Discrete Event Simulation of Dept. 110 114

1
Discrete Event Simulation of Dept. 110 / 114
1st DRAFT
By Robert Griffiths 11/30/99 rob
ert-griffiths_at_worldnet.att.net
2
Overview

• Report outline at-a-glance
• Review progress of simulation development
• Conclusions

3
Report Outline

• Structure of paper follows Banks' Discrete-Events
  System Simulation (sec 1.10)
  
• Problem Definition
• Introduction
• Statement of Objectives
• Model planning
• Data / Input database
• Simulation Results
• Experimention and findings

4
Problem Definition

• The resources of two manufacturing cells are to
  be combined due to reduced load in both
  departments.
  
• Other areas of the shop have declared needs for
  manpower and equipment.
  
• Early voluntary retirement will continue to have
  impact on available manpower and skill sets.
  
• Currently, a proposed layout for the new
  department has been developed and approved at
  850,000 re-organization cost.
  
• Development of new layout has been based on
  experience and precieved capacity requirements to
  maintain schedule.

5
Intro / Background

• Continuing evolution of the face of
  manufacturing machining centers, product
  centers (cells, one-piece flow), module centers
  (one-man, multi-machines)
• Lean manufacturing systems are "more sensitive"
  to unplanned downtimes. They are engineered
  systems- perform well if key inputs are
  controlled, performance much less than optimal if
  key inputs / metrics are not in control
• Waste can be designed into lean manufacturing
  systems if proper attention to details is not
  considered.

6
Statement of Objectives

• Develop a simulation of the new department.
• Simulation should highlight any potential
  bottlenecks in terms of machines and / or
  operators.
  
• Verify cell's capability to meet schedule
  requirements thru the year 2003

7
Model Planning

• AutoCad image file used to aid in development of
  locations

8
Model Planning- cont'

• Reality Simulation
  Comments
  
• 16 locations 15 locations
  Grinder not included in model.
  
  Will run
  parts from other depts,
• 
  
  other depts to provide
  resources
• 229A development 5 part schedule
  Development difficult to model
  
• 
  
  exactly- schedule may slip,
  
• 
  
  additional resource (ie.,
  M.E.) will
• 
  
  run machines. Use idle
  time of
• 
  
  cell to gauge abililty to
  run
• 
  
  development hardware.
  
• Shipping to outside areas Generic cell exit
  loc. No forktrucks modelled Signif.
  
• 
  
  shipping time to vendor
  assist not
• 
  
  modelled. Ablility to
  expediate
• 
  
  not captured.
  
• ACE Defined
  cell downtime Diffcult to estimate effect of
  ACE.
  
• 
  
  QCPC, TPM, training, etc.,
  some
• 
  
  of with can occur a
  supervisor's
• 
  
  discretion.

9
Model Planning- cont'

• Model file to-date
• 
  
  
• Formatted Listing of
  Model
  
• C\My Documents\grad_school\sma\t
  ermproj1.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, ,
  

10
Model Planning- cont'


Entities


Name Speed (fpm) Stats Cost
------------- ------------ ----------- ---
--------- F119_inner 50 Time Serie
s F119_Assembly 50 Time
Series F119_outer 50
Time Series JT8_Assembly 50
Time Series

Pa
th 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 75.59 1
N6 N7 Bi 97.00
1 N7
N2 Bi 97.08 1
N5
N8 Bi 46.47 1
N8 N9 Bi 40.05
1 N9
N6 Bi 12.39 1
N3
N7 Bi 105.13 1
N7 N11 Bi 67.35
1 net2 Passing Speed Distance N1
N2 Bi 76.24 1
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
11
Model Planning- cont'


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
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


Resources



Res Ent

Name Units Stats Search Search Path
Motion Cost --------- ----- -
------- ------ ------ ---------- --------------
------------ VTL 1 By Unit None Ol
dest Empty 150 fpm

Full 150 fpm HMC_VMC 1
By Unit None Oldest Empty 150 fpm

Full 150 fpm
HMC_VTL 1 By Unit None Oldest
Empty 150 fpm

Full 150 fpm DEBURR 1
By Unit None Oldest Empty 150 fpm

Full 150 fpm
Inspector 1 By Unit None Oldest
Empty 150 fpm

Full 150 fpm
12
Model Planning- cont'

• Processing / routing data collected and refined
  in spreadsheet form. For example, F119 outer
  routing
  

Seq Dept Location Description
1 114 VTL rough facing 2 114 VTL rough turning 3
114 4axis rough pockets 4 114 deburr break edges
5 114 alkali wash wash part 6 183 vacuum h.t. s
tress 7 114 VTL face to clean 8 114 VTL finish f
lowpath 9 114 hmc mill keyslot 10 113 producto p
rofile mill o.d. 11 114 4axis mill pocket floor
12 114 5axis mill pocket side walls
13 114 5axis mill strut slots 14 114 deburr break
edges 15 114 alkali wash wash part 16 109 f.p.i
inspect 17 114 inspect fx
13
Data Collection

• A combination of "engineered" and estimated
  processing time for each operation collected and
  tabulated

vc_part_no vc_oper_no fl_man_min fl_auto_min fl_wa
lk_min fl_setup_min fl_man_mach_min vc_oper_desc f
l_catspaw_labor_minutes fl_catspaw_machine_minutes
4320125-06 0010 228.26 100 0 73 128.26 ROUGH FAC
E TURN REAR SIDE 228.26 228.26
4320125-06 0020 108 100 0 10.8 108 ROUGH FACE
TURN FRONT SIDE OD 208.06 208.06
4320125-06 0035 18 0 0 20 18 MILL TIMING
SLOT 18 18 4320125-06 0045 200 403 0 10.8 200 MIL
L BUTTRESS SLOTS 603 603 4320125-06 0047 45 0 0 0
45 DEBURR BUTTRESS SLOTS O.D. 45 45
4320125-06 0080 0.001 0 0 0 0.001 VERIFY
ACCEPTANCE OF OP. 30, 40, 5 0.001 0.001
4320125-06 0100 23.4 0 0 0 23.4 16.9 16.9
4320125-06 0130 0.001 0 0 0 0.001 0.001 0.001
14
Data Collection- cont'

• Engineered times can be considered mean service
  times. However, distribution data may be
  unavailable or unreliable. May assume a
  particular distribution based on available
  resource.
• Delivery requirements obtained through mid-2002.
  This will be used to drive "starts"
  

CURRENT_QUANTITY GREGORIAN_DATE
1 20000126 1 20000131 1 20000203 1 20000208 1
20000211 1 20000221 1 20000224 1 20000229 1 20
000303 1 20000308 1 20000310 1 20000313
. .
15
Simulation Results

• None yet....

16
Conclusion

• Anticipate a completed model within a week.
• Data collection (accuracy of) remains biggest
  roadblock.
  
• Need to understand how to treat W.I.P. when
  simulation "starts" 1/1/2000
  
• Promodel problem?