Design And Analysis of Manufacturing System Using Simulation.
KOLEJ UNIVERSITI TEKNIKAL KEBANGSAAN
MALAYSIA
Design and Analysis of Manufacturing System
Using Simulation
Thesis submitted in accordance with the requirements of the
National Technical University College of Malaysia for the Degree of
Bachelor of Manufacturing Engineering (Honours) (Manufacturing Process)
By
Mohd Rajhan Bin Said
B050210069
Faculty of Manufacturing Engineering
May 2006
KUTKM Library (Pind.1/2005)
KOLEJ UNIVERSITI TEKNIKAL KEBANGSAAN MALAYSIA
BORANG PENGESAHAN STATUS TESIS*
JUDUL: DESIGN AND ANALYSIS OF MANUFACTURING SYSTEM USING SIMULATION
SESI PENGAJIAN : 2/ 2005-2006
Saya
_____________________________________________________________________
MOHD RAJHAN BIN SAID
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di
Perpust akaan Kolej Universit i Teknikal Kebangsaan Malaysia (KUTKM) dengan
syarat -syarat kegunaan sepert i berikut :
1. Tesis adalah hak milik Kolej Universit i Teknikal Kebangsaan Malaysia.
2. Perpust akaan Kolej Universit i Teknikal Kebangsaan Malaysia dibenarkan
membuat salinan unt uk t uj uan pengaj ian sahaj a.
3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran
ant ara inst it usi pengaj ian t inggi.
4. **Sila t andakan ( √)
SULIT
TERHAD
√
(Mengandungi maklumat yang berdarj ah keselamat an
at au kepent ingan Malaysia yang t ermakt ub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan
oleh organisasi/ badan di mana penyelidikan dij alankan)
TIDAK TERHAD
Disahkan oleh:
(TANDATANGAN PENULIS)
Alamat Tet ap:
No. 44, Lorong 3, Tmn Sri Selama,
34100, Selama,
Perak Darul Ridzuan.
Tarikh: _______________________
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh: _______________________
* Tesis dimaksudkan sebagai t esis bagi Ij azah Dokt or Falsaf ah dan Sarj ana secara penyelidikan, at au
disert asi bagi pengaj ian secara kerj a kursus dan penyelidikan, at au Laporan Proj ek Sarj ana Muda (PSM).
** Jika t esis ini SULIT at au TERHAD, sila lampirkan surat daripada pihak berkuasa/ organisasi berkenaan
dengan menyat akan sekali sebab dan t empoh t esis ini perlu dikelaskan sebagai SULIT at au TERHAD.
DECLARATION
I hereby, declare this thesis entitled “Design and Analysis of
Manufacturing System Using Simulation” is the results of my own research
except as cited in the reference.
Signature
:
……………………………
Author’s Name
:
Mohd Rajhan bin Said
Date
:
May 26th 2006
APPROVAL
This thesis submitted to the senate of KUTKM and has been accepted as fulfillment
of the requirement for the Bachelor of Manufacturing Engineering (manufacturing
Process) (Honours). The members of the supervisory committee are as follows:
………………………………………
Main supervisor
Faculty of Manufacturing Engineering
ABSTRACT
This report is about the application of simulation in manufacturing systems and
describes how the WITNESS simulation tool supports the simulation solution
deployment. There have several alternatives of simulation deployment are describe
includes reduce and increase number of stations. To run the simulation project the line or
area that needs an improvement must be studied. The related data is taken and doing an
analysis. Finally create and select a model, put the command of element and validate it.
This functionality is described in detail and related to real-world examples when
possible.
i
DEDICATION
For my beloved parents, Said bin Tasu and Rapiah binti Abdullah
To my supervisor, Prof. Dr. Mohd Razali bin Muhamad
And their supportive spirit
ii
ACKNOWLEDGEMENT
ﺣ ْﻴ ِﻢ
ِ ﻦ اﻟ ﱠﺮ
ِ ٰﺣﻤ
ْ ﷲ اﻟ ﱠﺮ
ِ ﺴ ِﻢ ا
ْ ِﺑ
Firstly, thanks a lot to Allah s.w.t because of given me a spirit and chance to
finish my thesis on time. I would like to thank my parent for given me a moral support,
motivation and also in financial support by preparing equipment in the likes of computer
and other expense. I would also like dedicate all my friends in which playing a major
role of this success. Not forget to my lecturer, Assoc. Prof. Chong Kuan Eng of given
me a research project from industry. Thank you to him because expend his time to guide
and teach me to solve a research problems.
All the hard work that has been during the spell with my supervisor, Prof. Dr.
