Solving Manufacturing Problems Using Simulation Modeling

The curriculum of the Faculty of Management includes courses that focus on the use of simulation modeling programs in production management. This book is intended to be used as part of these subjects. The book can also be used in English-language studies or courses jointly implemented by universities from diff erent countries.
The specific objectives of the lessons are for students to gain the ability to use simulation programs, to learn the methodology of researching the improvement of production processes using these programs, and to strengthen the concepts of management and organization of production. Some of the issues also relate to production logistics, including internal transportation and storage systems.

The book consists of sixteen chapters. The layout of each chapter from the 1st to the 15th is similar. It includes an identifi cation of the aim of the exercise, a description of the problem to be analyzed, a description of the objects and tools used, the building of the simulation model, assumptions for carrying out the simulation, and guidelines for performing an analysis of the solutions obtained. In the [1, 3, 5, 6, 8–11, 13, 15] exercises, the Tecnomatix Plant Simulation software, version 15, was used, and in the [2, 4, 7, 12, 14] exercises, the FlexSim 20.1.3 software was used. Inthe 16th exercise, the Production Line – Car Factory computer game, educational version, was used. For this reason, the layout of Exercise 16 is slightly diff erent.

Content

Introduction / 11

1. Modeling of production flow / 13
1.1. Purpose of the exercise / 13
1.2. Description of the problem/process / 13
1.3. Used objects/tools / 13
1.4. Structuring of the model / 15
1.4.1. Structuring of the model – Applying ParallelStation object / 15
1.4.2. Structuring of the model – Applying AssemblyStation object / 16
1.4.3. Structuring of the model – Applying Conveyor and TransferStation objects / 16
1.4.4. Structuring of the model – Applying FlowControl object and SankeyDiagram tool / 18
1.4.5. Structuring of the model – Model the work of employees / 18
1.5. Assumptions for the performance of the simulation / 19

2. Mapping material flows in a production processes / 21
2.1. Purpose of the exercise / 21
2.2. Description of the problem/process / 21
2.3. Used objects/tools / 21
2.4. Structuring of the model / 23
2.4.1. Structuring of the production process model – Basic objects / 23
2.4.2. Structuring of the production process – Process flow / 24
2.5. Assumptions for the performance of the simulation / 28
2.6. Guidelines for the analysis / 28

3. Modeling manufacturing of bulk and liquid products / 31
3.1. Purpose of the exercise / 31
3.2. Description of the problem/process / 31
3.3. Used objects/tools / 31
3.4. Structuring of the model / 33
3.4.1. Structuring of the manufacturing process model – Basic objects / 33
3.4.2. Structuring of the manufacturing process model – Adding Tank and Mixer object / 34
3.4.3. Structuring of the manufacturing process model – Adding discrete objects and conveyors / 36
3.5. Assumptions for the performance of the simulation / 38
3.6. Guidelines for the analysis / 38

4. Modeling production of fluid products. Fluid library / 39
4.1. Purpose of the exercise / 39
4.2. Description of the problem/process / 39
4.3. Used objects/tools / 40
4.4. Structuring of the model / 40
4.5. Assumptions for the performance of the simulation / 44
4.6. Guidelines for the analysis / 44

5. Modeling failures in the production processes / 45
5.1. Purpose of the exercise / 45
5.2. Description of the problem/process / 45
5.3. Used objects/tools / 45
5.4. Structuring of the model – Basic objects / 45
5.4.1. Structuring of the model – Basic settings parameters for failures / 47
5.5. Assumptions for the performance of the simulation / 48
5.5.1. Assumptions for the performance of the simulation – Machine maintenance / 48
5.5.2. Assumptions for the performance of the simulation – Machine availability / 49
5.5.3. Assumptions for the performance of the simulation – Tool change / 50
5.6. Guidelines for the analysis / 50

6. Using the Resource analysis tools to analyze production processes / 51
6.1. Purpose of the exercise / 51
6.2. Description of the problem/process / 51
6.3. Used objects/tools / 51
6.4. Structuring of the model / 51
6.4.1. Structuring of the manufacturing process model – Characteristics of the facilities CostAnalyzer and EnergyAnalyzer / 53
6.4.2. Structuring of the manufacturing process model – Methods implementation / 53
6.4.3. Structuring of the manufacturing process model – Adding basis model / 54
6.5. Assumptions for the performance of the simulation / 56
6.5.1. Energy analyzer / 56
6.5.2. Cost analyzer / 57
6.6. Guidelines for the analysis / 57
6.6.1. Analysis of the electricity consumption / 57
6.6.2. Cost analysis / 58

7. Optimization of the company’s assortment – quantity production plan / 59
7.1. Purpose of the exercise / 59
7.2. Description of the problem/process / 59
7.3. Used objects/tools / 59
7.4. Structuring of the model / 60
7.4.1. Building a production model – Construction of a production area with the set of basic characteristics / 60
7.4.2. Building a production model – Setting the characteristics of the production plan / 61
7.4.3. Building a production model – Defining basic parameters of the production process / 62
7.4.4. Building a production model – Setting the limitation of the availability of the machine working time fund / 63
7.4.5. Building a production model – Defining the method of determining the income from the implementation of a given production program / 63
7.5. Assumptions for the performance of the simulation / 64
7.6. Guidelines for the analysis / 65

