The results were:
Results of 95% Confidence Interval for WIP
Model
Original
Alternative 1
Alternative 2
High confidence level
23.5362
22.9843
18.015
Low confidence level
28.372
20.3485
15.7022
This investigation proved that the 3 models were in fact different from each other and
could be compared as good alternative method models.
Data Collection and Analysis
As stated in the problem statement, the metrics that were to be measured with the
different models included WIP and the cycle time of the products. In order to do this, the
following data was collected:




WIP comparison for all 3 models doing runtime of 1 month (24 hrs * 30 days)
with a warmup time of 70 hours.
WIP comparison of average WIP over 1 year (24 hrs * 7 days for 52 replications)
Cycle time comparison for all 3 models doing runtime of 1 month (24 hrs * 30
days) with a warmup time of 70 hours
Average cycle time comparison over 1 year (24 hrs * 7 days for 52 replications)
The following tables summarize the data collected. The data, in its entirety, can be found
in Appendix B.
Summary Data for Simulation of 1 month (30 day) period
Original Model Alternative 1
Avg. WIP
Galvanized Cycle Time (min)
Cold Rolled Cycle Time (min)
Full Hard Cycle Time (min)
56.4
197.4
7021.1
52.5
Alternative 2
56.2
92.7
6673.6
39.8
21.7
89.2
2538.7
40.8
Summary Data for Simulation of 1 year (52 week) period
Original Model
Avg. WIP
24.99 +/- 2.94
Alternative 1
Alternative 2
21.56 +/- 2.80
17.34 +/- 2.08
Galvanized Cycle Time (min)
Cold Rolled Cycle Time (min)
Full Hard Cycle Time (min)
182.04 +/- 25.55
92.4 +/- 1.51
90.45 +/- 2.58
3129.08 +/- 306.45 2760.23 +/- 266.85 2209.52 +/- 198.21
54.65 +/- 4.54
40.40 +/- .641
40.51 +/- .62
From the data in the last 2 tables, it starts to become clear that the second alternative is a
superior configuration when compared to the original model. The first alternative sits in
between the 2 models but does not seem to be a vast improvement over the original
model. When looking at the year data summary, one can pull out some additional
comparisons. For example, if you consider each item in WIP to be a certain weight the
numbers become surprising. By taking the median weight of the coils (16 tons) and
rounding off the WIP inventory to whole values we find the following:
WIP Comparison
Original Model
Alternative 1
Alternative 2
25
22
17
400 tons
-
352 tons
48 tons
272 tons
128 tons
Avg. WIP amount
Total weight of coils in system on
average
Savings over original model
The model shows that the second alternative could save an average of 128 tons of
material that would not be in WIP at any one time. This would be a huge cost savings.
Of course the weight could be more or less depending on the distribution of the coils.
It is pretty clear that the WIP savings are beneficial by going to either alternative 1 or
alternative 2.
The cycle time comparisons are also interesting to look at. The alternative 2, as shown in
the validation portion and in Appendix B, produces more of each type of coil than do
both the original model and the alternative 1. In fact, if you look at reduction time
percentages:
Galvanized Cycle Time
reduction
Cold Rolled Cycle Time
reduction
Full Hard Cycle Time
reduction
Alternative 1
49%
Alternative 2
51%
22%
29%
26%
26%
What the previous table points out is how alternative 2 reduces the more complex
operations by a greater percentage. The full hard cycle time can not get much lower. In
fact, it virtually stayed the same between the two alternatives because it is not very
difficult of an operation. The cold rolled cycle coils, on the other hand, are more labor
intensive and the reduction in its cycle time is much more apparent in the second
alternative.
When looking at the different models, we also have to take into account what is being
used (i.e. existing fixtures, new cranes, old cranes, etc.) For alternative 1, the addition is
only 1 new crane. Alternative 1 utilizes the rail system which the original configuration
neglects. Alternative 1 does include moving the TM annealing station over to the cold
sheet metal building. Alternative 2 includes adding 2 cranes that were not in the original
configuration and builds on alternative 1’s idea of using the existing rail stations.
Alternative 2 also requires that the TM annealing be moved to the cold sheet metal
building. One conclusion that can be drawn is that the consolidation of the annealing
buildings will reduce the back-and-forth ferrying of the coils between buildings.
Despite restrictions with the software and some educated guesses, it is my belief that the
models are consistent and reflect a representation of the California Steel Industry’s
operations. Among the shortcomings of the model include the inaccurate representation
of the rail system as conveyors. This could be changed with a more inclusive version of
the software. As it stands, it is about as close as I can come to a rail system. From the
validation aspect, the alternative models are different and thus can be used as statistically
different models. Although no direct courses of action will be determined from the
models, I feel as if they are a good first step in answering management’s questions about
a new system. From my data, alternative 2 is the best option and offers more benefits
over the original system than alternative 1. Alternative 1 is not a good enough step up to
consider spending money on. It’s benefits would probably be outweighed by the cost to
create it when one could just do alternative 2 with almost the same amount of money.