Mohd Razali bin Muhamad for almost one year. His guide and inspiration in providing
technical advisory is a great benefit for me because of his vast experience in industry
and education. Thanks to his dedication and hard work, I’ve managed to complete my
thesis on time even though there are problems and challenges during this project. Once
again, I would like to dedicate my respect and honor to him for his kindness for guiding
and teaching me to become a mature person.
iii
TABLE OF CONTENTS
Abstract………………………………………………………………………………….. i
Dedication………………………………………………………………………………..ii
Acknowledgement……………………………………………………………………….iii
Table of Contents…………………………………………………………………...…...iv
List of Figures……………………………………………………………………...…...xii
List of Tables………………………………………………………………………..….xiii
CHAPTER 1: INTRODUCTION
1.1
INTRODUCTION………………………………………………………...…. 1
1.2
PROBLEM STATEMENT……………………………………………….…..4
1.3
OBJECTIVES………………………………………………………………...5
1.3
SCOPE OF PROJECT………………………………………………………..5
CHAPTER 2: LITERATURE REVIEW
2.1
MANUFACTURING SYSTEM……………………………………………….6
2.1.1
Manufacturing System Components….………………………………..7
iv
2.1.2
Manufacturing System Classification…………………………….……9
2.1.2.1 Type I: Single Station………………………………………….10
2.1.2.2 Type II: Multi Station Cell…………………………………….10
2.1.2.3 Type III: Production Lines…………………………………….10
2.2
2.3
2.4
2.1.3
Characteristic of Manufacturing System……………………………....10
2.1.4
Manufacturing Terminology…………………………………………...11
MODELING A MANUFACTURING SYSTEM..............................................13
2.2.1
Manufacturing Modeling Technique………………………………..….13
2.2.2
Use Simulation of Manufacturing……………………………………...17
2.2.3
Advantages of Simulation……………………………………………... 19
2.2.4
Types of Simulation…………………………………………………… 21
2.2.5
Discrete of Simulation…………………………………………………. 22
2.2.6
Discrete Event vs. Continuous Simulation……………….......................25
ASSEMBLY LINE BALANCING……………………………………………..27
2.3.1
Assembly Line…………………………………………………………..27
2.3.2
Modeling a Assembly Line…………………………….……….……....27
SIMULATION TOOL: WITNESS…………………………………………......29
CHAPTER 3: METHODOLOGY
3.1
INTRODUCTION…………………………………………………………...….31
3.2
SIMULATION PLANNING……………………………………………………31
v
3.3
3.4
TOOLS…………………………………...…………...……………………….34
3.3.1
Data Collection……………………………………...……………….....34
3.3.2
Data Storage……………………………………………...……………..35
3.3.3
Simulation Software: WITNESS…………………………..…………...35
EXECUTION……………………………...…………………………………....37
3.4.1
Optimization…………………………………………………………….38
3.4.2
Project Planning……………………………...…………………………39
CHAPTER 4: DATA COLLECTION
4.1
INTRODUCTION…………………………………………………………..…..40
4.2
COMPANY BACKGROUND……………………………………………….....40
4.3
PRODUCTION PROCESS…………………..………………………….…...…41
4.4
ASSEMBLY LINE………………………………………………..………...…..41
4.5
4.4.1
Current Layout…………………………………….………..…..………42
4.4.2
Current Task Time and Station……………………………..….……….43
PROJECT ACTIVITIES……………………..…………………………………44
4.5.1
Observation………………………………………….…………….........44
4.5.2
Parameter Collection…………………………………………….…...…45
4.5.3
Assembly Line Balancing……………………………………………....46
4.5.4
COMSOAL Approach…………………………………………………..46
4.5.5
COMSOAL Procedure…………………………………………….…....47
vi
4.5.6
4.5
COMSOAL Advantages………………………………………………...47
ANALYSIS………………………………………………………………….….48
CHAPTER 5: SIMULATION MODEL DEVELOPMENT
5.1
INTRODUCTION………….…………………………………………………...49
5.2
MODEL DEFINATION………………………………….……………….….…49
5.3
5.2.1
Part……………………………..…………………………………….….50
5.2.2
Buffer…………………………………..…………………………….….51
5.2.3
Machine…………………………………..………………………….….52
5.2.4
Labor…………………………………………..……………………..…53
5.2.5
Variable………………………………………..………………………..54
MODEL DEVELOPMENT…………………………..………………….……..55
5.3.1
Beginning of Simulation Modeling…………………..…………….…...55
5.3.2
Assumption…………………..……………………………………….....56
5.4
STRUCTURAL MODEL………………………..……………………………..57
5.5
VERIFICATION………………….…………………………………….…........57
5.6
VALIDATION………………….……………………………………....………59
5.7
DETERMINATION OF WARM-UP PERIOD……………………….…...........60
vii
5.8
RUN TIME………………………………………………………………….......61
5.9
SIMULATION MODEL…………………………………………………….….61
CHAPTER 6: OPTIMIZATION
6.1
INTRODUCTION………………………………….………….….……………62
6.2
DESIGN DESCRIPTION………………………………………..………….….62
6.3
6.2.1
Problems………………………………………………..……………....63
6.2.2
Solution…………………………………………………..…………..…63
6.2.3
COMSOAL result sequence……………………………………..….…..65
6.2.4
Erase the Bottleneck…………………………………...……………..…67
DESIGN LIMITATION…………………………………………..….……...….70
6.3.1
Zoning Constraint………………………………………...………….….70
6.3.2
Technological Constraint……………………………………..….……..71
6.3.3
Parallel…………………………………………..…………….….……..71
CHAPTER 7: RESULTS
7.1
INTRODUCTION…………………………………………………...…….……72
7.2
RESULTS FOR CURRENT LAYOUT……………………………………..….72
7.2.1
Productivity for a week……………………………………………..…..73
viii
7.3
7.2.2
VMI 1 Utilization…………………………………………………..…...74
7.2.3
T3AB Utilization……………………………….…………………..…...76
7.2.4
T3C Utilization…………………………………………….………..…..77
7.2.5
T3D Utilization……………………………………………………...…..78
7.2.6
VMI 2B……………………………………………………,,,………..…79
