System Modeling Group 7
System Modeling Group 7
System Modeling Group 7
EMM 5706
DESIGN OF MANUFACTURING SYSTEM
System Modeling
Lecturer:
Assoc. Prof. Datin Dr Napsiah Ismail
Presented by Group 7
Hamidreza Soltani (GS26516)
Masoud Pishdar (GS26514)
Abdollah Omer Ibrahim (GS28223)
1. What is system?
Overview
2. What is modeling and simulation?
3. What is simulation modeling and analysis?
4. What types of problems are suitable for
simulation?
5. How to select simulation software?
6. What are the benefits and pitfalls in
modeling and simulation?
7. References
• SYSTEM MODELING
What is system?
System
A broader definition of a system is, “Any object which has some action
to perform and is dependent on number of objects called entities, is a
system”.
• SYSTEM MODELING
5
MODELING AND SIMULATION
• Block building
• Relevance
• Accuracy
• Aggregation
• Validation
Models can be put under three categories, physical
models, mathematical models and computer
models.
All of these types are further defined as static and dynamic
models.
Different types of models
PHYSICAL MODELS
16
• SYSTEM MODELING
Step 5 - Step 4 -
Validate the Formulate and
model. develop a model.
Step 7 - Step 8 -
Step 6 -
Select appropriate Establish
Document model
experimental experimental
for future use. design. conditions for runs.
Step 10 - Step 9 -
Interpret and Perform
present results. simulation runs.
Step 11 -
Recommend
further course of
action
Simulation Model
Steps Involved:
1- Identify the problem
Every study should begin with a statement of the problem. If the
statement is provided by the policy makers, or those that have the
problem, the analyst must ensure that the problem being described is
clearly understood. If the problem is being developed by the analyst, it is
important that the policy makers understand and agree with the
formulation
2- Formulate the problem
The objective indicates the questions to be answered by simulation. At
this point a determination should be made concerning whether
simulation is the appropriate methodology for the problem as
formulated and objectives as state. Assuming it is decided that
simulation is appropriate; the overall project plan should include a
statement of the alternative systems to be considered, and a method for
evaluating the effectiveness of these alternatives. It should also include
the plan for the study in terms of the number of people involve, the cost
of the study, and the number of days required to accomplish each phase
of work with the anticipated results at the end of each stage.
3- Collect the process real system data
The construction of a model of the system is problem as much
art as science. The art of modeling is enhanced by an ability to
abstract the essential features of a problem, to select and modify
basic assumptions that characterize the system, and then to
enrich and elaborate the model until a useful approximation
results. Thus it is best to start with a simple model and build
toward greater complexity. However, the model complexity
need not exceed that required to accomplish the purposes for
which the model is intended. It is not necessary to have a one-
to-one mapping between the model and the real system.
4-Formulate & develop a model
There is a constant interplay between the construction of the model and
the collection of the needed input data. As the complexity of the model
changes, the required data elements may also change. Also, since data
collection takes such a large portion of the total time required to
perform a simulation, it necessary to begin it as early as possible,
usually together with early stages of the model building.
5- Verification
• Performance measures
• Statistical Confidence
• Run Length
• Terminating and non-terminating systems.
• Warm-up period.
Steps in Simulation -contd.
Steps Involved:
7- Select appropriate experimental design
The alternatives that are to be simulated must be
determined. Often, the decision concerning which
alternatives to simulate may be a function of run that
have been completed and analyzed. For each system
design that is simulated, decision need to be made
concerning the length of the initialization period, the
length of simulation runs, and the number of
replications to be made of each run
8- Establish experimental conditions for runs
Production runs, and their subsequent analysis, are used to
estimate measures of performance for the system designs that are
being simulating.
Plan Study
Define System
Build Model
Run Experiments
Analyze Output
Report Results
Use of Simulation in Manufacturing
• Process hierarchy.
• Integrates with Microsoft desktop tools
• Spreadsheet interface
• Crystal reports
• Free runtime software.
• Fully graphical environment. No programming
required.
• VBA embedded.
• Optimization with Opt Quest for Arena.
• Builds reusable modules.