Bibliograpy
1. Harrell, Charles, Royce Bowden, and Biman K. Ghosh 2000
Simulation using ProModel Boston: McGraw-Hill
2. Nicol, David M., Jerry Banks, John S. Carson II and Barry Nelson 2001.
Discrete-Event System Simulation New Jersey: Prentice Hall
Appendix A
Model Layouts & Computer Code
Layout of Original Configuration for California Steel Industry
Original Configuration Code
********************************************************************************
*
*
*
Formatted Listing of Model:
*
*
C:\MYDOCU~1\SIMULA~1\FINALP~1\CALIFO~1.MOD
*
*
*
********************************************************************************
Time Units:
Distance Units:
Minutes
Feet
********************************************************************************
*
Locations
*
********************************************************************************
Name
Cap Units Stats
Rules
Cost
-------------------------- --- ----- ----------- ---------- -----------#
#ANNEALING STAND LOCATED IN TM
TM_ANNEALING
12 1 Time Series Oldest, ,
#
#STAND LOCATED IN TM
STAND5
1 1 Time Series Oldest, ,
#
#LOCATED IN TM
GALVANIZING2
1 1 Time Series Oldest, ,
#
#STORAGE FOR ANNEALING IN TM
TM_ANNEALING_STORAGE
INF 1 Time Series Oldest, ,
#
#STORAGE FOR STAND 5 IN TM
STAND5_STORAGE
INF 1 Time Series Oldest, ,
#
#STORAGE FOR GALVANIZING IN TM
GALVANIZING2_STORAGE
INF 1 Time Series Oldest, ,
#
#ANNEALING IN CSM
CSM_ANNEALING
3 1 Time Series Oldest, ,
#
#UPENDER IN CSM
UPENDER
1 1 Time Series Oldest, ,
#
#CLEANING IN CSM
CLEANING
1 1 Time Series Oldest, ,
#
#STORAGE FOR ANNEALING IN CSM
CSM_ANNEALING_STORAGE
INF 1 Time Series Oldest, ,
#
#STORAGE FOR UPENDER IN CSM
UPENDER_STORAGE
INF 1 Time Series Oldest, ,
#
#STORAGE FOR CLEANING IN CSM
CLEANING_STORAGE
INF 1 Time Series Oldest, ,
#
#GALVANIZING IN OWN BUILDING
GALVANIZING1
1 1 Time Series Oldest, ,
#
#STORAGE FOR GALVINIZING IN OWN BUILDING
GALVANIZING1_STORAGE
1 1 Time Series Oldest, ,
#
#SPOT FOR ARRIVALS (USED TO TEST VARIOUS ARRIVAL TIMES)
ARRIVALS
INF 1 Time Series Oldest, ,
#
#END PRODUCT LOCATION
GALVANIZED_COILS_SHIPPING INF 1 Time Series Oldest, ,
#
#END PRODUCT LOCATION
FULL_HARD_COILS_SHIPPING INF 1 Time Series Oldest, ,
#
#END PRODUCT LOCATION
COLD_ROLLED_COILS_SHIPPING INF 1 Time Series Oldest, ,
********************************************************************************
*
Entities
*
********************************************************************************
Name
Speed (fpm) Stats
Cost
---------------- ------------ ----------- -----------COIL
150
Time Series
GALVANIZED_COIL 150
Time Series
COLD_ROLLED_COIL 150
Time Series
FULL_HARD_COIL 150
Time Series
BATCH
150
Time Series
********************************************************************************
*
Path Networks
*
********************************************************************************
Name
Type
T/S
From To
BI Dist/Time Speed Factor
------------ ----------- ---------------- --------- --------- ---- ---------- -----------STAND5_CRANE Crane
Speed & Distance Origin Rail1End Uni
Origin BridgeEnd Uni
BridgeEnd Rail2End Uni
TM_INTERNAL Passing Speed & Distance N1
N2
Bi 3000
1
N1
N3
Bi 500
1
N4
N5
Bi 3000
1
N3
N4
Bi 20
1
EXTERNAL Passing Speed & Distance N1
N2
Bi 3000
1
N3
N4
Bi 3000
1
N1
N5
Bi 3000
1
N1
N6
Bi 3500
1
N7
N8
Bi 3000
1
N9
N6
Bi 4000
1
N2
N3
Bi 20
1
N6
N7
Bi 20
1
CSM_INTERNAL Passing Speed & Distance N1
N2
Bi 500
1
N2
N4
N3
N2
N3
N5
N4
N6
Bi
Bi
Bi
Bi
500
3000
20
20
1
1
1
1
********************************************************************************
*
Interfaces
*
********************************************************************************
Net
Node
Location
Coords (R,B)
------------ ---------- -------------------------- -----------STAND5_CRANE N1
STAND5
0.00, 4.00
N2
STAND5_STORAGE
24.00, 4.00
TM_INTERNAL N1
STAND5_STORAGE
N2
FULL_HARD_COILS_SHIPPING
N3
GALVANIZING2
N4
GALVANIZING2_STORAGE
N5
GALVANIZED_COILS_SHIPPING
EXTERNAL N1
STAND5_STORAGE
N2
GALVANIZING1
N3
GALVANIZING1_STORAGE
N4
GALVANIZED_COILS_SHIPPING
N5
CLEANING
N6
UPENDER
N7
UPENDER_STORAGE
N8
TM_ANNEALING
N9
TM_ANNEALING_STORAGE
CSM_INTERNAL N1
CLEANING_STORAGE
N2
UPENDER
N3
CSM_ANNEALING
N4
CSM_ANNEALING_STORAGE
N5
COLD_ROLLED_COILS_SHIPPING
N6
UPENDER_STORAGE
********************************************************************************
*
Resources
*
********************************************************************************
Res Ent
Name
Units Stats Search Search Path
Motion
Cost
----------------------- ----- -------- ------- ------ ------------ ------------------- -----------LARGE_DIESEL_HAULER 2 By Unit Closest Oldest EXTERNAL Empty: 200 fpm
Home: N1 Full: 180 fpm
TM_SMALL_DIESEL_HAULER 1 By Unit Closest Oldest TM_INTERNAL Empty: 150 fpm
Home: N1 Full: 150 fpm
CRANE1
1
By Unit Closest Oldest STAND5_CRANE Empty: 25,25 fpm
Home: Origin Full: 25,25 fpm
Pickup: 10 Seconds
Deposit: 10 Seconds
CSM_SMALL_DIESEL_HAULER 1 By Unit Closest Oldest CSM_INTERNAL Empty: 150 fpm
Home: N1 Full: 150 fpm
********************************************************************************
*
Clock downtimes for Resources
*
********************************************************************************
Res
Frequency First Time Priority Scheduled Node List Disable Logic
----------------------- ---------- ---------- ---------- --------- -------- -------- ------- -----------LARGE_DIESEL_HAULER 40 min 0
No
No
wait 10 min
TM_SMALL_DIESEL_HAULER 40
10
No
No
wait 10 min
CSM_SMALL_DIESEL_HAULER 40
20
No
No
wait 10 min
********************************************************************************
*
