vi
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
6.1 Introduction 66
6.2 Alternative explanation 67
6.3 Alternative overcome 72
6.4 Cost 74
6.4.1 Labor cost 75
6.4.2 Machine cost 76
6.4.3 Product cost 78
6.4.4 Other cost 79
6.4.5 Cost for actual process 79
6.4.6 Cost for alternative 1 using 72 labors and add 1 machine 80
at ranking process 6.4.7 Cost for alternative 2 using 72 labors and add 2 machines
80 at ranking process
6.4.8 Cost for alternative 3 using 60 labors and add 1 machine 81
6.4.9 Cost for alternative 4 using 60 labors and add 2 machines 81
6.4.10 Revenue 82
6.4.11 Profit 83
vii
CHAPTER VII: RESULT AND DISCUSSION
7.1 Introduction 85
7.2 Simulation analysis result 86
7.3 Discussion 93
CHAPTER VIII: CONCLUSION AND SUGGESTION
8.1 Conclusion 97
8.2 Suggestion 98
REFERENCES
APPENDICES Appendix A
A1 Layout for actual process
A2 Layout for alternative 1
A3 Layout for alternative 2
A4 Layout for alternative 3
A5 Layout for alternative 4
A6 Step in time study
A7 Proposed Multi-Pass Scheduling Mechanism
A8 Real-Time Monitoring and Control
A9 Model design steps
A10 Run toolbar A11 Adding Detail to machine and activities
Appendix B
B1 Result idle, busy and no. of operation for actual process in simulation
B2 Result idle, busy and no. of operation for alternative 1
B3 Result idle, busy and no. of operation for alternative 2
B4 Result idle, busy and no. of operation for alternative 3
B5 Result idle, busy and no. of operation for alternative 4
B6 10 interest factors for discrete compounding
viii
LIST OF FIGURES
2.1
Three flows concerning manufacturing: flow of material, flow of 8
information and flow of costs. 2.2
Basic simulation model component 13
2.3 Step in Simulation Study
28 2.4
Object Dependency in the Model 31
2.5 Present system cycle time performance
34 2.6
Set-up reduction for fabrication stage 36
2.7 Proposed system cycle time performance
36 3.1
Flow Chart Process for Methodology 43
3.2 Steps in time study
47 5.1
Simulation layout for actual simulation 62
6.1 Simulation layout for alternative 1
68 6.2
Simulation layout for alternative 2 69
6.3 Simulation layout for alternative 3
70 6.4
Simulation layout for alternative 4 71
6.5 Gating process layout
72 6.6
Ranking process layout 73
6.7 Cash flow diagram for machine cost
76 6.8
Graph for profit RM between each alternative 84
7.1 Graph for output between each alternative
91 7.2
Graph for productivity between each alternative 92
7.3 Graph for profit RM between each alternative
95
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LIST OF TABLES
1.1 Progress project for PSM I and PSM II
5 2.1
Setup times in color change 32
2.2 Result table
37 4.1
Cycle time gating process for 6 labors 56
4.2 Cycle time gating process for 5 labors
56 4.3
Cycle time ranking process for 6 machines 57
5.1 Element definition for Witness software
59 5.2
Push element in Witness software 60
5.3 Comparison actual and simulation model
63 5.4
Percentage for differential between actual model and simulation model 64
5.5 Simulation model result for production rate
64 6.1
Alternative explanation for changing and purpose 67
6.2 Salary cost for 72 labors and 60 labors
75 6.3
Differentiate between machine cost in each machine 77
6.4 Differentiate between product cost in each machine
78 6.5
Other cost for each machine 79
6.6 Cost for actual process per day
79 6.7
Cost for alternative 1 per day 80
6.8 Cost for alternative 2 per day
80 6.9
Cost for alternative 3 per day 81
6.10 Cost for alternative 4 per day 81
6.11 Differentiate between revenue in each machine 82
6.12 Differentiate for profit in each alternative 83
x 7.1
Result idle and busy process for actual process in simulation 86
7.2 Result idle and busy process for alternative 1
87 7.3
Result idle and busy process for alternative 2 88
7.4 Result idle and busy process for alternative 3
89 7.5
Result idle and busy process for alternative 4 90
7.6 Differentiate for productivity in each alternative
94 7.7
Differentiate for profit in each alternative 96
7.8 Table accepted and rejected for each table
96
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LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED NOMENCLATURE
N
The number of entities that are processed through the system. T
i
The system time for an individual entity arrival time – departure time
D
i
The queue time for an individual entity queue arrival time – service begin time
B Either 0 for idle or 1 for busy
Dt The length of time that is observed
T The total length of time for the simulation
Q The number in the queue for a given length of time
P Present value RM, the value of a project, loan, or financial activity
at the present time.
F Future value RM, the value of a project, loan, or financial at a future
point in time.
i Effective interest rate for a given period during which time the interest
is to be compounded e.g., percent per year.
n Number of interest periods.
NP Nested Partitioning
OCBA Optimal Computing Budget Allocation
WIP Work in Process
MRR Material Requirement Planning
JIT Just in Time
MPS Master Production Scheduling
FIFO First in First Out
SLP Systematic Layout Planning
TOC The Theory of Constraints
CCRs Capacity Constrained Resourses
CHAPTER I INTRODUCTION