Professional Documents
Culture Documents
by
KAILAS SREE CHANDRAN
(Roll No.:M100447ME)
CERTIFICATE
This is to certify that the report entitled SIMULATION OF JOB SHOP USING
ARENA is a bonafide record of the Mini Project done by KAILAS SREE
CHANDRAN (Roll No.: M100447ME), in partial fulfillment of the requirements for the
award of the degree of Master of Technology in Industrial Engineering and
Technology from National Institute of Technology Calicut.
Dr. R. Sridharan
Faculty-in-Charge
(ME6194 Mini Project)
Dept. of Mechanical Engineering
ACKNOWLEDGEMENT
I am deeply indebted to my guide Dr. R. Sridharan, Professor, Department
of Mechanical Engineering, for his invaluable guidance, consistent encouragement
and suggestions throughout the course of the work.
I wish to express my sincere thanks to Dr. S. Jayaraj, Professor and Head,
Department of Mechanical Engineering, for providing the necessary facilities to
carry out this work.
Last but not the least, I extend hearty thanks to all our teachers and
classmates whose constant support and encouragement helped me to complete this
mini-project on time.
ABSTRACT
A Job Shop includes jobs which have different sequence of operations. Here a Gear
manufacturing Job Shop which produces three types of gears was modeled in ARENA
Simulation software to study the Gear flow times (by type), Gear delays at operations
locations, Machine utilizations etc. While modeling the system, the sequence of operations
for different types of gears, plant layout, distance between different facilities, processing time
of each operation, transportation of jobs through the factory, speed of transporter etc. were
considered. The model is run for 1 year with three 8 hour shifts per day. The results were
analyzed and a suggestion was also made to improve the system.
CONTENTS
List of Tables
1
3.
Introduction
01
1.1
01
1.2
01
1.3
02
Problem Environment
04
2.1
Problem Statement
04
2.2
Assumptions
05
2.3
06
ARENA Model
07
3.1
07
3.1.1
08
3.1.2
Gear Transportation
09
3.1.3
Gear Processing
12
3.1.4
Gear Departure
15
3.2
18
4.
Results
20
5.
23
5.1
24
5.2
Comparison of Results
24
6.
Conclusion
Reference
25
26
LIST OF TABLES
2.1
04
2.2
05
5.1
24
5.2
24
5.3
24
CHAPTER 1
INTRODUCTION
1.1 JOB SHOP PRODUCTION
Job Shop production is characterized by the manufacture of one or few numbers of a single
product designed and manufactured strictly to customers specifications, within, the given
period and wit/tin the price fixed prior to tile contract. Some typical examples of industries
engaged in Job Shop production are: general repair shops; special purpose machine tool
manufacturers; workshops to manufacture jigs and fixtures for other units; building
contractors; tailoring shops manufacturing made-to-measure suite of clothes; manufacturers
of ships, cranes, furnaces, turbo-generators, pressure vessels; and others manufacturing
articles made to customers orders.
1.2 CHARACTERISTICS OF JOB SHOP PRODUCTION
1.2.1 Disproportionate Manufacturing Cycle Time
A considerable amount of pre-planning and organization is necessary in such a venture.
Relatively long delays occur at the assembly as well as at the materials processing stages due
to lack of materials or components, imbalanced work flow, design changes, design errors
detected during manufacture, inaccurate work measurements, etc. which tend to lengthen the
manufacturing cycle time. At times, tile time needed to design the product exceeds its
manufacturing time.
1.2.2 Large Work-In-Progress
The work-in-progress inventory in a Job Shop production is generally very large as detailed
scheduling and progress control in this type of production is economically infeasible. For
various reasons, jobs get delayed causing temporary work shortages. To overcome work
shortages and keep men and machines busy, more work is released to the shop which in turn
increases work-in-progress.