RESULT FOR NEW LAYOUT……………………………………..………….80
7.2.1
Productivity for a week…………………………………………...…….80
7.2.2
VMI 1 Utilization………………………………..…….…………...…...81
7.2.3
T3AB Utilization……………………………………………………......83
7.2.4
T3C Utilization……………………………………………………...…..84
7.2.5
T3D Utilization……………………………………………………...…..85
7.2.6
VMI 2B……………………………………………………………...…..86
CHAPTER 8: DISCUSSION & CONCLUSION
8.1
Discussion…………………………………………………………………...….87
8.2
Constraint………………………………………………………………........…87
8.3
Overall………………………………………………………………….…...….88
8.4
Conclusion……………………………………………………………….……..91
REFERENCES…………………………………………………………….…..………92
ix
APPENDICES
A
Gantt chart for PSM 1
B
Gannt Chart for PSM 2
C
VMI 1 results (optimized)
D
VMI 1 results (validate)
E
T3AB Results
F
T3C Results
G
T3D Results
H
VMI 2B Results
I
Layouts
J
Data Sheets
x
LIST OF FIGURES
2.1
The position of the manufacturing………………...…………………………….7
system in the larger production system
2.2
Types of routing in multiple station manufacturing systems:
(a) Variable routing and (b) Fixed routing…………………………………...…..8
2.3
Modeling Transfer Machine ………………………..……………….………….15
2.4
Continuous Flow System …………………………………………….…………16
2.5
Quantity of flow when: a) rate is constant, b) rate is changing……..….……… 16
2.6
Flow Chart of How Discrete Event Simulation Work ….……………….……. 24
2.7
Discrete Event cause Discrete State Change…………………………..………. 26
2.8
Comparison of Discrete Change State Variable
and Continuous Change State Variable……………………...…………….……26
3.1
The iterative process of simulation model development.……………….………33
3.2
Example of stopwatch…………………………………………………….….....34
3.3
Run Time Toolbar; capable…………………………………………….…….....35
3.4
Push and Pull concept between elements…………………………………….....36
3.5
Setup the elements (e.g.: Machine) …………………………………….….…...36
3.6
Research Planning Flow Chart………………………………………………….39
4.1
Current Assembly Line Layout………………………………………………....42
5.1
Parts exist in the assembly line (in simulation layout)……………………….…50
5.2
PlasticWindowtray, PCBtray, and MetalChassisTray………………………......51
5.3
Ultra Sonic Welding Machine…………………………………………..............52
5.4
Pressing Jig…………………………………………………………….……..…52
5.5
Computer for T3AB – Programming ………………………………………......52
xi
5.6
Labor (Machine Modifying)………………………………………………..…...52
5.7
Ultra Sonic Welding Machine……………………………………………..……53
5.8
Pressing Jig……………………………………………………………..….…....53
5.9
Computer for T3AB – Programming …………………………….…….....…....53
5.10
Connection between the stations in simulation…………………………..…..…56
5.11
Input same as Output…………………………………………….….……….….58
5.12
Tolerance Graph for Validation…………………………………………...…….59
6.1
Current Assembly Line Precedence Structure……………………..…………....64
6.2
Bottleneck…………………………………………………………….………....68
7.1
VMI 1 utilization for one week………………………………….…..………….75
7.2
T3AB utilization for 1 week………………………………………..……….…..76
7.3
T3C utilization for 1 week………………………………………………....…....77
7.4
T3D utilization for 1 week…………………………………………………..….78
7.5
VMI 2 utilization for 1 week………………………………………………..…..79
7.6
Graph for VMI 1 after optimization (run in 1 week)………………………........82
7.7
Graph of T3AB after optimization…………………………………….……..…83
7.8
Graph for T3C after optimization………………………………….………...….84
7.9
Graph for T3D after optimization………………………………….………...….85
7.10
Graph for VMI2B after optimization………………………………..……….....86
8.1
Parallel..........................................................................................................…....88
xii
LIST OF TABLES
2.1
Factor in Manufacturing Systems Classification Scheme………………………..9
4.1
Major Parameter in Assembly Line…………………………………...…….…..43
4.2
Task Time and Head Count (Station)……………………………..……….……44
5.1
Validation results…………………………………………….……………….....60
6.1
COMSOAL result sequence for assembly line…………..……………………..65
6.2
Bottleneck area……………………………………………………………….....69
7.1
VMI 1 utilization for one week…………………………………………………74
7.2
T3AB utilization for 1 week…………………………………………………….76
7.3
T3C utilization for 1 week……………………………………………………....77
7.4
T3D utilization for 1 week……………………………………………………...78
7.5
VMI 2 utilization for 1 week…………………………………………………....79
7.6
VMI 1 after optimization………………………………………………………..81
7.7
T3AB utilization after optimization…………………………………………….83
7.8
T3C utilization after optimization……………………………………………....84
7.9
T3D utilization after optimization……………………………………………....85
7.10
VMI 2B utilization after optimization…………………………………………..86
xiii
CHAPTER 1
INTRODUCTION
1.1
INTRODUCTION
Modern high technology manufacturing systems, such as those in the electronics,
semiconductor, aerospace, and automotive industries, can be extremely complex. The
complexity of these systems is due to factors such as (Czarnecki, et al., 1997):
a)
Multiple part types made in the same facility/line,
b)
Numerous manufacturing steps (300-500 steps is not uncommon),
c)
Batch processing, very complex equipment which leads to high
levels of preventive maintenance and downtime,
d)
Multiple levels of subassemblies, just to name a few.
