Chapter Seven Applications Using Arena McGraw-Hill/Irwin © 2005 The McGraw-Hill Companies, Inc. All rights reserved.

Chapter Seven Learning Objectives Ability to model manufacturing cells using Arena Ability to incorporate inspection and rework into manufacturing cells models Ability to use Arena's advanced transfer template panel to model material handling processes Ability to develop a preliminary simulation model design using a design checklist

Chapter Seven Worksheet Menu

Chapter Seven Files

Chapter Seven Outline Manufacturing Simulation Models Modeling Inspection – Rejection – Rework Modeling Material Handling Equipment Modeling Multiple Product Flows Arena Academic Edition Limits Process Simulation Model Design Checklist

Manufacturing Simulation Models Exhibit 7-1 p. 186 Page: Manufacturing Cell Models

Manufacturing Cell Flow Exhibit 7-2 p. 187 Page: Manufacturing Cell Flow

Manufacturing Cell Models Exhibit 7-3 p. 187 Sheet: Static Analysis

Manufacturing Cell Models Single Item Base Model Manufacturing Cell 1.doe Batch Mode Base Model Manufacturing Cell 2.doe Manufacturing Cell 3.doe Operator in SubModel Manufacturing Cell 4.doe Scheduled Operators Manufacturing Cell 5.doe Input/Output Manufacturing Cell 6.doe Variables Comparison of Expected Verses Simulated Results

Manufacturing Cell Models Exhibit 7-4 p. 188 Sheet: Manufacturing Cell Models

Manufacturing Cell Models Exhibit 7-5 p. 188 Sheet: Manufacturing Cell Models

Manufacturing Cell Models Resources Exhibit 7-6 p. 189 Sheet: Resources

Manufacturing Cell Models Attributes Exhibit 7-35 p. 198 Sheet: Attributes

Single Item Base Model Manufacturing Cell 1.doe Exhibit 7-7 p. 198 Model Manufacturing Cell 8 Hours

Manufacturing Cell 1.doe Exhibit 7-8 p. 198 Automatic Process has Space Decide Module Dialog NQ (Automatic Process.Queue) < NQ (Manual Process.Queue) + 2

Manufacturing Cell 1.doe Exhibit 7-11 p. 190 Resource Spreadsheet Exhibit 7-9 p. 190 Crystal Reports Cost Summary

Batch Mode Base Model Manufacturing Cell 2.doe Exhibit 7-12 p. 191 Model Manufacturing Cell 8 Hours

Manufacturing Cell 2.doe Exhibit 7-14 p. 191 Process Spreadsheet View Initial Process Time: Batch.Size * Normal (0.95, 0.10, 3) Automatic Process Time: Batch.Size * Normal (1.50, 0.05, 4) Manual Process Time: Batch.Size * Normal (2.00, 0.10, 6) Mean, Std Dev, Stream Entity Attribute

Manufacturing Cell 2.doe Exhibit 7-13 p. 191 Assign Batch Size Dialog Batch.Size= MAX (ANINT (Normal (10, 3, 2)), 1) Positive Integer with mean of 10 units

Manufacturing Cell 3.doe Operator in SubModel Exhibit 7-15 p. 192 Model Manufacturing Cell 3.doe Automatic Process Submodel Exhibit 7-16 p. 192 Queue Spreadsheet

Manufacturing Cell 4.doe Scheduled Operators Exhibit 7-17 p. 193 Model Manufacturing Cell 4.doe Schedule.1 Exhibit 7-18 p. 193 Model Manufacturing Cell 4.doe Resource Spreadsheet

Manufacturing Cell 4.doe Operator Set Exhibit 7-19 p. 193 Set Spreadsheet Exhibit 7-20 p. 194 Load Batch Process Module Dialog

Manufacturing Cell 4.doe Tally Exhibit 7-21 p. 194 Record Module Dialog Exhibit 7-22 p. 194 User Specified Crystal Report

Manufacturing Cell 5.doe Worksheet Input.xls Exhibit 7-28 p. 196 Model Manufacturing Cell 5.doe Input Cycle

Manufacturing Cell 5.doe Worksheet Input.xls Exhibit 7-29 p. 196 Read Input File Module Dialog Exhibit 7-30 p. 196 File Spreadsheet Exhibit 7-31 p. 197 Workbook Input.xls

Manufacturing Cell 5.doe Assign Batch Start Time Module Exhibit 7-32 p. 197 Assign Batch Start Time Module

Manufacturing Cell 5.doe Worksheet Output.xls Exhibit 7-33 p. 197 Write Output File Module Dialog Exhibit 7-34 p. 198 Workbook Output.xls

Manufacturing Cell 5.doe Resource Failures Exhibit 7-24 p. 195 Sheet: Failures Exhibit 7-25 p. 195 Sheet: DensityFunctions Exhibit 7-23 p. 195 Model Manufacturing Cell 5.doe Failure Spreadsheet

Manufacturing Cell 5.doe Frequency Statistics Exhibit 7-27 p. 196 Frequency Statistics Replication 1 Exhibit 7-26 p. 195 Statistic Spreadsheet

