iv
TABLE OF CONTENTS
Acknowledgement i
Abstract ii
Table of Contents iv
List of Figures viii
List of Tables ix
List of Abbreviations, Symbols, specialized nomenclature xi
CHAPTER I: INTRODUCTION
1.1 Background 1
1.2 Problem Statement 2
1.3 Objectives of the Research 3
1.4 Scope of Research 4
CHAPTER II: LITERATURE REVIEW
2.1 Introduction to Manufacturing Simulation 6
2.1.1 Structure of Manufacturing Systems 10
2.1.1.1 Plant layout 10
2.1.2 Basic Simulation Concepts 12
2.1.3 Modeling and Simulation 19
2.1.4 Types of simulation 20
2.1.4.1 Static simulation 20
2.1.4.2 Dynamic simulation 21
2.1.5 Manufacturing simulation applications 22
2.1.6 Manufacturing Modeling features 22
2.1.6.1 Resources 23
2.1.6.2 Material Handling 23
2.1.6.3 Workstation Logic 23
2.1.6.4 Buffers 24
2.1.6.5 Order Process Plans 24
v 2.2 Introduction to Shop Floor Scheduling
24 2.3 Why Use Simulation
25 2.3.1 Typical simulation applications
26 2.3.2 Step in Simulation Study
28 2.4 Shop Floor Scheduling with Simulation
29 2.5 The Case for the Organizational Use of Simulation
32 2.5.1 The Simulation Study
33 2.5.2 Simulation Model Analysis
34 2.5.3 Simulation study results
36 2.6 Advantages and Disadvantages to Simulation
38 2.6.1 Advantages to Simulation
38 2.6.2 Disadvantages to Simulation
39
CHAPTER III: METHODOLOGY
3.1 Introduction to Methodology 42
3.1.1 Flow Chart Process for Methodology 43
3.2 Case Study 45
3.2.1 Implementation Simulation 45
3.2.2 Collect the data using what method to do the analysis 46
3.2.2.1 Step in time study 47
3.2.2.1.1 Selecting job for time study 48
3.2.2.1.2 Obtaining and recording information 48
3.2.2.1.3 Breaking the jobs into elements 49
3.2.2.1.4 Measure- duration of each element 50
3.2.2.1.5 Extend observed time into normal time 50
3.2.2.1.6 Determine relaxation and other allowances 50
3.2.2.1.7 Calculate standard time for the job 51
3.3 Bottleneck Scheduling 51
3.3.1 The Theory of Constraints TOC 52
3.3.2 Identification of Bottlenecks 53
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CHAPTER IV: DATA COLLECTIONDATA INPUT
4.1 Introduction 54
4.2 Data collection 55
CHAPTER V: SIMULATION MODEL DEVELOPMENT
5.1 Introduction 58
5.2 Element definition 58
5.3 Structural model 60
5.4 Assumption 61
5.5 Verification and Validation 61
5.5.1 Verification 61
5.5.2 Validation 63
5.6 Run time 65
CHAPTER VI: ALTERNATIVES