This complexity combined with the high cost of setting up and maintaining such a
system necessitates the use of formal models of the system, rather than just relying on
experience or simple rules of thumb for performance evaluation and decision making.
Models are intended to support management decisions about the system and a
single model will often not be capable of supporting all decisions. Rather, different
decisions require different models because various aspects of the design and operation of
the system will be important for the questions being asked of the model. While
spreadsheet and queuing models are useful for answering basic questions about
1
manufacturing systems, discrete event simulation models are often needed to answer
detailed questions about how a complex manufacturing system will perform. Simulation
models lend themselves to incorporating additional details about the manufacturing
system and therefore often give more accurate estimates of manufacturing system
behavior than the simpler models mentioned above, but usually at the cost of more
computation.
In general, simulation is a practical methodology for understanding the highlevel dynamics of a complex manufacturing system. Simulation has several strengths
including (Bowden Jr., et al., 2003):
a)
Time compression – the potential to simulate years of real system
operation in a much shorter time.
b)
Component integration – the ability to integrate complex system
components to study their interactions.
c)
Risk avoidance – hypothetical or potentially dangerous systems
can be studied without
d)
The financial or physical risks that may be involved in building
and studying a real system.
e)
Physical scaling – the ability to study much larger or smaller
versions of a system,
f)
Repeatability – the ability to study different systems in identical
environments or the same system in different environments.
g)
Control – everything in a simulated environment can be precisely
monitored and exactly controlled.
2
Next, these are about a Manufacturing Issues Address by Simulation. The following are
some of the specific issues that simulation is used to address in manufacturing (Law &
McComas, 1999):
a)
The need for and the quantity of equipment and personnel
b)
Number, type, and layout of machines for a particular objective
c)
Requirements for transporters, conveyors, and other support
equipment (e.g., pallets and fixtures)
d)
Location and size of inventory buffers
e)
Evaluation of a change in product volume or mix
f)
Evaluation of the effect of a new piece of equipment on an
existing manufacturing system
g)
Evaluation of capital investments
h)
Labor-requirements planning
i)
Number of shifts
Performance of a manufacturing system evaluation can be made through a simulation
model using (Law & McComas, 1999):
a)
Throughput analysis
b)
Time-in-system analysis
c)
Bottleneck analysis
The evaluations of operational procedures of the manufacturing system are performed in
the following areas (Law & McComas, 1999):
a)
Production scheduling
b)
Inventory policies
c)
Control strategies [e.g., for an automated guided vehicle system
(AGVS)]
3
d)
Reliability analysis (e.g., effect of preventive maintenance)
e)
Quality-control policies
The following are some of the performance measures commonly estimated by
simulation (Law & McComas, 1999):
1.2
a)
Throughput
b)
Time in system for parts
c)
Times parts spend in queues
d)
Queue sizes
e)
Timeliness of deliveries
f)
Utilization of equipment or personnel
PROBLEM STATEMENT
The use of simulation for manufacturing system and analysis is justified for the
following reasons:
a)
Experimentation with the real system is infeasible, disruptive and too
expensive.
b)
Other mathematical or analytical method will not work.
c)
Need to examine systems as they would operate over a given time frame.
d)
Need to compare alternative proposed system design, or alternative
operating policies for a single system, to see which best meets the
specified requirements.
4
1.3
OBJECTIVES
The outcome of the project is to be achieved through the following objectives:
a)
To developed a primary model of a manufacturing system using
WITNESS simulation package.
b)
To study the effects of varying the design parameters on the performance
of the manufacturing system.
1.4
SCOPE OF PROJECT
WITNESS simulation package will be used package to develop a simulation in
manufacturing system and then to know clearly about the effects when we using a
several types of parameter at different values. The design of manufacturing system is
normally confronted with the ‘what if’ question. Physically, to answer such question will
incur high cost. Hence, simulation is used as an alternative. A manufacturing system will
be selected as a case study. Various design options will be tested. For a selected design
layout, various design parameters will be changed and the effects will be studied.
5
CHAPTER 2
LITERATURE REVIEW
2.1
MANUFACTURING SYSTEM
A manufacturing system is defined as a collection of integrated equipment and
human resources, whose function is to perform one or more processing and/or assembly
operations on a starting raw material, part, or set of parts. The integrated equipment
includes production machines and tools, material handling and work positioning devices,
and computer systems. Human resources are required either full time or periodically to
keep the system running. The manufacturing system is where the value-added work is
accomplished on the part or product. The position of the manufacturing system in the
larger production system is seen in Figure 2.1 Examples of manufacturing systems
includes (Groover, 2001):
a)
One worker tending one machine, which operates on semiautomatic cycle
b)
A cluster of semi-automatic machines, attended by one worker
c)
A fully automated assembly machine, periodically attended by a
human worker
d)
A group of automated machines working on automatic cycles to
produce a family of similar parts
e)
A team of workers performing assembly operations on a
production line.
6
Figure 2.1: The position of the manufacturing
system in the larger production system.
2.1.1
Manufacturing System Components
Manufacturing system consists of several components. In a given system, these
components usually include (Groover, 2001):
a)
Production machines plus tools, fixtures, and other related
hardware.
b)
Material handling system.
c)
Computer systems to coordinate and/or control the above
components.
d)
Human workers.