Manufacturing Cell 6.doe Variables Exhibit 7-36 p. 198 Model Manufacturing Cell 6.doe Variable Spreadsheet Exhibit 7-37 p. 199 Model Manufacturing Cell 6.doe Failure Spreadsheet

Manufacturing Cell 8 Hours

Comparison of Expected Verses Simulated Results Exhibit 7-38 p. 199 Sheet: Simulation Analysis Exhibit 7-39 p. 199 Sheet: Simulation Analysis Exhibit 7-40 p. 199 Sheet: Simulation Analysis

Modeling Inspection – Rejection – Rework Reject Batch.doe Reject Single.doe Rework Batch.doe Rework Single.doe

Reject Batch.doe Exhibit 7-41 p. 200 Reject Batch.doe Special Model Logic

Reject Batch.doe Exhibit 7-42 p. 200 Separate Rejects Exhibit 7-43 p. 201 Separate Good

Reject Single.doe Exhibit 7-44 p. 201 Special Model Logic Exhibit 7-45 p. 201 Decide Module Dialog

Rework Batch.doe Exhibit 7-46 p. 202 Rework Batch.doe Special Model Logic

Rework Single.doe Exhibit 7-47 p. 202 Rework Single.doe Special Model Logic

Modeling Material Handling Equipment Route.doe Route PickStation.doe Route Sequence.doe Conveyor.doe Transporter.doe AGV.doe

Route.doe Exhibit 7-48 p. 203 Route.doe Special Model Logic

Route.doe Exhibit 7-49 p. 204 Route.doe Enter Spreadsheet Exhibit 7-50 p. 204 Route.doe Leave Spreadsheet

Route Set.doe Exhibit 7-51 p. 204 Route Set.doe Leave for Final Processing Station Final Processing Stations (2 - (NQ (Automatic Process.Queue) < NQ (Manual Process.Queue) + 2)) Exhibit 7-52 p. 204 Route Set.doe Advanced Set Spreadsheet

Route PickStation.doe Exhibit 7-53 p. 205 Route PickStation.doe Special Model Logic

Route Sequence.doe Exhibit 7-54 p. 205 Route Sequence.doe Special Model Logic Entity.Sequence = Sequence Number (1+ (NQ (Automatic Process.Queue) > NQ (Manual Process.Queue) + 2)) Exhibit 7-57 p. 205 Assign Sequence Module

Route Sequence.doe Exhibit 7-55 p. 205 Sequence Spreadsheet Exhibit 7-56 p. 206 Advanced Set Spreadsheet

Conveyor.doe Exhibit 7-58 p. 206 Conveyor.doe Special Model Logic

Conveyor.doe Exhibit 7-59 p. 207 Segment Spreadsheet Exhibit 7-60 p. 207 Conveyor Spreadsheet

Transporter.doe Exhibit 7-61 p. 207 Transporter.doe Special Model Logic

Transporter.doe Exhibit 7-63 p. 207 Distance Spreadsheet Exhibit 7-62 p. 207 Transporter Spreadsheet

AGV.doe Exhibit 7-64 p. 208 AGV.doe Special Model Logic

AGV.doe Exhibit 7-66 p. 208 Network Spreadsheet Exhibit 7-65 p. 208 Transporter Spreadsheet

AGV.doe Exhibit 7-67 p. 208 Network Link Spreadsheet Exhibit 7-69 p. 209 Station Automatic and Manual Intersection Definitions Exhibit 7-68 p. 209 Station Initial Intersection Definition

Modeling Multiple Product Flows Exhibit 7-70 p. 209 Page: Two-Product Flow Products Separate.doe Products Combined.doe Products Sequence.doe

Products Separate.doe Exhibit 7-71 p. 210 Products Separate.doe Model Logic Exhibit 7-72 p. 210 Process Module Spreadsheet

Products Combined.doe Exhibit 7-74 p. 211 Assign Dialog Exhibit 7-75 p. 211 Process Spreadsheet Exhibit 7-73 p. 210 Products Combined.doe Model Logic

Products Sequence.doe Exhibit 7-76 p. 211 Products Sequence.doe Model Logic Exhibit 7-77 p. 211 Sequence Spreadsheet

Arena Academic Edition Limits Limit Entities.doe Large Accumulator.doe Exhibit 7-78 p. 212 Sheet: Academic Limits

Concurrent Entities Exhibit 7-79 p. 212 Arena Academic Edition 150 Entities Error Message

Limit Entities.doe Exhibit 7-80 p. 212 Model Limit Entities.doe EntitiesWIP (Entity.Single) > Entity.Limit – 3

Large Accumulator.doe Exhibit 7-81 p. 213 Large Accumulator.doe Accumulator.Contents > Accumulator.Size - 1

Large Accumulator.doe Exhibit 7-82 p. 213 Assign 1 Detail Exhibit 7-83 p. 213 Assign to Accumulator Detail Exhibit 7-84 p. 214 Assign from Accumulator Detail

Process Simulation Model Design Checklist Exhibit 7-85 p. 213 Sheet: Model Design Checklist

Summary Applications Using Arena Manufacturing Simulation Models Modeling Inspection – Rejection – Rework Modeling Material Handling Equipment Modeling Multiple Product Flows Arena Academic Edition Limits Process Simulation Model Design Checklist Next: VBA