1.2.3 Limited Functions Of Production Planning And Control
The success of Job Shop production mainly depends on the ability of the engineer in-charge
of the contract.
in a Job Shop production are the reservoir of job knowledge. The supervisor besides being
able administrator is expected to improvise and determine best work methods, determine tool
requirements, select the best process and provide management with reliable estimates of labor
and materials for specific orders. The span of control - the number of workmen to be
supervised by a supervisor - is kept low because of technical nature of the job.
1.3.6 Simple Mechanism
Tools control function is simple. Standard tools are stocked while special tools are either
made on the shop floor by the operators or purchased on request from supervisor.
1.3.7 Decentralized Process
The scheduling activity is more or less decentralized. A schedule is prepared to show the start
and completion date of each major component of the product. Job tickets giving completion
date of each component are raised and given to the shop. The activity of day to day
scheduling is left to the individual shop supervisor.
CHAPTER 2
PROBLEM ENVIRONMENT
2.1 PROBLEM STATEMENT
Consider a Job Shop producing three types of gears, G1, G2, and G3, for a ship. The job shop
is spread out geographically on the factory floor and its layout consists of the following
locations:
An arrival dock
A shop exit
Milling
Station
Drilling
Station
Paint
Shop
Polishing
Area
Shop Exit
100
100
250
250
550
300
400
150
300
150
400
500
300
400
Arrival
Dock
Milling
Station
Drilling
Station
100
100
300
Paint Shop
250
400
150
Polishing
Area
250
150
400
300
Shop Exit
550
300
500
400
200
200
Gear jobs arrive in batches of 10 units and their inter-arrival times are uniformly distributed
between 400 and 600 minutes. Of arriving batches, 50% are of type G1, 30% are of type G2,
and 20% are of type G3. A gear job arrives at the arrival dock and from there is dispatched to
its specific (type-dependent) sequence of manufacturing operations. A sequence consists of a
subset of milling, drilling, painting, and polishing operations. Table 2.2 displays the
operations plan showing the sequence of operations and the associated processing times for
each gear type. The layout of the job shop and operation sequences of gear types are depicted
in Figure 2.1.
Table 2.2 Operation Plan for gears by type
GEAR TYPE
OPERATION
SEQUENCES
PROCESSING
TIME(Minutes)
Milling
35
Drilling
20
Painting
55
Polishing
15
Milling
25
Painting
35
Polishing
15
Drilling
18
Painting
35
Polishing
15
G1
G2
G3
Gears are transported among locations by two trucks running at a constant speed of 100
feet/minute. Each truck can carry only one gear at a time. When a job is complete at a
location, the gear is placed into an output buffer, a transport request is made for a truck, and
the gear waits for the truck to arrive. Once a gear is transported to the next location, it is
placed in a FIFO input buffer. Finally, when the polishing operation is completed, the
finished gear departs from the job shop via the shop exit.
To analyze the performance of the job shop, plan to run a simulation over 1 year of operation.
2.2 ASSUMPTIONS
These assumptions were made during modeling the system.
a. Transporter (Truck) speed is same for both loaded and empty.
b. The freed transporter stays at the destination station until requested by another
station.
c. The Job Shop works for 24 hours a day in 3 shifts at 8 hours each.
Milling
Workstation
Painting Shop
Arrival Dock
Shop Exit
G1
Drilling
Workstation
G2
Polishing
Area
G3
Figure 2.1 Layout of the Job Shop and Operation Sequences by Gear type.
2.3 OBJECTIVE OF THE PROJECT
The following statistics are of interest:
Machine utilizations
The objective of the project is to model the Gear Manufacturing Job Shop in ARENA
Simulation Software and find;
i. Gear Flow Time (by Type)
ii. Gear Delays at operation locations
iii. Utilization of Resources
iv. Suggest an improvement
CHAPTER 3
ARENA MODEL
3.1 MODELING THE SYSTEM
The given system is modeled in ARENA Simulation software. Figure 3.1 depicts the Arena
model for the gear shop, consisting of three main segments:
1. Gear Job Arrivals
2. Gear Transportation
3. Gear Processing
4. Gear Departure
A segment-by-segment walkthrough of the model follows next.
