Simulation Modeling and Analysis
Final Project
Spring 2002
Virginia Marques-Arbogast
Final Project Selection
Balancing the production line at Southern California Door
Company
My selection for the final project is Case Study 5 in the book Simulation Using ProModel
by Dr. Charles Harel, Dr. Biman Ghosh, and Dr. Royce Bowden.
Description
Southern California Door Company produces solid wooden doors of various designs. The
current production facility is not balanced well. The objective of this simulation project is
to model the current production flow and present an alternative layout to increase the
current production.
Locations (Current work stations)
Rip_Saw
Moulding_Shaper
Chop_Saw
DET
Preassembly
Auto_Door
Glue_Trimming
Triple_Sander
Sand_Finishing
Entities
Raw Wood
Cut Pieces
Grooved wood
Batch
Door
Process Flow
1
Raw Wood material is taken from the raw material storage, inspected, and fed
into the rip saw machine.
2. Cut pieces are then placed in a carriage.
3. Cut pieces are taken from the carriage and, place onto moulding shaper to be
grooved on one side.
4. Grooved wood is transported to the chop saw where after being inspected, they
are chop to smaller pieces and stack on chop saw storage.
5. In 2 to 4 batches, some parts are moved to the DET (Double End Tenoner) to get
grooved on both sides, and stacked.
6. An operator gets parts from the storage racks, inspects for defects, and matches
frame parts by color. (Preassembly 1)
7. A second operator matches the center panel and four frame parts by color, glues
and preassembles them, and places them in the auto clamp conveyor.
8. The conveyor feeds the preassembled parts into the auto door clamp machine.
9. A third operator removes the assembled door from the machine and inspects it for
excess glue, trimming if any.
10. Assembled door is then moved to the triple sander where it undergoes the sanding
process, and sent back to the DET, where it is grooved on two of the sides and is
fed again to the machine to get grooved on the other two sides.
11. The assembly is put in storage until it is picked up from an operator from the sand
finishing station and it gets finished and moved to the storage racks to wait for
further processing.
MODEL VERIFICATION
The model was verified by conducting the following tasks:

Animation options included with the ProModel software package were used to aid
in the visualization of entity flow paths. This technique made it possible to ensure
that entities were traveling to the proper location in accordance with the entity
flow description. Using color to designate specific entity and path networks
allowed for easier visual tracking of entity flow.

The trace command included with the ProModel software package was used to
verify that the entity flow logic, resource operations, and designed path networks
simulated the system processes as intended..
Discrepancies in model logic discovered during the verification process were
subsequently rectified.
MODEL VALIDATION
The model was validated by conducting the following tasks:

Statistical variation was incorporated in the process times. These variations were
included to provide flexibility in the model to better represent variability in the
manufacturing process.

The animation and trace techniques were applied as discussed with the model
verification process to ensure proper model execution
PRESENT FACILITY LAYOUT
ALTERNATIVE 1 LAYOUT
ALTERNATIVE 2 LAYOUT
MODELS TEXT FILES
OUTPUT FILES
PRESENTATION