7
MALAYSIA
Design and Analysis of Manufacturing System
Using Simulation
Thesis submitted in accordance with the requirements of the
National Technical University College of Malaysia for the Degree of
Bachelor of Manufacturing Engineering (Honours) (Manufacturing Process)
By
Mohd Rajhan Bin Said
B050210069
Faculty of Manufacturing Engineering
May 2006
KUTKM Library (Pind.1/2005)
KOLEJ UNIVERSITI TEKNIKAL KEBANGSAAN MALAYSIA
BORANG PENGESAHAN STATUS TESIS*
JUDUL: DESIGN AND ANALYSIS OF MANUFACTURING SYSTEM USING SIMULATION
SESI PENGAJIAN : 2/ 2005-2006
Saya
_____________________________________________________________________
MOHD RAJHAN BIN SAID
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di
Perpust akaan Kolej Universit i Teknikal Kebangsaan Malaysia (KUTKM) dengan
syarat -syarat kegunaan sepert i berikut :
1. Tesis adalah hak milik Kolej Universit i Teknikal Kebangsaan Malaysia.
2. Perpust akaan Kolej Universit i Teknikal Kebangsaan Malaysia dibenarkan
membuat salinan unt uk t uj uan pengaj ian sahaj a.
3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran
ant ara inst it usi pengaj ian t inggi.
4. **Sila t andakan ( √)
SULIT
TERHAD
√
(Mengandungi maklumat yang berdarj ah keselamat an
at au kepent ingan Malaysia yang t ermakt ub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan
oleh organisasi/ badan di mana penyelidikan dij alankan)
TIDAK TERHAD
Disahkan oleh:
(TANDATANGAN PENULIS)
Alamat Tet ap:
No. 44, Lorong 3, Tmn Sri Selama,
34100, Selama,
Perak Darul Ridzuan.
Tarikh: _______________________
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh: _______________________
* Tesis dimaksudkan sebagai t esis bagi Ij azah Dokt or Falsaf ah dan Sarj ana secara penyelidikan, at au
disert asi bagi pengaj ian secara kerj a kursus dan penyelidikan, at au Laporan Proj ek Sarj ana Muda (PSM).
** Jika t esis ini SULIT at au TERHAD, sila lampirkan surat daripada pihak berkuasa/ organisasi berkenaan
dengan menyat akan sekali sebab dan t empoh t esis ini perlu dikelaskan sebagai SULIT at au TERHAD.
DECLARATION
I hereby, declare this thesis entitled “Design and Analysis of
Manufacturing System Using Simulation” is the results of my own research
except as cited in the reference.
Signature
:
……………………………
Author’s Name
:
Mohd Rajhan bin Said
Date
:
May 26th 2006
APPROVAL
This thesis submitted to the senate of KUTKM and has been accepted as fulfillment
of the requirement for the Bachelor of Manufacturing Engineering (manufacturing
Process) (Honours). The members of the supervisory committee are as follows:
………………………………………
Main supervisor
Faculty of Manufacturing Engineering
ABSTRACT
This report is about the application of simulation in manufacturing systems and
describes how the WITNESS simulation tool supports the simulation solution
deployment. There have several alternatives of simulation deployment are describe
includes reduce and increase number of stations. To run the simulation project the line or
area that needs an improvement must be studied. The related data is taken and doing an
analysis. Finally create and select a model, put the command of element and validate it.
This functionality is described in detail and related to real-world examples when
possible.
i
DEDICATION
For my beloved parents, Said bin Tasu and Rapiah binti Abdullah
To my supervisor, Prof. Dr. Mohd Razali bin Muhamad
And their supportive spirit
ii
ACKNOWLEDGEMENT
ﺣ ْﻴ ِﻢ
ِ ﻦ اﻟ ﱠﺮ
ِ ٰﺣﻤ
ْ ﷲ اﻟ ﱠﺮ
ِ ﺴ ِﻢ ا
ْ ِﺑ
Firstly, thanks a lot to Allah s.w.t because of given me a spirit and chance to
finish my thesis on time. I would like to thank my parent for given me a moral support,
motivation and also in financial support by preparing equipment in the likes of computer
and other expense. I would also like dedicate all my friends in which playing a major
role of this success. Not forget to my lecturer, Assoc. Prof. Chong Kuan Eng of given
me a research project from industry. Thank you to him because expend his time to guide
and teach me to solve a research problems.
All the hard work that has been during the spell with my supervisor, Prof. Dr.
Mohd Razali bin Muhamad for almost one year. His guide and inspiration in providing
technical advisory is a great benefit for me because of his vast experience in industry
and education. Thanks to his dedication and hard work, I’ve managed to complete my
thesis on time even though there are problems and challenges during this project. Once
again, I would like to dedicate my respect and honor to him for his kindness for guiding
and teaching me to become a mature person.