Processing
*
********************************************************************************
Process
Routing
Entity
Location
Operation
Blk Output
Destination
Rule
Move Logic
---------------- -------------------------- ------------------ ---- ---------------- -------------------------- ----------------- -----------COIL
ARRIVALS
WEIGHT = T(5,16,32)
ANNEALED = 0
1 COIL
STAND5
FIRST 1
COIL
STAND5
TIME_IN = CLOCK()
WIP = WIP + 1
WAIT N(8,2) MIN
1 GALVANIZED_COIL STAND5_STORAGE
0.600000 1
MOVE WITH CRANE1 THEN FREE
COLD_ROLLED_COIL STAND5_STORAGE
0.350000
MOVE WITH CRANE1 THEN FREE
FULL_HARD_COIL STAND5_STORAGE
0.050000
MOVE WITH CRANE1 THEN FREE
FULL_HARD_COIL STAND5_STORAGE
1 FULL_HARD_COIL
FULL_HARD_COILS_SHIPPING FIRST 1
MOVE WITH TM_SMALL_DIESEL_HAULER
THEN FREE
FULL_HARD_COIL FULL_HARD_COILS_SHIPPING TOTAL_FHC = TOTAL_FHC + 1
WIP = WIP - 1
FH_TOTAL_WEIGHT = FH_TOTAL_WEIGHT + WEIGHT
LOG "FULL HARD COIL CYCLE TIME =", TIME_IN
1 FULL_HARD_COIL EXIT
FIRST 1
GALVANIZED_COIL STAND5_STORAGE
1 GALVANIZED_COIL
GALVANIZING2
0.400000 1
MOVE WITH TM_SMALL_DIESEL_HAULER THEN
FREE
GALVANIZED_COIL GALVANIZING1
0.600000
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
GALVANIZED_COIL GALVANIZING2
WAIT N(25,4) MIN 1 GALVANIZED_COIL
GALVANIZING2_STORAGE
FIRST 1
MOVE FOR 1 MIN
GALVANIZED_COIL GALVANIZING2_STORAGE
1 GALVANIZED_COIL
GALVANIZED_COILS_SHIPPING FIRST 1
MOVE WITH TM_SMALL_DIESEL_HAULER
THEN FREE
GALVANIZED_COIL GALVANIZING1
WAIT N(30,8)
1 GALVANIZED_COIL
GALVANIZING1_STORAGE
FIRST 1
MOVE FOR 1 MIN
GALVANIZED_COIL GALVANIZING1_STORAGE
1 GALVANIZED_COIL
GALVANIZED_COILS_SHIPPING FIRST 1
MOVE WITH LARGE_DIESEL_HAULER THEN
FREE
GALVANIZED_COIL GALVANIZED_COILS_SHIPPING TOTAL_GC = TOTAL_GC + 1
WIP = WIP - 1
GC_TOTAL_WEIGHT = GC_TOTAL_WEIGHT + WEIGHT
LOG "GALVANIZED COIL CYCLE TIME =", TIME_IN
1 GALVANIZED_COIL EXIT
FIRST 1
COLD_ROLLED_COIL STAND5_STORAGE
1 COLD_ROLLED_COIL
CLEANING
0.700000 1
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL UPENDER
0.300000
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL CLEANING
WAIT N(15,3) MIN 1 COLD_ROLLED_COIL
CLEANING_STORAGE
FIRST 1
MOVE FOR 1 MIN
COLD_ROLLED_COIL CLEANING_STORAGE
1 COLD_ROLLED_COIL
UPENDER
EMPTY 1
MOVE WITH CSM_SMALL_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL UPENDER
WAIT 3 MIN
1 COLD_ROLLED_COIL
UPENDER_STORAGE
IF ANNEALED = 0, 1 MOVE FOR 1 MIN
COLD_ROLLED_COIL CSM_ANNEALING
IF
ANNEALED = 1 MOVE WITH CSM_SMALL_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL UPENDER_STORAGE
1 COLD_ROLLED_COIL
TM_ANNEALING
0.660000 1
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL CSM_ANNEALING
0.340000
MOVE WITH CSM_SMALL_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL TM_ANNEALING
TM_ANNEAL_WEIGHT =
TM_ANNEAL_WEIGHT + WEIGHT
GROUP 12 AS BATCH
BATCH
TM_ANNEALING
UNGROUP
WAIT TM_ANNEAL_WEIGHT*5 MIN
COLD_ROLLED_COIL TM_ANNEALING
ANNEALED = 1
TM_ANNEAL_WEIGHT = 0
1 COLD_ROLLED_COIL TM_ANNEALING_STORAGE
FIRST 1
MOVE FOR 1 MIN
COLD_ROLLED_COIL TM_ANNEALING_STORAGE
1 COLD_ROLLED_COIL
UPENDER
FIRST 1
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL CSM_ANNEALING
CSM_ANNEAL_WEIGHT =
CSM_ANNEAL_WEIGHT + WEIGHT
GROUP 3 AS BATCH
BATCH
CSM_ANNEALING
UNGROUP
WAIT CSM_ANNEAL_WEIGHT*5 MIN
COLD_ROLLED_COIL CSM_ANNEALING
ANNEALED = 1
CSM_ANNEAL_WEIGHT = 0
1 COLD_ROLLED_COIL CSM_ANNEALING_STORAGE
FIRST 1
MOVE FOR 1 MIN
COLD_ROLLED_COIL CSM_ANNEALING_STORAGE
1 COLD_ROLLED_COIL
COLD_ROLLED_COILS_SHIPPING FIRST 1
MOVE WITH CSM_SMALL_DIESEL_HAULER
THEN FREE
COLD_ROLLED_COIL COLD_ROLLED_COILS_SHIPPING TOTAL_CRC = TOTAL_CRC + 1
CR_TOTAL_WEIGHT = CR_TOTAL_WEIGHT + WEIGHT
WIP = WIP - 1
LOG "COLD ROLLED COIL CYCLE TIME =", TIME_IN
1 COLD_ROLLED_COIL EXIT
FIRST 1
********************************************************************************
*
Arrivals
*
********************************************************************************
Entity Location Qty each First Time Occurrences Frequency Logic
-------- -------- ---------- ---------- ----------- ---------- -----------COIL ARRIVALS 1
0
INF
45 MIN
********************************************************************************
*
Attributes
*
********************************************************************************
ID
Type
Classification
---------- ------------ -------------WEIGHT Integer
Entity
TIME_IN Integer
Entity
ANNEALED Integer
Entity
********************************************************************************
*
Variables (global)
*
********************************************************************************
ID
Type
Initial value Stats
----------------- ------------ ------------- ----------#
#This variable totals up the number of Full Hard Coils that reach shipping
TOTAL_FHC
Integer
0
Time Series
#
#This variable tracks the current works in process
WIP
Integer
0
Time Series
#
#This variable totals up the galvanized coils that arrive at shipping
TOTAL_GC
Integer
0
Time Series
#
#This variable sums up the weight of the coils that approach the tin mill
annealing machine so that the duration of the annealing process
#can be calculated. The tin annealing machine takes 12 coils at once and
operates at 5 hours per ton.
TM_ANNEAL_WEIGHT Integer
0
Time Series
#
#This variable does the same as the TM_ANNEAL_WEIGHT except for the cold
sheet mill. The cold sheet mill takes 3 coils at a time and also
#operates at 5 tons per hour.
CSM_ANNEAL_WEIGHT Integer
0
Time Series
#
#This variable totals up the number of cold rolled coils that are sent to
shipping.