• $1,000 - $17,000 ($US). Various add-in modules
available
Manufacturing Systems modeling
Manufacturing Systems
• Identify problem areas
• Quantify system performance
Supporting Systems
• Effects of changes in order profiles
• Truck/trailer queueing
• Effectiveness of materials handling
• Recovery from surges
METHODOLOGY FOR SELECTION OF SIMULATION SOFTWARE
Stage 3
Evaluation
Stage 4
Software selection
Stage 5
Software contract negotiation
Stage 6
Software purchase
56
Figure – 3 : Stages of simulation software selection methodology
Needfor
Need for
purchasing
purchasing
simulation
simulation
software
software
Initial
Initial
software
software
survey
survey
57
Continued in the next slide
Short list of software
for evaluation
Initial
Initial software Initial software Initial software Initial software
software
survey survey survey survey
survey
Initial software
Initial survey
software
survey
Results of Evaluation
Software
Software
selection
selection
Selection of software
Legend:
Software
Software
contract Stages
contract
negotiation
negotiation
Contract acceptable
Intermediate
Results
Software
Software
purchase
purchase Elements
ProModel
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Promodel
• State-of-the-art simulation
engine
• Graphical user interface
• Distribution-fitting.
• Output analysis module
• Optional optimizer.
• Modules designed for:
– Manufacturing
– Healthcare
– Services
• $17,000 ($US)
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Case study
Table – 1 : Machine Area Information
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Table – 2 : Part Job Sequence and Quantity Information
P1 0 0 0 2 0 3 0 2+ 0 4
1
P2 0 6 0 0 0 0 2 0 3 0
P3 0 0 0 0 4 1 0 0 0 0
P4 2 0 2+ 0 0 0 0 0 0 0
5
P5 0 0 0 0 4 2 1 0 0 5
P6 0 0 0 0 0 0 2+ 2 4 0
1
P7 0 0 0 0 0 0 4 0 1 0
P8 3 0 4 2 0 2 0 0 0 0
P9 0 3 0 0 0 0 2 0 0 0
P10 0 5 0 0 1 0 3 0 1 0
P11 0 0 0 0 2 0 0 2 0 1
P12 1 0 3 0 0 0 0 0 0 3
P13 0 0 0 0 1 2 0 2 0 3
P14 0 2 0 0 0 0 1 0 3 0
P15 0 0 0 0 0 2 0 1 0 2
P16 0 0 4 2 0 0 0 0 0 0
P17 0 0 0 0 5 3 0 0 0 0
P18 4 0 6 2 0 0 0 0 0 0
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Here the initial solution for the above case study is obtained using
genetic algorithm as below
Cell Formation
Cell 1 = 3 1 10 4
Cell 2 = 8 6
Cell 3 = 2 9 7 5
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Step 2 : From job sequence of parts, check the minimum sequence (2 machines)
common for all parts e.g. M7 – M9, M5 – M6, M4 – M3, M8 – M6, M8 – M10 and bring
those 2 machines closer or nearer to each other.
M1-4
M2-4
M3-6
M4-4
M5-6
M6-7
M7-8
M8-6
M9-5
M10-6
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The least utilized machines are M1,M2 and M4. these machines are kept away from remaining
machines or at periphery so that they will not obstruct other more utilized machines.( e.g. 3-1-3, 1-
3-10, 3-4-1-6 i.e. 3 must be closer to 1 and 2-7, 2-7-9-5, 9-2-7, i.e. 2 must be closer to 7 & 9). In
this step, since the row distance is high, it will take more time for the vehicle to move from one
machine to another machine. So the row distance is reduced from 5 machines to 3 and 4
machines.
72
(Run hours 223.24)
Step 5: Here M5 is accompanied M6, M7 is accompanied by
M9, M3 is accompanied by M4. These machines are kept at
minimum possible distance.
Step 6: now considering maximum number of parts to be
processed and their job sequence.
P7=360, 7-9
P2=310, 7-9-2,
P14=315, 9-2-7
So these machines are at minimum distance in straight line
manner (7-9-2)
In next iteration next lower maximum parts are considered.
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(Run hours 213) 74
Step 7: place remaining machines closer to respective machines according
to job sequence.
1571.84 min.
average material handling time per part type = (82.26*213.45*60) / (100*18)
= 585.27 min average process time(%) per part =
(42.98+16.24+21.75+12.88+12.10+23.54+18.43+24.83+25.92+22.25)/18 =
12.273%=0.1273 76
average process time per part type =0.1273*213.45*60 = 1571.84 min.
CELL FORMATION
Cell 1 – 2 9 7
Cell 2 - 10 5 6
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Cell 3- 4 3 8 1
CONCLUSIONS
The end