ALTERNATIVES RESULT AND DISCUSSION CONCLUSION AND SUGGESTION

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 ix 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 xi 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