1. 1 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Information flow Manufacturing Operation As A Single System OPERATION OUTPUT(PRODUCTS) INPUT (RAW MATERIALS) CONTROL

2. 2 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Information flow Manufacturing Operation As A Single System OPERATION OPERATION THROUGPUT(Products/Time) WORK IN PROCESS (Units of RAW MATERIALS) CONTROL CYCLE TIME (Time) LITTLE`S law: TH=WIP/CT

3. 3 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Sources Of Variability In A Single Operation Machine Failures Shut downs due to quality problems Operator´s Off Times Slow downs due to set ups Scheduled maintenance Tardy arrivals of materials High Work In Process Priorities Recycles Defective materials Tardy arrivals Incomplete lots Wrong lots Variability

4. 4 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Parameters And Variability Interrelationships WIP WIP TH TH CT CT Wo Variability

5. 5 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Parameters And Variability Interrelationships

6. 6 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Dependency Phenomenon 2 3 4 1 5 Raw materials End Products Most Dependent Operation

7. 7 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Variability And Dependency Phenomenona Affect: THROUGHPUT (TH) WORK IN PROCESS (WIP) CYCLE TIME (CT) VARIABILITY DEPENDENCY

8. 8 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Bottleneck Effect 12 3 r1 r2 r3 r1 = min (r1,r2,r3) is the bottleneck Even if W increases as infinite, TH is maximum r1 ri = Production rate (parts/unit time)

9. 9 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Bottleneck Effect

10. 10 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Global Processing Time:To 12 3 t1t2 t3 Global Processing Time To To = t1 + t2 + t3 ti = Production time (time per unit)

11. 11 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Critical Wip:Wo To = Global Processing Time Wo = (rb). To rb = bottleneck rate

12. 12 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Best Performance Law W/To W/To, if W < Wo or W =Wo rb rb, otherwise To To, if W < Wo or W =Wo W/rb, otherwise Ctbest = Thbest =

13. 13 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Worst Performance Law THworst = { W/(Wo+W-1)}* rb CTworst = To + (W-1)/rb

14. 14 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Some Performance Tips AS WIP INCREMENTS CT INCREMENTS TH REMAINS EQUAL OR LESSER

15. 15 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Some Performance Tips MANUFACTURING PLANNERS Wo MUST TO KNOW Wo rb IT MEANS THEY HAVE TO KNOW rb Wo = rb.To BECAUSE Wo = rb.To

16. 16 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Some Performance Tips WIP MUST BE A CONTROL WIP MUST BE A CONTROLPARAMETER

17. 17 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Some Performance Tips 1. TO CONTROL WIP INSTEAD OF TO CONTROL THROUGHPUT 2. TO CONTROL VARIABILITY

18. 18 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Some Performance Tips MRP SYSTEMS CONTROL THROUGHPUT INSTEAD OF CONTROLLING WIP MRP IS A POWERFUL INFORMATION TOOL SOME MRP SYSTEMS TREAT TO CONTROL VARIABILITY

19. 19 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Some Performance Tips

20. 20 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Some Performance Tips

21. 21 Luis Ernesto BLANCO RIVERO "SIMULATION AS A TOOL FOR UNDERSTANDING MANUFACTURING" Animated Simulation Benefits STUDENTS MAY OBSERVE AND ANALYZE MANUFACTURING PARAMETERS WHILE SIMULATION RUNS STUDENTS MAY CONSTRUCT STEP BY STEP MORE COMPLEX SYSTEMS STUDENTS LEARN FACTORY PHYSICS BY DOING SIMULATION