8. Using assembly line balancing to improve production processes / 67
8.1. Purpose of the exercise / 67
8.2. Description of the problem/process / 67
8.3. Used objects/tools / 68
8.4. Structuring of the model / 69
8.4.1. Structuring of the manufacturing process model – Making a table of processing times / 69
8.4.2. Structuring of the manufacturing process model – Mapping the manufacturing process / 71
8.4.3. Structuring of the manufacturing process model – Adding objects representing workplace / 71
8.4.4. Structuring of the manufacturing process model – Building a system for gathering information / 71
8.5. Assumptions for the performance of the simulation / 73
8.6. Guidelines for the analysis / 74

9. Using the U-shaped structure to improve the production line / 75
9.1. Purpose of the exercise / 75
9.2. Description of the problem/process / 75
9.3. Used objects/tools / 76
9.4. Structuring of the model / 77
9.5. Assumptions for the performance of the simulation / 78
9.6. Guidelines for the analysis / 79

10. Using the Bottleneck Analyzer tool to identify bottlenecks / 81
10.1. Purpose of the exercise / 81
10.2. Description of the problem/process / 81
10.3. Used objects/tools / 81
10.4. Structuring of the model / 83
10.4.1. Structuring of the manufacturing process model – Basic objects / 84
10.4.2. Structuring of the manufacturing process model – Machine failure settings / 85
10.4.3. Structuring of the manufacturing process model – Shift schedule and employees / 86
10.4.4. Structuring of the manufacturing process model – Lockout zone / 87
10.5. Assumptions for the performance of the simulation / 87
10.6. Guidelines for the analysis / 88

11. Using the Experiment Manager tool to improve production processes / 89
11.1. Purpose of the exercise / 89
11.2. Description of the problem/process / 89
11.3. Used objects/tools / 90
11.4. Structuring of the model / 91
11.4.1. Building a production process model – Picking a potato pallet from the warehouse and their transport to the production line / 92
11.4.2. Building a production process model – Cutting, frying and salting fries / 93
11.4.3. Building a production process model – Packing in bags and packing in collective packages / 93
11.4.4. Building a production process model – Transport of finished products to the warehouse / 94
11.5. Assumptions for the performance of the simulation / 95
11.6. Guidelines for the analysis / 96

12. Using the Experimenter tool to improve the production processes / 97
12.1. Purpose of the exercise / 97
12.2. Description of the problem/process / 97
12.3. Used objects/tools / 98
12.4. Structuring of the model / 99
12.5. Assumptions for the performance of the simulation / 101
12.6. Guidelines for the analysis / 101

13. Using the GAWizard tool in improving the production processes / 103
13.1. Purpose of the exercise / 103
13.2. Description of the problem/process / 103
13.3. Used objects/tools / 105
13.4. Structuring of the model / 107
13.4.1. Structuring of the production process model – Creation of flow objects and defining variables / 107
13.4.2. Structuring of the production process model – Lenses hardening process / 107
13.4.3. Structuring of the production process model – Adding workers / 108
13.4.4. Structuring of the production process model – Use of methods / 109
13.5. Assumptions for the performance of the simulation / 111
13.6. Guidelines for the analysis / 111

14. Using the Optimizer tool to improve the production processes / 113
14.1. Purpose of the exercise / 113
14.2. Description of the problem/process / 113
14.3. Used objects/tools / 115
14.4. Structuring of the model / 115
14.4.1. Structuring of the production process model – Basic objects / 115
14.4.2. Structuring of the production process model – Creation of flow objects / 117
14.4.3. Structuring of the production process model – Working week schedule / 120
14.5. Assumptions for the performance of the simulation / 120
14.6. Guidelines for the analysis / 120

15. Building a production process model / 123
15.1. Purpose of exercise / 123
15.2. Description of the problem/process / 123
15.3. Used objects/tools / 123
15.4. Structuring of the model / 125
15.5. Assumptions for the performance of the simulation / 126
15.6. Guidelines for the analysis / 127

16. Simulation of the manufacturing process in the automotive industry using computer game Production Line – Car Factory / 129
16.1. Purpose of the exercise / 129
16.2. Description of the problem/process / 129
16.3. Used objects/tools / 129
16.4. Structuring of the model / 130
16.4.1. Structuring of the manufacturing process model – Choice of production line location / 131
16.4.2. Building of the manufacturing process model – Key workstations / 131
16.4.3. Building of the manufacturing process model – Enabling flow between stations / 132
16.4.4. Structuring of the manufacturing process model – Attachment of material resources / 132
16.4.5. Building of the manufacturing process model – Additional functions / 133
16.5. Assumptions for the performance of the simulation / 133
16.6. Guidelines for the analysis / 133

List of tables / 135
List of figures / 137

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