Figure 3.1 Arena Model for the Gear Manufacturing Job Shop
Entity.Sequence is assigned the value of the Type attribute. This attribute acts as an index that
associates a gear type with the corresponding operations sequence.
Figure 3.4 Dialog box of the Assign module Assign Job Type and Sequence.
The operations sequences for gear types are specified in the Sequence module from the
Advanced Transfer template panel, whose dialog spreadsheet is displayed at the bottom of
Figure 3.5. Three sequences (row entries) are defined here, one for each gear type. Each
sequence consists of a sequence name (Name column) and a series of steps (Steps column),
listed in the order of processing.
To specify steps, the modeler clicks the button under the Steps column and pops up the Steps
dialog spreadsheet. The five steps of type G1 gears processing are displayed in the middle
spreadsheet of Figure 3.5. Each step is a row entry specifying the location name and
associated values (under the Assignments column). Clicking the corresponding button pops
up the associated Assignments dialog spreadsheet. The assignment of time for the milling
time operation is exemplified in the top spreadsheet of Figure 3.5.
3.1.2 Gear Transportation
Gear Transportation segment includes jobs arriving to Arrive Dock, Requesting the truck and
transporting the jobs to job shop. The segment is shown in Figure 3.6.
Figure 3.5 Dialog spreadsheet of the Sequence module (bottom), the Steps dialog spreadsheet
for specifying operations steps of type G1 gears (middle), and the Steps Assignment
spreadsheet for specifying milling time assignment of type G1 gears (top).
Job shop locations are modeled as Station modules. Accordingly, every gear entity proceeds
to the Station module, called Arrive_Dock, to model its physical arrival at the job shops
arrival dock. From here, gear entities will be transported to the job shop floor to start the first
step in their operations sequence.
10
entity. The saved ID will be used in due time to free that particular truck. Since requesting
transporters from multiple locations is a form of contention for resources, the Priority field
allows the modeler to assign a priority to requests issued at multiple Request modules (here a
high priority is assigned in order to clear the arrival dock as soon as possible). The Entity
Location field indicates the location of the requesting entity, and the Velocity field specifies
the transporters velocity, which is 100 feet/minute in our case. Finally, gear entities
requesting transportation at the same Request module are instructed in the Queue Name field
to wait in the queue, called a Truck.Queue, until a transporter becomes available.
11
attribute or expression. The gear entity and the transporter move as a grouped entity at a
velocity of 100 feet/minute as specified in the Velocity field. Note that the velocity may
depend on trip type, so that an empty truck and a loaded one can be made to move at different
velocities.
Figure 3.8 Dialog box of the Transport module Transport to Shop Floor
Next, the distances between different facilities are specified. Figure 3.9 displays the dialog
spreadsheet of the Distance module (left), as well as a corresponding Stations dialog
spreadsheet (right), which pops up on clicking a button under the formers Stations column.
3.1.3 Gear Processing
This segment includes the actual processing of gears. The gear processing segment
encompasses sets of Station modules, each modeling an operation in the sequence, from
milling to polishing. Since all sets have the same structure (except for names), only the
milling operation logic is explained here. The segment is shown in Figure 3.10.
When a gear entity is transported to the milling operation, it enters the Station module, called
Milling Station. It then proceeds to the Free module, called Free Truck at Mill, whose dialog
box is displayed in Figure 3.11. Here, the Transporter Name and Unit Number fields specify
the truck to be freed for use by other gear entities, using the Truck_ID attribute of the freeing
gear entity.
12
Figure 3.9 Dialog spreadsheet of the Distance module (left) and the Stations dialog
spreadsheet (right).
13
Figure 3.11 Dialog box of the Free module Free Truck at Mill
In this case, it enters the Process module, called Milling, whose dialog box is displayed in
Figure 3.12. The Seize Delay Release option in the Action field is used to model gear delays
at this process. The resource seized is Milling Machine and the processing time is kept in the
Milling Time attribute specified in the Sequence module of Figure 3.5. Furthermore, to model
four milling machines at the milling workstation, resource Milling Machine has to be
declared as having a capacity of four in the spreadsheet view of the Resource module. The
capacity of other machine groups is similarly declared. Figure 3.13 shows it.
