frame assemblies sent to rework, on the flowtime for completad assemblies, and on the utilization of each workstation.

b) Use the model to develop a 0.95 confidence interval on the flowtime for a completed assembly. Exercise 8.2 Parts arrive to a workstation and are processed on one of two machines in parallel. The time between arrivals is exponentially distributed with a mean of eight minutes. The processing time on the first machine is normally distributed with a mean of 10 minutes and a standard deviation of 2 minutes. The processing time for the same parts on the second machine is also normally distributed, but with a mean of 16 minutes and a standard deviation of 4 minutes. Because of the difference in processing speeds, preference is given to machine 1 when both machines are idle. Simlate this system for a 5,000-minute period, and record statistics on the utilization of the two machines and on the number of parts waiting in the queue. Exercise 8.3 Two different part types arrive to a workstation consisting of a single machine. The time between part arrivals is exponentially distributed with a mean of five minutes. The distribution of arriving parts is 80% Typc I and 20% lype 2. The part types are maintained in seprate queues in front of the machine. Type 1 parts have priority over Type 2 parts, and henee the machine only processes a Type 2 part if no Type 1 parts are available. However, once processing of a Type 2 part begins, it is not interrupted by an arriving Type 1 part. The processing time for each part type is jic-rmally distributed with a mean of four minutes and a standard deviation of two minutes. Simlate this system for 480 minutes; record statistics on the lengths of each part queue and on the flowtime by part type. Exercise 8.4 Modify the model for Exercise 8-3 to permit an arriving Type 1 part to interrupt the processing of a Type 2 part on the machine. Simlate this system for 480 minutes; record additional statistics on the number of Type 2 parts preempted from the machine. Exercise 8.5 Sub-assemblies A and B arrive to a workcenter where one of each part is assembled into a sub-assembly. The interarrival time for Sub-assembly A is normally distributed with a mean of 10 minutes and a standard deviation of 2 minutes. The interarrival time for Sub-assembly B is normally distributed with a mean of 10 minutes and a standard deviation of 3 minutes. The time required to complete an assembly has a triangular distribution with a minimum of 6, a mode of 9, and a mximum of 12 minutes. Simlate this system for a 1,000-hour period;

record statistics on the utilization of the assembly station and on the number of waiting sub-assemblies by type.
Exercise 8.6

Metal sheets arrive to a stamping station with an exponential interarrival time with a mean of 1 minute. At the stamping station, each metal sheet is stamped and cut into six workpieces. The time required to load a sheet onto the stamping machine is normally distributed with a mean of 0.8 minute and a standard devia-tien of Q,2 minute: The workpiicis ar then placed on a pallet. Oee the palla is filled to its capacity of 36, it is moved to a finishing station where the workpieces are removed from the pallet and are individually trimmed and polished. The pallet travel time between the stamping and finishing stations is negligible. The time required to trim and polish each workpiece at the finishing station is normally distributed with a mean of eight seconds and a standard deviation of two seconds. Simlate this system for 480 minutes; record statistics on the flow-time through the system and on the length of the queues at the stamping and finishing stations.
Exercise 8.7

Batches of 40 Ibs. of candy arrive to final coating process according to a normal distribution with a mean of 17.0 minutes and a standard deviation of 2.5 minutes. The batches are held in a single queue feeding two idntica! coating hoppers; coating time is uniformly distributed with a minimum of 27.0 minutes and a mximum of 34.0 minutes. When a batch has completed coating, it is divided into equal one-pound batches for bagging. These one-pound batches of candy are then routed to one of four baggers; each batch "selects" the bagger having the fewest batches in its input queue. The baggers run at a constant rate of 1.0,0.9, 0.8, 0.7 minutes for baggers 1 through 4 respectively. Two packaging machines place groups of 16 bags in a box; the bags from the first two baggers use the first packager, and the other two baggers feed the second packager. Packaging time is normally distributed with a mean of 7.0 minutes and a standard deviation of 0.8 minute and all 16 bags must be available before the packing operation can begin. a. Model this candy production line for 120 hours. Collect statistics on the time to complete bagging; on the queue lengths at final coat, at bagging, and at packag ing; on the time spent in the bagging queue; and on the number of boxes of candy produced. b. Add an inspector to the system. Once each half hour, the inspector removes from each of the bagger queues any 1-pound candy batches that have been waiting (since completion of final coat) for more than 8 minutes. It takes the inspector two minutes to dump each batch into a nearby reject hopper. Re-run the simulation for 120 hours; add a count of how many pounds of candy are rejected.

Exercise 8.8

A drive-in bank has two adjacent service laes for processing arriving customers. Each lae has room for the car being served plus three additional waiting cars. When a car arrives to the system, it enters the shortest lae, with ties broken randomly between the two laes. If both laes are full, the arriving car leaves and does not retum. Once a car enters a lae, it cannot leave the system until it is processed. However, a car will change laes whenever the other lae is shorter by two cars. We are interested in studying the operation of this drive-in bank during its open hours on Saturday when it is open from 9 A.M. until 1 P.M. The time between arrivals to the system during this period is exponentially distributed with a mean of 35 seconds. The service time is normally distributed with a mean of I minute and a standard deviation of 0.2 minute. When the bank closes at 1 RM., any customers waiting in the lae are denied service. Develop a model of this system. Record statistics on the number of lae changes, the utilization of the two tellers, the number of lost customers, and the customer f lowtime through the system. Construct a 0.95 conf idence interval on the number of lost customers based on 20 replications of the model.
Exercise 8.9