TOTAL_CRC
Integer
0
Time Series
FH_TOTAL_WEIGHT Integer
GC_TOTAL_WEIGHT Integer
CR_TOTAL_WEIGHT Integer
0
0
0
Time Series
Time Series
Time Series
Layout of Alternative #1 Configuration for California Steel Industry
First Alternative Configuration Code
********************************************************************************
*
*
*
Formatted Listing of Model:
*
*
C:\MYDOCU~1\SIMULA~1\FINALP~1\CALIFO~2.MOD
*
*
*
********************************************************************************
Time Units:
Distance Units:
Minutes
Feet
********************************************************************************
*
Locations
*
********************************************************************************
Name
Cap Units Stats
Rules
Cost
-------------------------- -------- ----- ----------- -------------- -----------TM_ANNEALING
12
1 Time Series Oldest, ,
STAND5
1
1 Time Series Oldest, ,
GALVANIZING2
1
1 Time Series Oldest, ,
TM_ANNEALING_STORAGE
INF
1 Time Series Oldest, ,
STAND5_STORAGE
INF
1 Time Series Oldest, ,
CSM_ANNEALING
3
1 Time Series Oldest, ,
UPENDER
1
1 Time Series Oldest, ,
CLEANING
1
1 Time Series Oldest, ,
CSM_ANNEALING_STORAGE
INF
1 Time Series Oldest, ,
UPENDER_STORAGE
INF
1 Time Series Oldest, ,
CLEANING_STORAGE
INF
1 Time Series Oldest, ,
GALVANIZING1
1
1 Time Series Oldest, ,
GALVANIZED_COILS_SHIPPING INF
1 Time Series Oldest, ,
FULL_HARD_COILS_SHIPPING INF
1 Time Series Oldest, ,
COLD_ROLLED_COILS_SHIPPING INF
1 Time Series Oldest, ,
RAIL1
INFINITE 1 Time Series Oldest, FIFO,
RAIL2
INFINITE 1 Time Series Oldest, FIFO,
RAIL3
INFINITE 1 Time Series Oldest, FIFO,
RAIL4
INFINITE 1 Time Series Oldest, FIFO,
********************************************************************************
*
Entities
*
********************************************************************************
Name
Speed (fpm) Stats
Cost
---------------- ------------ ----------- -----------COIL
150
Time Series
GALVANIZED_COIL 150
Time Series
COLD_ROLLED_COIL 150
Time Series
FULL_HARD_COIL 150
Time Series
BATCH
150
Time Series
********************************************************************************
*
Path Networks
*
********************************************************************************
Name
Type
T/S
From To
BI Dist/Time Speed Factor
----------------- ----------- ---------------- --------- --------- ---- ---------- -----------STAND5_CRANE
Crane
Speed & Distance Origin Rail1End Uni
Origin BridgeEnd Uni
BridgeEnd Rail2End Uni
EXTERNAL
Passing Speed & Distance N1
N5
Bi 3000
1
N1
N6
Bi 3500
1
CSM_INTERNAL
Passing Speed & Distance N1
N2
Bi 500
1
N2
N3
Bi 500
1
N4
N5
Bi 3000
1
N3
N4
Bi 20
1
N2
N6
Bi 20
1
N1
N7
Bi 100
1
N1
N8
Bi 500
1
N9
N8
Bi 20
1
GALVANIZING_CRANE Crane
Speed & Distance Origin Rail1End Uni
Origin BridgeEnd Uni
BridgeEnd Rail2End Uni
********************************************************************************
*
Interfaces
*
********************************************************************************
Net
Node
Location
Coords (R,B)
----------------- ---------- -------------------------- -----------STAND5_CRANE
N1
STAND5
0.00, 4.00
N2
STAND5_STORAGE
24.00, 4.00
EXTERNAL
N1
STAND5_STORAGE
N5
CLEANING
N6
UPENDER
CSM_INTERNAL
N1
CLEANING_STORAGE
N2
UPENDER
N3
CSM_ANNEALING
N4
CSM_ANNEALING_STORAGE
N5
COLD_ROLLED_COILS_SHIPPING
N6
UPENDER_STORAGE
N8
TM_ANNEALING
N9
TM_ANNEALING_STORAGE
GALVANIZING_CRANE N1
GALVANIZING2
N3
STAND5_STORAGE
25.73, 4.40
N4
RAIL1
16.18, 1.62
9.05, 3.56
********************************************************************************
*
Resources
*
********************************************************************************
Res Ent
Name
Units Stats Search Search Path
Motion
Cost
----------------------- ----- -------- ------- ------ ----------------- ------------------- -----------LARGE_DIESEL_HAULER 2 None Closest Oldest EXTERNAL
Empty: 200 fpm
Home: N1
Full: 180 fpm
CRANE1
1
By Unit Closest Oldest STAND5_CRANE
Home: Origin
Full: 25,25 fpm
Pickup: 10 Seconds
Deposit: 10 Seconds
Empty: 25,25 fpm
CSM_SMALL_DIESEL_HAULER 1 By Unit Closest Oldest CSM_INTERNAL
Home: N1
Full: 150 fpm
CRANE2
1
Empty: 150 fpm
By Unit Closest Oldest GALVANIZING_CRANE Empty: 150,150 fpm
Home: Origin
Full: 150,150 fpm
********************************************************************************
*
Clock downtimes for Resources
*
********************************************************************************
Res
Frequency First Time Priority Scheduled Node List Disable Logic
----------------------- ---------- ---------- ---------- --------- -------- -------- ------- -----------LARGE_DIESEL_HAULER 40 min 0
No
No
wait 10 min
CSM_SMALL_DIESEL_HAULER 40
20
No
No
wait 10 min
********************************************************************************
*
Processing
*
********************************************************************************
Process
Routing
Entity
Location
Operation
Blk Output
Destination
Rule
Move Logic
---------------- -------------------------- ------------------ ---- ---------------- -------------------------- ----------------- -----------COIL