iii
TABLE OF CONTENTS
Abstract………………………………………………………………………………….. i
Dedication………………………………………………………………………………..ii
Acknowledgement……………………………………………………………………….iii
Table of Contents…………………………………………………………………...…...iv
List of Figures……………………………………………………………………...…...xii
List of Tables………………………………………………………………………..….xiii
CHAPTER 1: INTRODUCTION
1.1
INTRODUCTION………………………………………………………...…. 1
1.2
PROBLEM STATEMENT……………………………………………….…..4
1.3
OBJECTIVES………………………………………………………………...5
1.3
SCOPE OF PROJECT………………………………………………………..5
CHAPTER 2: LITERATURE REVIEW
2.1
MANUFACTURING SYSTEM……………………………………………….6
2.1.1
Manufacturing System Components….………………………………..7
iv
2.1.2
Manufacturing System Classification…………………………….……9
2.1.2.1 Type I: Single Station………………………………………….10
2.1.2.2 Type II: Multi Station Cell…………………………………….10
2.1.2.3 Type III: Production Lines…………………………………….10
2.2
2.3
2.4
2.1.3
Characteristic of Manufacturing System……………………………....10
2.1.4
Manufacturing Terminology…………………………………………...11
MODELING A MANUFACTURING SYSTEM..............................................13
2.2.1
Manufacturing Modeling Technique………………………………..….13
2.2.2
Use Simulation of Manufacturing……………………………………...17
2.2.3
Advantages of Simulation……………………………………………... 19
2.2.4
Types of Simulation…………………………………………………… 21
2.2.5
Discrete of Simulation…………………………………………………. 22
2.2.6
Discrete Event vs. Continuous Simulation……………….......................25
ASSEMBLY LINE BALANCING……………………………………………..27
2.3.1
Assembly Line…………………………………………………………..27
2.3.2
Modeling a Assembly Line…………………………….……….……....27
SIMULATION TOOL: WITNESS…………………………………………......29
CHAPTER 3: METHODOLOGY
3.1
INTRODUCTION…………………………………………………………...….31
3.2
SIMULATION PLANNING……………………………………………………31
v
3.3
3.4
TOOLS…………………………………...…………...……………………….34
3.3.1
Data Collection……………………………………...……………….....34
3.3.2
Data Storage……………………………………………...……………..35
3.3.3
Simulation Software: WITNESS…………………………..…………...35
EXECUTION……………………………...…………………………………....37
3.4.1
Optimization…………………………………………………………….38
3.4.2
Project Planning……………………………...…………………………39
CHAPTER 4: DATA COLLECTION
4.1
INTRODUCTION…………………………………………………………..…..40
4.2
COMPANY BACKGROUND……………………………………………….....40
4.3
PRODUCTION PROCESS…………………..………………………….…...…41
4.4
ASSEMBLY LINE………………………………………………..………...…..41
4.5
4.4.1
Current Layout…………………………………….………..…..………42
4.4.2
Current Task Time and Station……………………………..….……….43
PROJECT ACTIVITIES……………………..…………………………………44
4.5.1
Observation………………………………………….…………….........44
4.5.2
Parameter Collection…………………………………………….…...…45
4.5.3
Assembly Line Balancing……………………………………………....46
4.5.4
COMSOAL Approach…………………………………………………..46
4.5.5
COMSOAL Procedure…………………………………………….…....47
vi
4.5.6
4.5
COMSOAL Advantages………………………………………………...47
ANALYSIS………………………………………………………………….….48
CHAPTER 5: SIMULATION MODEL DEVELOPMENT
5.1
INTRODUCTION………….…………………………………………………...49
5.2
MODEL DEFINATION………………………………….……………….….…49
5.3
5.2.1
Part……………………………..…………………………………….….50
5.2.2
Buffer…………………………………..…………………………….….51
5.2.3
Machine…………………………………..………………………….….52
5.2.4
Labor…………………………………………..……………………..…53
5.2.5
Variable………………………………………..………………………..54
MODEL DEVELOPMENT…………………………..………………….……..55
5.3.1
Beginning of Simulation Modeling…………………..…………….…...55
5.3.2
Assumption…………………..……………………………………….....56
5.4
STRUCTURAL MODEL………………………..……………………………..57
5.5
VERIFICATION………………….…………………………………….…........57
5.6
VALIDATION………………….……………………………………....………59
5.7
DETERMINATION OF WARM-UP PERIOD……………………….…...........60
vii
5.8
RUN TIME………………………………………………………………….......61
5.9
SIMULATION MODEL…………………………………………………….….61
CHAPTER 6: OPTIMIZATION
6.1
INTRODUCTION………………………………….………….….……………62
6.2
DESIGN DESCRIPTION………………………………………..………….….62
6.3
6.2.1
Problems………………………………………………..……………....63
6.2.2
Solution…………………………………………………..…………..…63
6.2.3
COMSOAL result sequence……………………………………..….…..65
6.2.4
Erase the Bottleneck…………………………………...……………..…67
DESIGN LIMITATION…………………………………………..….……...….70
6.3.1
Zoning Constraint………………………………………...………….….70
6.3.2
Technological Constraint……………………………………..….……..71
6.3.3
Parallel…………………………………………..…………….….……..71
CHAPTER 7: RESULTS
7.1
INTRODUCTION…………………………………………………...…….……72
7.2
RESULTS FOR CURRENT LAYOUT……………………………………..….72
7.2.1
Productivity for a week……………………………………………..…..73
viii
7.3
7.2.2
VMI 1 Utilization…………………………………………………..…...74
7.2.3
T3AB Utilization……………………………….…………………..…...76
7.2.4
T3C Utilization…………………………………………….………..…..77
7.2.5
T3D Utilization……………………………………………………...…..78
7.2.6
VMI 2B……………………………………………………,,,………..…79
RESULT FOR NEW LAYOUT……………………………………..………….80
7.2.1
Productivity for a week…………………………………………...…….80
7.2.2
VMI 1 Utilization………………………………..…….…………...…...81
7.2.3
T3AB Utilization……………………………………………………......83
7.2.4
T3C Utilization……………………………………………………...…..84
