SIMULATION , MODELLING FOR

MANUFACTURING SYSTEMS

RAVINDER JHORAR 2011PMM5173

Simulation
Is the process of building a mathematical or logical model of a system or a decision problem

Experimenting with the model to obtain insight into the systems behavior or to assist in solving the decision problem.

WHEN SIMULATION IS APPROPRIATE?

Simulation enables the study of, and experimentation with, the internal interactions of a complex system, or of a subsystem within a complex system. Informational, organizational, and environmental changes can be simulated , and the effect of these alterations on the models behavior can be observed. The knowledge gained in designing a simulation model may be of great value toward suggesting improvement in the system under investigation By changing simulation inputs and observing the resulting outputs, valuable insight may be obtained into which variables are most important and how variables interact.

WHEN SIMULATION IS APPROPRIATE?

Simulation can be used as a pedagogical device to analytic solution methodologies. reinforce

Simulation can be used to experiment with new designs or policies prior to implementation, so as to prepare for what may happen.

Simulation can be used to verify analytic solutions.

By simulating different capabilities for a machine , requirements can be determined. Simulation models designed for training allow learning without the cost and disruption of on-the-job learning. Animation shows a system in simulated operation so that he plan can be visualized.

WHEN SIMULATION IS NOT APPROPRIATE?

The Problem is solved by common sense.

The Problem is solved by analytical means.

It is easier to perform direct experimentation The resources are not available The cost exceeds savings Unreasonable expectations

THE ELEMENTS OF DISCRETE SIMULATION

1. 2. Entity: Building blocks of mfg. sys. (M/Cs, AGVs) Activities: Function performed by entites.They are just like verbs in simulation language. Duration is assumed as fixed. Activity start end times are known Events :Points on time scale at which some changes takes places in the model. they represent the beginning or end of one or more activities. events are classified as endogenous (internal), exogenous (external).

3.

Activity cycle diagram

This is a diagram used in defining the logic of a simulation model. It is equivalent to a flow-chart of a general-purpose computer program. Conventions for drawing ACDs are as follows : (i) Each type of entity has an activity cycle. (ii) The cycle consists of activities and queues. (iii) The cycle is closed (iv) Activities are depicted by rectangles and queues by circles or ellipse.

simple ACD for a machine shop

Common Modeling Elements

Type of system Manufacturing

Entities Part

Attributes Part number, due date Destination, message length Flight number, weight

Resources Machines, workers Nodes, links

Queues Queues or buffers Buffers

Communications

Message

Airport

Airplane

Runways, gates

Queues

Insurance agency Application, claim

Name, policy Agents, clerks number, amount

Queues

Use of Simulation in Manufacturing

Manufacturing Environments Manufacturing Issues Performance Measurement of Manufacturing System Throughput (number of jobs produced per unit of time). Time in system for jobs (makespan). Times jobs spend in queues. Time that jobs spend being transported. Sizes of in-process inventories (WIP or queue sizes). Utilization of equipment and personnel (i.e., proportion of time busy). Proportion of time that a machine is under fadum, blocked until and starved. Proportion of jobs produced which must be reworked or scrapped. Return on investment for a new or modified manufacturing system.

New equipment and buildings are required (called green fields). New equipment is required in an old building. A new product will be produced in all or part of an existing building. Upgrading of existing equipment or its operation. Concerned with producing the same product more efficiently. Changes may be in the equipment (e.g., introduction of a robot) or in operational procedures (e.g., scheduling rule employed).

Number and type of machines for a particular objective. Location and size of inventory buffers. Evaluation of a change in product mix (impact of new products). Evaluation of the effect of a new piece of equipment on an existing manufacturing line. Evaluation of capital investments. Manpower requirements planning. Throughput analysis. Makespan analysis. Bottleneck analysis. Evaluation of operational procedures. Evaluation of policies for component part or raw material inventory levels. Evaluation of control strategies

Benefits and Limitations

Does not require simplifying Building models and simulating is

assumptions Can deal with problems not possible to solve analytically Provides an experimental laboratory: possible to evaluate decisions/systems without implementing them Generally easier to understand

time-consuming for complex systems Simulation results /simulated systems are always approximations of the real ones

Does not guarantee an optimal solution - lack of precise answers

Should not be used indiscriminately in place of sound analytical of models.

Problem Definition
Statement of Objectives

Model Formulation , Planning Data Collection

Model Development

Continues Development Verified?