STAND5
WEIGHT = T(5,16,32)
ANNEALED = 0
TIME_IN = CLOCK()
WIP = WIP + 1
WAIT N(8,2) MIN
1 GALVANIZED_COIL STAND5_STORAGE
0.600000 1
MOVE WITH CRANE1 THEN FREE
COLD_ROLLED_COIL STAND5_STORAGE
0.350000
MOVE WITH CRANE1 THEN FREE
FULL_HARD_COIL STAND5_STORAGE
0.050000
MOVE WITH CRANE1 THEN FREE
FULL_HARD_COIL STAND5_STORAGE
1 FULL_HARD_COIL RAIL1
FIRST 1
MOVE WITH CRANE2 THEN FREE
FULL_HARD_COIL RAIL1
1 FULL_HARD_COIL
FULL_HARD_COILS_SHIPPING FIRST 1
FULL_HARD_COIL FULL_HARD_COILS_SHIPPING TOTAL_FHC = TOTAL_FHC + 1
WIP = WIP - 1
FH_TOTAL_WEIGHT = FH_TOTAL_WEIGHT + WEIGHT
LOG "FULL HARD COIL CYCLE TIME =", TIME_IN
1 FULL_HARD_COIL EXIT
FIRST 1
GALVANIZED_COIL STAND5_STORAGE
1 GALVANIZED_COIL
GALVANIZING2
0.400000 1
MOVE WITH CRANE2 THEN FREE
GALVANIZED_COIL RAIL4
0.600000
MOVE FOR 1 MIN
GALVANIZED_COIL RAIL4
1 GALVANIZED_COIL GALVANIZING1
FIRST 1
GALVANIZED_COIL GALVANIZING2
WAIT N(25,4) MIN 1 GALVANIZED_COIL
RAIL1
FIRST 1
MOVE WITH CRANE2 THEN FREE
GALVANIZED_COIL RAIL1
1 GALVANIZED_COIL RAIL3
FIRST 1
GALVANIZED_COIL RAIL3
1 GALVANIZED_COIL
GALVANIZED_COILS_SHIPPING FIRST 1
GALVANIZED_COIL GALVANIZED_COILS_SHIPPING TOTAL_GC = TOTAL_GC + 1
WIP = WIP - 1
GC_TOTAL_WEIGHT = GC_TOTAL_WEIGHT + WEIGHT
LOG "GALVANIZED COIL CYCLE TIME =", TIME_IN
1 GALVANIZED_COIL EXIT
FIRST 1
GALVANIZED_COIL GALVANIZING1
WAIT N(30,8)
1 GALVANIZED_COIL
RAIL2
FIRST 1
MOVE FOR 1 MIN
GALVANIZED_COIL RAIL2
1 GALVANIZED_COIL RAIL3
FIRST 1
COLD_ROLLED_COIL STAND5_STORAGE
1 COLD_ROLLED_COIL
CLEANING
0.700000 1
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL UPENDER
0.300000
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL CLEANING
WAIT N(15,3) MIN 1 COLD_ROLLED_COIL
CLEANING_STORAGE
FIRST 1
MOVE FOR 1 MIN
COLD_ROLLED_COIL CLEANING_STORAGE
1 COLD_ROLLED_COIL
UPENDER
EMPTY 1
MOVE WITH CSM_SMALL_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL UPENDER
WAIT 3 MIN
1 COLD_ROLLED_COIL
UPENDER_STORAGE
IF ANNEALED = 0, 1 MOVE FOR 1 MIN
COLD_ROLLED_COIL CSM_ANNEALING
IF
ANNEALED = 1 MOVE WITH CSM_SMALL_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL UPENDER_STORAGE
1 COLD_ROLLED_COIL
TM_ANNEALING
0.660000 1
MOVE WITH CSM_SMALL_DIESEL_HAULER THEN
FREE
COLD_ROLLED_COIL CSM_ANNEALING
0.340000
MOVE WITH CSM_SMALL_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL TM_ANNEALING
TM_ANNEAL_WEIGHT =
TM_ANNEAL_WEIGHT + WEIGHT
GROUP 12 AS BATCH
BATCH
TM_ANNEALING
UNGROUP
WAIT TM_ANNEAL_WEIGHT*5 MIN
COLD_ROLLED_COIL TM_ANNEALING
ANNEALED = 1
TM_ANNEAL_WEIGHT = 0
1 COLD_ROLLED_COIL TM_ANNEALING_STORAGE
FIRST 1
MOVE FOR 1 MIN
COLD_ROLLED_COIL TM_ANNEALING_STORAGE
1 COLD_ROLLED_COIL
UPENDER
FIRST 1
MOVE WITH CSM_SMALL_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL CSM_ANNEALING
CSM_ANNEAL_WEIGHT =
CSM_ANNEAL_WEIGHT + WEIGHT
GROUP 3 AS BATCH
BATCH
CSM_ANNEALING
UNGROUP
WAIT CSM_ANNEAL_WEIGHT*5 MIN
COLD_ROLLED_COIL CSM_ANNEALING
ANNEALED = 1
CSM_ANNEAL_WEIGHT = 0
1 COLD_ROLLED_COIL CSM_ANNEALING_STORAGE
FIRST 1
MOVE FOR 1 MIN
COLD_ROLLED_COIL CSM_ANNEALING_STORAGE
1 COLD_ROLLED_COIL
COLD_ROLLED_COILS_SHIPPING FIRST 1
MOVE WITH CSM_SMALL_DIESEL_HAULER
THEN FREE
COLD_ROLLED_COIL COLD_ROLLED_COILS_SHIPPING TOTAL_CRC = TOTAL_CRC + 1
CR_TOTAL_WEIGHT = CR_TOTAL_WEIGHT + WEIGHT
WIP = WIP - 1
LOG "COLD ROLLED COIL CYCLE TIME =", TIME_IN
1 COLD_ROLLED_COIL EXIT
FIRST 1
********************************************************************************
*
Arrivals
*
********************************************************************************
Entity Location Qty each First Time Occurrences Frequency Logic
-------- -------- ---------- ---------- ----------- ---------- -----------COIL STAND5 1
0
INF
40 MIN
********************************************************************************
*
Attributes
*
********************************************************************************
ID
Type
Classification
---------- ------------ -------------WEIGHT Integer
Entity
TIME_IN Integer
Entity
ANNEALED Integer
Entity
********************************************************************************
*
Variables (global)
*
********************************************************************************
ID
Type
Initial value Stats
----------------- ------------ ------------- ----------#
#This variable totals up the number of Full Hard Coils that reach shipping
TOTAL_FHC
Integer
0
Time Series
#
#This variable tracks the current works in process
WIP
Integer
0
Time Series
#
#This variable totals up the galvanized coils that arrive at shipping
TOTAL_GC
Integer
0
Time Series
#
#This variable sums up the weight of the coils that approach the tin mill
annealing machine so that the duration of the annealing process
#can be calculated. The tin annealing machine takes 12 coils at once and
operates at 5 hours per ton.
TM_ANNEAL_WEIGHT Integer
0
Time Series
#
#This variable does the same as the TM_ANNEAL_WEIGHT except for the cold
sheet mill. The cold sheet mill takes 3 coils at a time and also
#operates at 5 tons per hour.
CSM_ANNEAL_WEIGHT Integer
0
Time Series
#
#This variable totals up the number of cold rolled coils that are sent to
shipping.