7.2.5
T3D Utilization……………………………………………………...…..85
7.2.6
VMI 2B……………………………………………………………...…..86
CHAPTER 8: DISCUSSION & CONCLUSION
8.1
Discussion…………………………………………………………………...….87
8.2
Constraint………………………………………………………………........…87
8.3
Overall………………………………………………………………….…...….88
8.4
Conclusion……………………………………………………………….……..91
REFERENCES…………………………………………………………….…..………92
ix
APPENDICES
A
Gantt chart for PSM 1
B
Gannt Chart for PSM 2
C
VMI 1 results (optimized)
D
VMI 1 results (validate)
E
T3AB Results
F
T3C Results
G
T3D Results
H
VMI 2B Results
I
Layouts
J
Data Sheets
x
LIST OF FIGURES
2.1
The position of the manufacturing………………...…………………………….7
system in the larger production system
2.2
Types of routing in multiple station manufacturing systems:
(a) Variable routing and (b) Fixed routing…………………………………...…..8
2.3
Modeling Transfer Machine ………………………..……………….………….15
2.4
Continuous Flow System …………………………………………….…………16
2.5
Quantity of flow when: a) rate is constant, b) rate is changing……..….……… 16
2.6
Flow Chart of How Discrete Event Simulation Work ….……………….……. 24
2.7
Discrete Event cause Discrete State Change…………………………..………. 26
2.8
Comparison of Discrete Change State Variable
and Continuous Change State Variable……………………...…………….……26
3.1
The iterative process of simulation model development.……………….………33
3.2
Example of stopwatch…………………………………………………….….....34
3.3
Run Time Toolbar; capable…………………………………………….…….....35
3.4
Push and Pull concept between elements…………………………………….....36
3.5
Setup the elements (e.g.: Machine) …………………………………….….…...36
3.6
Research Planning Flow Chart………………………………………………….39
4.1
Current Assembly Line Layout………………………………………………....42
5.1
Parts exist in the assembly line (in simulation layout)……………………….…50
5.2
PlasticWindowtray, PCBtray, and MetalChassisTray………………………......51
5.3
Ultra Sonic Welding Machine…………………………………………..............52
5.4
Pressing Jig…………………………………………………………….……..…52
5.5
Computer for T3AB – Programming ………………………………………......52
xi
5.6
Labor (Machine Modifying)………………………………………………..…...52
5.7
Ultra Sonic Welding Machine……………………………………………..……53
5.8
Pressing Jig……………………………………………………………..….…....53
5.9
Computer for T3AB – Programming …………………………….…….....…....53
5.10
Connection between the stations in simulation…………………………..…..…56
5.11
Input same as Output…………………………………………….….……….….58
5.12
Tolerance Graph for Validation…………………………………………...…….59
6.1
Current Assembly Line Precedence Structure……………………..…………....64
6.2
Bottleneck…………………………………………………………….………....68
7.1
VMI 1 utilization for one week………………………………….…..………….75
7.2
T3AB utilization for 1 week………………………………………..……….…..76
7.3
T3C utilization for 1 week………………………………………………....…....77
7.4
T3D utilization for 1 week…………………………………………………..….78
7.5
VMI 2 utilization for 1 week………………………………………………..…..79
7.6
Graph for VMI 1 after optimization (run in 1 week)………………………........82
7.7
Graph of T3AB after optimization…………………………………….……..…83
7.8
Graph for T3C after optimization………………………………….………...….84
7.9
Graph for T3D after optimization………………………………….………...….85
7.10
Graph for VMI2B after optimization………………………………..……….....86
8.1
Parallel..........................................................................................................…....88
xii
LIST OF TABLES
2.1
Factor in Manufacturing Systems Classification Scheme………………………..9
4.1
Major Parameter in Assembly Line…………………………………...…….…..43
4.2
Task Time and Head Count (Station)……………………………..……….……44
5.1
Validation results…………………………………………….……………….....60
6.1
COMSOAL result sequence for assembly line…………..……………………..65
6.2
Bottleneck area……………………………………………………………….....69
7.1
VMI 1 utilization for one week…………………………………………………74
7.2
T3AB utilization for 1 week…………………………………………………….76
7.3
T3C utilization for 1 week……………………………………………………....77
7.4
T3D utilization for 1 week……………………………………………………...78
7.5
VMI 2 utilization for 1 week…………………………………………………....79
7.6
VMI 1 after optimization………………………………………………………..81
7.7
T3AB utilization after optimization…………………………………………….83
7.8
T3C utilization after optimization……………………………………………....84
7.9
T3D utilization after optimization……………………………………………....85
7.10
VMI 2B utilization after optimization…………………………………………..86
xiii
CHAPTER 1
INTRODUCTION
1.1
INTRODUCTION
Modern high technology manufacturing systems, such as those in the electronics,
semiconductor, aerospace, and automotive industries, can be extremely complex. The
complexity of these systems is due to factors such as (Czarnecki, et al., 1997):
a)
Multiple part types made in the same facility/line,
b)
Numerous manufacturing steps (300-500 steps is not uncommon),
c)
Batch processing, very complex equipment which leads to high
levels of preventive maintenance and downtime,
d)
Multiple levels of subassemblies, just to name a few.
