1 By Terence James Haydock Manufacturing Cell A simulated response in Arena

2 Overview Introduction Modelling Approach Model Layout Animation Process and Transfer Times Tutorial (step by step guide) Results Summary

3 Introduction Two types of parts arrive at a four-machine system according to an exponential distribution with a mean of 25 minutes. Eighty percent of the parts entering the system are Part A’s and the remaining twenty percent are Part B’s. Parts move through the following stations with the processing times shown below. All processing times shown are in minutes and follow the triangular distribution. Aim: To simulate a manufacturing cell in Rockwell Arena.

4 Modelling Approach MODELLING APPROACH Part arrivals: Use the Create module to model part arrivals. Machines: Use Process modules to model the machines. Warehouse: Use the Dispose module to model the warehouse. Routes: Use Routes to define the movement paths. Process plans: Use the Sequences module to define the part process plans. Run the simulation for 80 hours and collect statistics on the machine utilization and part flowtime. FromToTime (minutes) Part ArrivalMachine 12 Machine 22 Machine 42 Part ArrivalMachine 32 Machine 22 Machine 4Warehouse4 Type AMachine 1( 18, 19, 20 ) Machine 2( 18, 20, 22 ) Machine 4( 18, 20, 22 ) Type BMachine 3( 15, 20, 25 ) Machine 2( 25, 26, 27 ) Machine 4( 20, 30, 31 ) Processing Times Transfer Times

5 Model Layout

6 Animation Layout

7 Step by Step guide Aim: Visualization if your part through the system and define transfer times.

8 Or, right click on row & edit via dialogue box Double click on row Aim: define the sequence of your parts through the system and operating times.

9 Repeat for Part B Aim: define process plans and a triangular distributed time for machine processes

10 Provide Set Module

11 Aim: Create the arrival of your parts Aim: Assign attributes to the entities i.e. your parts Aim: define arrival station Aim: define route sequence

12 Aim: arrival, process and leave of your part, all associated with machine 1

13 Aim: arrival, process and leave of your part, all associated with machine 2

14 Aim: arrival, process and leave of your part, all associated with machine 3

15 Aim: arrival, process and leave of your part, all associated with machine 4

16 Aim: send your parts to the warehouse, while also taking count of the flowtime and the number of parts disposed of i.e. manufactured Aim: provide animation for visual reference

17 Report / Results Analyze the results and offer improvements to the model. Here it can be seen that machine 3 has a much lower usage than the rest. What would you propose to better utilize the system? A different layout/floor plan maybe? Now you have completed the tutorial your aim is to study and dissect the model to gain further knowledge of the process in play.

18 Summary Rockwell Arena software is a valuable tool for analysing discrete event simulations. The ability to incorporate variables, recourses and assign attributes to entities allows the user to simulate real life processes, in this case a manufacturing cell. Furthermore, by studying the generated results you are able to offer intelligent alternatives to the system in order to bring about improvements.

19 References