TOTAL_CRC
Integer
0
Time Series
FH_TOTAL_WEIGHT Integer
0
Time Series
GC_TOTAL_WEIGHT Integer
0
Time Series
CR_TOTAL_WEIGHT Integer
0
Time Series
Layout of Alternative #2 Configuration for California Steel Industry
Second Alternative Configuration Code
********************************************************************************
*
*
*
Formatted Listing of Model:
*
*
C:\MYDOCU~1\SIMULA~1\FINALP~1\CALIFO~5.MOD
*
*
*
********************************************************************************
Time Units:
Distance Units:
Minutes
Feet
********************************************************************************
*
Locations
*
********************************************************************************
Name
Cap Units Stats
Rules
Cost
-------------------------- -------- ----- ----------- -------------- -----------TM_ANNEALING
12
1 Time Series Oldest, ,
STAND5
1
1 Time Series Oldest, ,
GALVANIZING2
1
1 Time Series Oldest, ,
TM_ANNEALING_STORAGE
INF
1 Time Series Oldest, ,
STAND5_STORAGE
INF
1 Time Series Oldest, ,
CSM_ANNEALING
3
1 Time Series Oldest, ,
UPENDER
1
1 Time Series Oldest, ,
CLEANING
1
1 Time Series Oldest, ,
CSM_ANNEALING_STORAGE
INF
1 Time Series Oldest, ,
UPENDER_STORAGE
INF
1 Time Series Oldest, ,
CLEANING_STORAGE
INF
1 Time Series Oldest, ,
GALVANIZING1
1
1 Time Series Oldest, ,
GALVANIZED_COILS_SHIPPING INF
1 Time Series Oldest, ,
FULL_HARD_COILS_SHIPPING INF
1 Time Series Oldest, ,
COLD_ROLLED_COILS_SHIPPING INF
1 Time Series Oldest, ,
RAIL1
INFINITE 1 Time Series Oldest, FIFO,
RAIL2
INFINITE 1 Time Series Oldest, FIFO,
RAIL3
INFINITE 1 Time Series Oldest, FIFO,
CSM_ARRIVALS
1
1 Time Series Oldest, ,
********************************************************************************
*
Entities
*
********************************************************************************
Name
Speed (fpm) Stats
Cost
---------------- ------------ ----------- -----------COIL
150
Time Series
GALVANIZED_COIL 150
Time Series
COLD_ROLLED_COIL 150
Time Series
FULL_HARD_COIL 150
Time Series
BATCH
150
Time Series
********************************************************************************
*
Path Networks
*
********************************************************************************
Name
Type
T/S
From To
BI Dist/Time Speed Factor
------------ ----------- ---------------- --------- --------- ---- ---------- -----------STAND5_CRANE Crane
Speed & Distance Origin Rail1End Uni
Origin BridgeEnd Uni
BridgeEnd Rail2End Uni
EXTERNAL Passing Speed & Distance N1
N2
Bi 3000
1
N1
N3
Bi 3500
1
CSM_CRANE Crane
Speed & Distance Origin Rail1End Uni
Origin BridgeEnd Uni
BridgeEnd Rail2End Uni
EXTERNAL_2 Passing Speed & Distance N1
N2
Bi 3500
1
********************************************************************************
*
Interfaces
*
********************************************************************************
Net
Node
Location
Coords (R,B)
------------ ---------- -------------------------- -----------STAND5_CRANE N1
STAND5
0.00, 4.00
N2
STAND5_STORAGE
24.00, 4.00
N3
GALVANIZING2
11.90, 1.15
N4
RAIL1
20.89, 2.28
EXTERNAL N1
STAND5_STORAGE
N2
CSM_ARRIVALS
N3
GALVANIZING1
CSM_CRANE
N2
N3
N4
N5
N6
N7
N8
N9
EXTERNAL_2
N2
N1
UPENDER_STORAGE
3.40, 1.85
UPENDER
4.59, 3.23
CLEANING_STORAGE
22.37, 1.77
CLEANING
19.03, 3.15
CSM_ANNEALING_STORAGE
8.63, 4.83
CSM_ANNEALING
9.87, 5.78
TM_ANNEALING
20.50, 5.81
TM_ANNEALING_STORAGE
26.07, 6.47
CSM_ARRIVALS
13.19, 0.97
N1
CSM_ANNEALING_STORAGE
COLD_ROLLED_COILS_SHIPPING
********************************************************************************
*
Resources
*
********************************************************************************
Res Ent
Name
Units Stats Search Search Path
Motion
Cost
------------------- ----- -------- ------- ------ ------------ ------------------- -----------#
#MOVES ITEMS BETWEEN TM AND CSM
LARGE_DIESEL_HAULER 1 By Unit Closest Oldest EXTERNAL
Home: N1 Full: 180 fpm
(Return)
#
#CRANE IN TM
CRANE1
1
#
#CRANE IN CSM
CRANE2
1
Empty: 200 fpm
By Unit Closest Oldest STAND5_CRANE Empty: 25,25 fpm
Home: Origin Full: 25,25 fpm
Pickup: 10 Seconds
Deposit: 10 Seconds
By Unit Closest Oldest CSM_CRANE Empty: 150,150 fpm
Home: Origin Full: 150,150 fpm
EXTERNAL_TRANSPORT 1 By Unit Closest Oldest EXTERNAL_2 Empty: 150 fpm
Home: N1 Full: 150 fpm
********************************************************************************
*
Clock downtimes for Resources
*
********************************************************************************
Res
Frequency First Time Priority Scheduled Node List Disable Logic
------------------- ---------- ---------- ---------- --------- -------- -------- ------- -----------LARGE_DIESEL_HAULER 40 min 0
No
No
wait 10 min
********************************************************************************
*
Processing
*
********************************************************************************
Process
Routing
Entity
Location
Operation
Blk Output
Destination
Rule
Move Logic
---------------- -------------------------- ------------------ ---- ---------------- -------------------------- ----------------- -----------COIL
STAND5
WEIGHT = T(5,16,32)
ANNEALED = 0
TIME_IN = CLOCK()
WIP = WIP + 1
WAIT N(8,2) MIN
1 GALVANIZED_COIL STAND5_STORAGE
0.600000 1
MOVE WITH CRANE1 THEN FREE