This complexity combined with the high cost of setting up and maintaining such a
system necessitates the use of formal models of the system, rather than just relying on
experience or simple rules of thumb for performance evaluation and decision making.
Models are intended to support management decisions about the system and a
single model will often not be capable of supporting all decisions. Rather, different
decisions require different models because various aspects of the design and operation of
the system will be important for the questions being asked of the model. While
spreadsheet and queuing models are useful for answering basic questions about
1
manufacturing systems, discrete event simulation models are often needed to answer
detailed questions about how a complex manufacturing system will perform. Simulation
models lend themselves to incorporating additional details about the manufacturing
system and therefore often give more accurate estimates of manufacturing system
behavior than the simpler models mentioned above, but usually at the cost of more
computation.
In general, simulation is a practical methodology for understanding the highlevel dynamics of a complex manufacturing system. Simulation has several strengths
including (Bowden Jr., et al., 2003):
a)
Time compression – the potential to simulate years of real system
operation in a much shorter time.
b)
Component integration – the ability to integrate complex system
components to study their interactions.
c)
Risk avoidance – hypothetical or potentially dangerous systems
can be studied without
d)
The financial or physical risks that may be involved in building
and studying a real system.
e)
Physical scaling – the ability to study much larger or smaller
versions of a system,
f)
Repeatability – the ability to study different systems in identical
environments or the same system in different environments.
g)
Control – everything in a simulated environment can be precisely
monitored and exactly controlled.
2
Next, these are about a Manufacturing Issues Address by Simulation. The following are
some of the specific issues that simulation is used to address in manufacturing (Law &
McComas, 1999):
a)
The need for and the quantity of equipment and personnel
b)
Number, type, and layout of machines for a particular objective
c)
Requirements for transporters, conveyors, and other support
equipment (e.g., pallets and fixtures)
d)
Location and size of inventory buffers
e)
Evaluation of a change in product volume or mix
f)
Evaluation of the effect of a new piece of equipment on an
existing manufacturing system
g)
Evaluation of capital investments
h)
Labor-requirements planning
i)
Number of shifts
Performance of a manufacturing system evaluation can be made through a simulation
model using (Law & McComas, 1999):
a)
Throughput analysis
b)
Time-in-system analysis
c)
Bottleneck analysis
The evaluations of operational procedures of the manufacturing system are performed in
the following areas (Law & McComas, 1999):
a)
Production scheduling
b)
Inventory policies
c)
Control strategies [e.g., for an automated guided vehicle system
(AGVS)]
3
d)
Reliability analysis (e.g., effect of preventive maintenance)
e)
Quality-control policies
The following are some of the performance measures commonly estimated by
simulation (Law & McComas, 1999):
1.2
a)
Throughput
b)
Time in system for parts
c)
Times parts spend in queues
d)
Queue sizes
e)
Timeliness of deliveries
f)
Utilization of equipment or personnel
PROBLEM STATEMENT
The use of simulation for manufacturing system and analysis is justified for the
following reasons:
a)
Experimentation with the real system is infeasible, disruptive and too
expensive.
b)
Other mathematical or analytical method will not work.
c)
Need to examine systems as they would operate over a given time frame.
d)
Need to compare alternative proposed system design, or alternative
operating policies for a single system, to see which best meets the
specified requirements.
4
1.3
OBJECTIVES
The outcome of the project is to be achieved through the following objectives:
a)
To developed a primary model of a manufacturing system using
WITNESS simulation package.
b)
To study the effects of varying the design parameters on the performance
of the manufacturing system.
1.4
SCOPE OF PROJECT
WITNESS simulation package will be used package to develop a simulation in
manufacturing system and then to know clearly about the effects when we using a
several types of parameter at different values. The design of manufacturing system is
normally confronted with the ‘what if’ question. Physically, to answer such question will
incur high cost. Hence, simulation is used as an alternative. A manufacturing system will
be selected as a case study. Various design options will be tested. For a selected design
layout, various design parameters will be changed and the effects will be studied.
5
CHAPTER 2
LITERATURE REVIEW
2.1
MANUFACTURING SYSTEM
A manufacturing system is defined as a collection of integrated equipment and
human resources, whose function is to perform one or more processing and/or assembly
operations on a starting raw material, part, or set of parts. The integrated equipment
includes production machines and tools, material handling and work positioning devices,
and computer systems. Human resources are required either full time or periodically to
keep the system running. The manufacturing system is where the value-added work is
accomplished on the part or product. The position of the manufacturing system in the
larger production system is seen in Figure 2.1 Examples of manufacturing systems
includes (Groover, 2001):
a)
One worker tending one machine, which operates on semiautomatic cycle
b)
A cluster of semi-automatic machines, attended by one worker
c)
A fully automated assembly machine, periodically attended by a
human worker
d)
A group of automated machines working on automatic cycles to
produce a family of similar parts
e)
A team of workers performing assembly operations on a
production line.
6
Figure 2.1: The position of the manufacturing
system in the larger production system.
2.1.1
Manufacturing System Components
Manufacturing system consists of several components. In a given system, these
components usually include (Groover, 2001):
a)
Production machines plus tools, fixtures, and other related
hardware.
b)
Material handling system.
c)
Computer systems to coordinate and/or control the above
components.
d)
Human workers.
7