Modify the model in Exercise 8-8 such that the customers who arrive to the bank and find both laes full have a 0.5n probability of driving around the block and returning to the bank, where n denotes the number of attempts to enter the bank. The time around the block is normally distributed with a mean of 3 minutes and a standard deviation of 0.8 minutes. In addition to the previous statistics, also record the total time spent by each customer in traveling around the block.
Exercise 8.10

Electronic components arrive in"kits" to a kit prep rea where they receive one or both of two kit preparations prior to being sent to an assembly operation. The two prepping operations are called Prep 1 and Prep 2. One alternative that has been suggested for operating the kit prep rea is to dedicate each of the two preppers to one of the two preparations (i.e., prepper 1 performs only the Prep 1 operation). Arriving kits are placed in the in-buffer where they wait for a prepper. When a prepper completes processing on a kit, the kit is returned to the in-buffer if an additional prep remains. Otherwise, the kit is sent to the assembly operation. In either case the prepper examines the in-buffer for another kit that requires a prep at that prep station. If there is none, the prepper waits for either a new kit arrival or a returned kit from the other prepper. The time berween kit arrivals is exponentially distributed with a mean of 0.6 minute. The following table summarizes the distribution of kit arrivals by type and the kit processing time at each prep station. Zero indicates that no prep is required.

a. Simlate this system for 1,000 time units, and record statistics on the utilization of the preppers, on the flowtime through the kit prep rea, and on the size of the in-buffer. b. Develop a 0.95 confidence interval on the size of the in-buffer.
Exercise 8.11

Compare the flowtime in the proposed system in Exercise 8-10 to a modified system in which each prepper can perform either prep, but the mean prep time is increased by 10% for all operations.
Exercise 8.12

This problem involves modeling the SIX rule for jobshop scheduling [Eilon, Chowdhury and Serghiou, 1975]. The jobshop consists of six different machines. The job interarrival time is exponentially distributed with a mean of 15 minutes. There are four different job types processed through the facility. Each job is processed on a series of machines as defined by the visitation sequence for the job. The distribution of job types and the job lead-time (minutes), visitation sequence, and mean processing time (minutes) at each machine within the sequence are summarized in the following table.

The processing times are normally distributed with a standard deviation that is equal to 0.3 times the mean processing time. When a job arrives, its due date is assigned as the arrival time plus the leadtime. The scheduling rule at each machine divides the Jobs into two classes: regular Jobs and high-priority Jobs. High-priority Jobs are those with negative float. Float is the job due date minus the current time, minus the remaining processing time, minus a safety factor of 50 minutes. Regular jobs are those not designated highpriority Jobs. The SIX scheduling rule processes all high-priority jobs before regular jobs, and within each job class processes jobs in the order of shortest mean processing time.

a. Simlate this system for 4,800 minutes. Record statistics on the Job flowtime, the machine queue lengths, and the number of tardy Jobs. b. Develop a 0.95 confidence interval on the Job flowtime.

Exercise 8.13

Modify the model in Exercise 8-12 to incorprate the shortest-processing-time (SPT) rule with preemption. Specifically, an arriving Job may preempt the Job in process on a machine if its processing time is five or more minutes less than the remaining processing time of the Job being served. When an arriving Job preempts the job in process, the preempted Job rejoins the queue with its new SPT priority based on its remaining processing time. Evalate this rule versus the SIX rule based on the number of tardy jobs.
Exercise 8.14

A Just-In-Time (JIT) assembly operation consists of two serial workstations. Components arrive to the first workstation in a tote. At the first workstation they are assembled into sub-assemblies, which are placed back into the tote and then sent to the second workstation for final assembly. The system operates under a "pul" rather than "push" production strategy whereby work is only performed at a workstation when there is a downstream request for the work. Henee work is initiated at the second workstation by the arrival of an external request for a completed assembly. When such a request arrives, the second workstation issues a request to the first workstation. When the first workstation receives the request, it issues a request to the supplier for an additional tote containing components to be assembled. Each workcenter has both a work-request queue and an incoming-tote queue. For work to begin at either workstation, there must be both a work request and an incoming tote containing the needed materials (components or subassemblies) at the workstation. A small buffer of totes containing work (components or sub-assemblies) is initially stocked at each workcenter as a means of reducing production delays from starvation for needed material. External requests for completed assemblies arrive at the second workstation with an exponentially distributed interarrival time with a mean of five minutes. The time required to perform the assembly operation at this workcenter is nor-mally distributed with a mean of four minutes and a standard deviation of one minute. The time required to make the subassemblies at the first workcenter is normally distributed with a mean of three minutes and a standard deviation of one minute. The time required for the external supplier to supply a tote containing components is normally distributed with a mean of 4.2 minutes and a standard deviation of 1.3 minutes. Simlate this system for an 80-hour period, and record statistics on the number of totes in each input queue and on the time required for the second work-

station to meet external requests for completed assemblies. Assume that the system begins with three totes in the input buffer at each workstation.
Exercise 8.15

Modify the model/experiment for Exercise 8-14 to incorprate four initial totes at each workstation instead of just three. Compare the results obtained to determine if the additional tote at each workstation produces a statistically significant improvement in the time required to satisfy external requests at workstation 2.