COLD_ROLLED_COIL STAND5_STORAGE
0.350000
MOVE WITH CRANE1 THEN FREE
FULL_HARD_COIL STAND5_STORAGE
0.050000
MOVE WITH CRANE1 THEN FREE
FULL_HARD_COIL STAND5_STORAGE
1 FULL_HARD_COIL RAIL1
FIRST 1
MOVE WITH CRANE1 THEN FREE
FULL_HARD_COIL RAIL1
1 FULL_HARD_COIL
FULL_HARD_COILS_SHIPPING FIRST 1
FULL_HARD_COIL FULL_HARD_COILS_SHIPPING TOTAL_FHC = TOTAL_FHC + 1
WIP = WIP - 1
FH_TOTAL_WEIGHT = FH_TOTAL_WEIGHT + WEIGHT
LOG "FULL HARD COIL CYCLE TIME =", TIME_IN
1 FULL_HARD_COIL EXIT
FIRST 1
GALVANIZED_COIL STAND5_STORAGE
1 GALVANIZED_COIL
GALVANIZING2
0.400000 1
MOVE WITH CRANE1 THEN FREE
GALVANIZED_COIL GALVANIZING1
0.600000
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
GALVANIZED_COIL GALVANIZING2
WAIT N(25,4) MIN 1 GALVANIZED_COIL
RAIL1
FIRST 1
MOVE WITH CRANE1 THEN FREE
GALVANIZED_COIL RAIL1
1 GALVANIZED_COIL RAIL3
FIRST 1
GALVANIZED_COIL RAIL3
1 GALVANIZED_COIL
GALVANIZED_COILS_SHIPPING FIRST 1
GALVANIZED_COIL GALVANIZED_COILS_SHIPPING TOTAL_GC = TOTAL_GC + 1
WIP = WIP - 1
GC_TOTAL_WEIGHT = GC_TOTAL_WEIGHT + WEIGHT
LOG "GALVANIZED COIL CYCLE TIME =", TIME_IN
1 GALVANIZED_COIL EXIT
FIRST 1
GALVANIZED_COIL GALVANIZING1
WAIT N(30,8)
1 GALVANIZED_COIL
RAIL2
FIRST 1
MOVE FOR 1 MIN
GALVANIZED_COIL RAIL2
1 GALVANIZED_COIL RAIL3
FIRST 1
COLD_ROLLED_COIL STAND5_STORAGE
1 COLD_ROLLED_COIL
CSM_ARRIVALS
0.700000 1
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL CSM_ARRIVALS
0.300000
MOVE WITH LARGE_DIESEL_HAULER THEN FREE
COLD_ROLLED_COIL CSM_ARRIVALS
1 COLD_ROLLED_COIL
CLEANING
FIRST 1
MOVE WITH CRANE2 THEN FREE
COLD_ROLLED_COIL CLEANING
WAIT N(15,3) MIN 1 COLD_ROLLED_COIL
CLEANING_STORAGE
FIRST 1
MOVE FOR 1 MIN
COLD_ROLLED_COIL CLEANING_STORAGE
1 COLD_ROLLED_COIL
UPENDER
EMPTY 1
MOVE WITH CRANE2 THEN FREE
COLD_ROLLED_COIL UPENDER
WAIT 3 MIN
1 COLD_ROLLED_COIL
UPENDER_STORAGE
IF ANNEALED = 0, 1 MOVE FOR 1 MIN
COLD_ROLLED_COIL CSM_ANNEALING
IF
ANNEALED = 1 MOVE WITH CRANE2 THEN FREE
COLD_ROLLED_COIL UPENDER_STORAGE
1 COLD_ROLLED_COIL
TM_ANNEALING
0.660000 1
MOVE WITH CRANE2 THEN FREE
COLD_ROLLED_COIL CSM_ANNEALING
0.340000
MOVE WITH CRANE2 THEN FREE
COLD_ROLLED_COIL TM_ANNEALING
TM_ANNEAL_WEIGHT =
TM_ANNEAL_WEIGHT + WEIGHT
GROUP 12 AS BATCH
BATCH
TM_ANNEALING
UNGROUP
WAIT TM_ANNEAL_WEIGHT*5 MIN
COLD_ROLLED_COIL TM_ANNEALING
ANNEALED = 1
TM_ANNEAL_WEIGHT = 0
1 COLD_ROLLED_COIL TM_ANNEALING_STORAGE
FIRST 1
MOVE FOR 1 MIN
COLD_ROLLED_COIL TM_ANNEALING_STORAGE
1 COLD_ROLLED_COIL
UPENDER
FIRST 1
MOVE WITH CRANE2 THEN FREE
COLD_ROLLED_COIL CSM_ANNEALING
CSM_ANNEAL_WEIGHT =
CSM_ANNEAL_WEIGHT + WEIGHT
GROUP 3 AS BATCH
BATCH
CSM_ANNEALING
UNGROUP
WAIT CSM_ANNEAL_WEIGHT*5 MIN
COLD_ROLLED_COIL CSM_ANNEALING
ANNEALED = 1
CSM_ANNEAL_WEIGHT = 0
1 COLD_ROLLED_COIL CSM_ANNEALING_STORAGE
FIRST 1
MOVE FOR 1 MIN
COLD_ROLLED_COIL CSM_ANNEALING_STORAGE
1 COLD_ROLLED_COIL
COLD_ROLLED_COILS_SHIPPING FIRST 1
MOVE WITH EXTERNAL_TRANSPORT THEN
FREE
COLD_ROLLED_COIL COLD_ROLLED_COILS_SHIPPING TOTAL_CRC = TOTAL_CRC + 1
CR_TOTAL_WEIGHT = CR_TOTAL_WEIGHT + WEIGHT
WIP = WIP - 1
LOG "COLD ROLLED COIL CYCLE TIME =", TIME_IN
1 COLD_ROLLED_COIL EXIT
FIRST 1
********************************************************************************
*
Arrivals
*
********************************************************************************
Entity Location Qty each First Time Occurrences Frequency Logic
-------- -------- ---------- ---------- ----------- ---------- -----------COIL STAND5 1
0
INF
40 MIN
********************************************************************************
*
Attributes
*
********************************************************************************
ID
Type
Classification
---------- ------------ -------------WEIGHT Integer
Entity
TIME_IN Integer
Entity
ANNEALED Integer
Entity
********************************************************************************
*
Variables (global)
*
********************************************************************************
ID
Type
Initial value Stats
----------------- ------------ ------------- ----------#
#This variable totals up the number of Full Hard Coils that reach shipping
TOTAL_FHC
Integer
0
Time Series
#
#This variable tracks the current works in process
WIP
Integer
0
Time Series
#
#This variable totals up the galvanized coils that arrive at shipping
TOTAL_GC
Integer
0
Time Series
#
#This variable sums up the weight of the coils that approach the tin mill
annealing machine so that the duration of the annealing process
#can be calculated. The tin annealing machine takes 12 coils at once and
operates at 5 hours per ton.
TM_ANNEAL_WEIGHT Integer
0
Time Series
#
#This variable does the same as the TM_ANNEAL_WEIGHT except for the cold
sheet mill. The cold sheet mill takes 3 coils at a time and also
#operates at 5 tons per hour.
CSM_ANNEAL_WEIGHT Integer
0
Time Series
#
#This variable totals up the number of cold rolled coils that are sent to
shipping.
TOTAL_CRC
Integer
0
Time Series
FH_TOTAL_WEIGHT Integer
0
Time Series
GC_TOTAL_WEIGHT Integer
0
Time Series
CR_TOTAL_WEIGHT Integer
0
Time Series
Appendix B
Simulation Data
Graphs used in determining arrival time
Due to lack of decent output numbers, the 60 minute arrival time was not used. The 45
minute arrival time not only gave a good WIP but also provided a decent coil output.