Validated? Experimentation Results Analysis More Runs? Documentation & Presentation
Implementation

Steps in simulation study

SIMULATION SOFTWARE
1st Category Channel purpose language FORTRANC, C + +VB, VB+ + . . ............ . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .many other oriented languages 2nd Category Simulation language
GPSS (1965)SIMSCRIPT (1963)SIMULA GASP (1961)ALGOL SLAM (1979)SIMAN GPSS/4 (1977)SLAM IIAWESIM (1995)GEMS

3rd Category Simulation Packages ARENA (1993)AutoMOD QUEST EXTEND PROMODEL TaylorED WITNESS. . . . . . . . . . .and many more

Webbased simulation

JAVASIMWEBBASED SIMULATION. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . .....

METHODOLOGY FOR SELECTION OF SIMULATION SOFTWARE

Stage 1 Need for purchasing simulation software

Stage 2

Initial software survey

Evaluation

Stage 3

Stage 4

Software selection
Software contract negotiation

Stage 5

Stage 6

Software purchase

Stages of simulation software selection methodology

SOFTWARE SELECTION

Brainstorming

Self-Evaluation

Note: All ratings shown above are meant as a sample only for demonstration purposes

Simulations shortcomings
1.Simulation in discrete parts manufacturing seldom addresses sustainability issues. 2. Current simulation products do not typically support the modeling of environmental concerns or impacts; e.g., energy consumption or carbon footprint, waste/hazardous materials disposal, and pollution. . 3. Information on alternative manufacturing technologies, processes, and data is not readily available to the simulation analyst to incorporate into models. 4. Regional differences in environmental safety requirements are not represented in simulation environments. 5. Recovery, recycling, and life cycle costs (LCC) of materials are not addressed in design and manufacturing simulations. 6. Simulations do not deal with the usage and disposal practices of product users after sale.

SIMTER - ADVANCED SIMULATION-BASED PRODUCTION DEVELOPMENT TOOL FOR TRADITIONAL MANUFACTURING INDUSTRIES 1 Collaboration of Finnish and Swedish Government

In Finland project participants are VTT technical research centre of finland, visual components and holming works (Industries)
In Sweden- Project Participants are chalmers university of technology , volvo technology and EKA chemicals

The SIMTER project aimed to produce a simulation tool, which would enable joint multi parameter analysis of a production system. Thus, the project focused on producing three sub-tools (LoA, ergonomics, environmental) and integrating them into a single SIMTER tool.

Simter- Core Area

1. 2. 3. 4. Discrete event simulation Level of automation Environmental impacts Ergonomics

Level of Automation (LoA) scales for mechanized and computerized task

Part of the system design interface where LoA can be altered.

Environmental impacts

1. Environmental waste 2. Environmental Metrics

Product life cycle Based on EU LCA Platform

LCI data

The data is entered by the user into the SIMTER input database. In the analysis phase, the environmental data and simulation run results are combined in an MS Excel workbook.

Ergonomics
In the SIMTER project, integrated simulation tool developed to maximize production efficiency and to balance manual and automated work subject to ergonomics constraints. Several common and validated methods for evaluating the ergonomics of working postures are employed in the SIMTER tool. These are 1. RULA-Rapid Upper Limb Assessment 2. Ovako Working posture Analysis System 3. ERGOCAN-(Combination of RULA and OWAS)

Environmental Waste

According to the U.S. Environmental Protection Agency or EPA

Environmental wastes include:-

1. energy, water, or raw materials consumed in excess of what is needed to meet customer needs 2. pollutants and material wastes released into the environment, such as air emissions, wastewater discharges, hazardous wastes and solid wastes (trash or discarded scrap) 3. hazardous substances that adversely affect human health or the environment during their use in production or their presence in products

Environmental Metrics
The environmental metrics were adapted from EPA and GreenSCOR (2008) During the development the following metrics were tested

Environmental calculations are based on 1. 2. 3. 4. number of products manufactured Raw materials used machine utilizations scrap and rework rate

If there are any process phases or equipment consuming fuels, the direct CO2 is also calculated.

Case Example - The SIMTER Toy Case

Toy case processed through following five steps. 1.Assembly 2. Inspection 3. Painting 4. Drying 5. Packing

The product consists of four parts, made from 1. plastics 2. wood 3. iron.

Results
Environmental impact is calculated in an MS Excel workbook

Resource sheet: equipment energy data, simulation run results and energy calculations.

Analysis results are shown per product and per year

Future Work
1. Refinement of Subtools. 2. Determining the influence of levels of automation on ergonomics, and environmental impacts. 3. Fill the gap between Life Cycle Assessment and conventional process simulation, and identifying the most significant environmental factors to be taken into account. 4. Integration with manufacturing simulation provides a structure not just for measuring performance and environmental metrics, but also for identifying where action can be taken to improve green performance.

References