Validation Calculations
Original vs. Alternate 1 calculation
Original Model
Alternate 1 Model
Total Coils Produced
182
178
182
167
185
182
185
194
189
201
Total Coils Produced
192
186
185
188
192
186
192
191
188
191
Difference
10
8
3
21
7
4
7
-3
-1
-10
(D - Dbar)^2
29.16
11.56
2.56
268.96
5.76
0.36
5.76
57.76
31.36
213.16
Dbar
s(D)
s(Dbar)
4.6
8.342661
2.638181
2.262
Confidence level
Interval
5.967566
10.56757 High
1.367566 Low
Original vs. Alternate 2 calculation
Original Model
Alternate 2 Model
Total Coils Produced
182
178
182
167
185
182
185
194
189
201
Total Coils Produced
206
201
208
205
204
206
201
207
202
203
Difference
24
23
26
38
19
24
16
13
13
2
(D - Dbar)^2
17.64
10.24
38.44
331.24
0.64
17.64
14.44
46.24
46.24
316.84
Dbar
s(D)
s(Dbar)
19.8
9.658617
3.054323
2.262
Confidence level
Interval
6.908879
26.70888 High
12.89112 Low
Alternate 1 vs. Alternate 2 calculation
Alternate 1 Model
Alternate 2 Model
Total Coils Produced
192
186
185
188
192
186
192
191
188
191
Total Coils Produced
206
201
208
205
204
206
201
207
202
203
Difference
14
15
23
17
12
20
9
16
14
12
(D - Dbar)^2
1.44
0.04
60.84
3.24
10.24
23.04
38.44
0.64
1.44
10.24
Original Model (Running for 1 month)
-------------------------------------------------------------------------------General Report
Output from C:\My Documents\Simulation Modeling & Analysis\Final
Project\California_Steel_Industry.MOD
Date: Apr/25/2002 Time: 12:33:19 AM
-------------------------------------------------------------------------------Scenario
: Normal Run
Replication : 1 of 1
Warmup Time : 70 hr
Simulation Time : 790 hr
-------------------------------------------------------------------------------VARIABLES
Variable
Name
Average
Total Minutes Minimum Maximum Current Average
Changes Per Change Value Value Value Value
Dbar
s(D)
s(Dbar)
15.2
4.077036
1.289272
2.262
Confidence level
Interval
2.916333
18.11633 High
12.28367 Low
----------------- ------- ---------- ------- ------- ------- ------TOTAL FHC
53 802.665509
5
58
58 33.4488
WIP
1858 23.242734
25
91
91 56.3543
TOTAL GC
582 74.190931
44
626
626 337.124
TM ANNEAL WEIGHT
342 124.982050
0
227
212 140.299
CSM ANNEAL WEIGHT
530 81.503681
0
80
69 38.8172
TOTAL CRC
263 161.496433
16 279 279 146.906
FH TOTAL WEIGHT
53 802.665509 122 1043 1043 606.892
GC TOTAL WEIGHT
582 74.190931
668 10702 10702 5722.46
CR TOTAL WEIGHT
263 161.496433
285 4764 4764 2510.86
LOGS
Log
Number Of Minimum
Maximum
Average
Name
Observations
Value
Value
Value
----------------------------- ------------ ---------- ------------ ----------FULL HARD COIL CYCLE TIME =
53 31.272000 118.147000 52.472226
GALVANIZED COIL CYCLE TIME =
582 69.426000 658.874000 197.436074
COLD ROLLED COIL CYCLE TIME =
263 556.611000 13588.562000 7021.053213
Alternative 1 (Running for 1 month)
------------------------------------------------------------------------------General Report
Output from C:\My Documents\Simulation Modeling & Analysis\Final
Project\California_Steel_Industry_Alternative.MOD
Date: Apr/25/2002
Time: 12:33:51 AM
------------------------------------------------------------------------------Scenario
: Normal Run
Replication
: 1 of 1
Warmup Time
: 70 hr
Simulation Time : 790 hr
------------------------------------------------------------------------------VARIABLES
Variable
Average
Name
Value
--------------------
Total
Average
Minutes
Minimum
Maximum
Current
Changes
Per Change
Value
Value
Value
-------
-----------
-------
-------
-------
---
TOTAL FHC
28.2561
WIP
56.1547
TOTAL GC
335.859
TM ANNEAL WEIGHT
140.141
CSM ANNEAL WEIGHT
38.5092
TOTAL CRC
153.564
FH TOTAL WEIGHT
501.109
GC TOTAL WEIGHT
5709.41
CR TOTAL WEIGHT
2592.67
42
1014.115667
7
49
49
1858
23.247719
21
90
88
564
76.547002
52
616
616
389
110.276314
0
235
190
588
73.425389
0
75
38
292
147.925555
9
301
301
42
1014.115667
110
845
845
564
76.547002
845
10549
10549
292
147.925555
151
5153
5153
LOGS
Log
Average
Name
Value
--------------------------------------FULL HARD COIL CYCLE TIME =
39.755548
GALVANIZED COIL CYCLE TIME =
92.741762
COLD ROLLED COIL CYCLE TIME =
6673.613805
Number Of
Minimum
Maximum
Observations
Value
Value
------------
----------
------------
42
34.712000
43.246000
564
60.893000
127.348000
292
475.433000
13042.063000
Alternative 2 (Running for 1 month)
-------------------------------------------------------------------------------General Report
Output from C:\My Documents\Simulation Modeling & Analysis\Final
Project\California_Steel_Industry_Alternative2.MOD
Date: Apr/25/2002 Time: 12:28:13 AM
-------------------------------------------------------------------------------Scenario
: Normal Run
Replication : 1 of 1
Warmup Time : 70 hr
Simulation Time : 790 hr
-------------------------------------------------------------------------------VARIABLES
Average
Variable
Total
Minutes Minimum Maximum Current Average
Name
Changes Per Change Value Value Value Value
----------------- ------- ----------- ------- ------- ------- -------
TOTAL FHC
42 1016.308952
3
45
45 25.3374
WIP
1923 22.460332
9
32
22 21.6891
TOTAL GC
572 75.509124
54
626
626 346.943
TM ANNEAL WEIGHT
459 93.297235
0
252
208 166.651
CSM ANNEAL WEIGHT
700 61.587341
0
75
29 43.8477
TOTAL CRC
349 123.664049
12 361 361 179.864
FH TOTAL WEIGHT
42 1016.308952
54
808
808 460.998
GC TOTAL WEIGHT
572 75.509124
920 10761 10761 6042.17
CR TOTAL WEIGHT
349 123.664049
232 6234 6234 3159.95
LOGS
Log
Number Of Minimum
Maximum
Average
Name
Observations
Value
Value
Value
----------------------------- ------------ ---------- ----------- ----------FULL HARD COIL CYCLE TIME =
42 37.358000 44.691000 40.849143
GALVANIZED COIL CYCLE TIME =
572 62.659000 138.031000 89.248804
COLD ROLLED COIL CYCLE TIME =
349 347.542000 4682.120000 2538.694461