14
15
Figure 3.14 Dialog box of the Request module Request Truck at Milling
Next, the transporting truck is freed in the Free module, called Free Truck at Exit, and the
finished gear entity is ready to record some statistics and then depart from the model at a
Dispose module.
16
specified in the Set module spreadsheet from the Basic Process template panel. Figure 3.17
displays the Set spreadsheet and the members of the Flow Times set.
Figure 3.16 Dialog box of the Record module Tally Flow Time
Figure 3.17 Dialog spreadsheet of the Set module (bottom) and the Members dialog
spreadsheet of the Flow Times set (top)
Arena computes travel times of transporters among Station modules based on their distances
and transporter speeds. Figure 3.18 introduces Fork Truck transporters into the model and
specifies their parameters in the Transporter module spreadsheet. These include columns for
a Name field to specify the transporter set, a capacity field (Number of Units), a Distance Set
field for specifying the name of a Distance module allowing the user to specify distances
between pairs of Station modules, a Velocity and Units fields that specify the transporter
speed (in our case, in feet per minute), and an Initial Position Status column of buttons,
which pop up the Initial Position Status dialog spreadsheet. The latter is used to specify the
location at which a transporter resides initially (at simulation time 0). Note that the
transporter speed is the default speed. Arena allows the modeler to override this value and to
17
further distinguish between the speed of an empty transporter (specified in a Request module)
and a loaded transporter (specified in a Transport module).
Figure 3.19 Dialog spreadsheet of the Statistic module for collecting fork truck utilization and
flow-time tallies.
3.2 SIMULATING THE MODEL
The ARENA job shop model was simulated for 1 year. Parameters like Replication Length
and Hours Per Day etc. are given in Run Setup. The Figure 3.20 shows it. While simulation,
we can see the movement of entities (gears) through different facilities, waiting for
processing, transfer between machines etc.
We are assuming that the plant works for 24 hours. i.e. Three shifts with eight hours each.
After completing the simulation, report will be generated automatically. From the generated
report, we can find Gear flow times (by type), Gear delays at operations locations, Machine
utilizations etc.
18
19
CHAPTER 4
RESULTS
The resulting output report is displayed in Figure 4.1. The Time per Entity section lists the
statistics of gear waiting times for each operation. As expected, the average waiting time at
the paint shop is very large as compared to the other operation locations, since spray times
are quite long. The results are displayed in graphical forms in Figure 4.2, 4.3 and 4.4.
45
Waiting Time(Minutes)
40
35
30
25
20
14.6109
15
10
5
3.0743
0.6656
0
Drilling
Milling
Painting
Polishing
Resource Utilization
50
44.8
45
37.63
40
Utilization, %
35
29.88
30
25
20
15
10
12.48
8.98
5
0
Drilling M/C
Milling M/C
Paint Booth
Polishing Worker
20
Fork Truck
Figure 4.1 Simulation results for the gear manufacturing job shop model
The Usage section displays resource utilizations at individual operation locations. For
instance, the utilization of a drilling machine is about 0.0898. The User Specified section
displays fork truck utilization statistics and flow-time statistics by gear type. The fact that the
average flow times are much larger than the total processing time bears witness to excessive
delays in resource queues.
21
250
240.46
200
153.2
150
105.16
100
50
0
G1
G2
22
G3
CHAPTER 5
IMPROVING THE SYSTEM
5.1 SUGGESTION FOR IMPROVEMENT
In Figure 4.2, its visible that Paint shop is having more waiting time compared to other
stations. To reduce the wait at the paint booth, we modify the job shop model by increasing
the number of paint booth from two to three. The impact of this modification on gear delays
and flow times is indicated in the simulation results of Figure 5.1. Clearly, the addition of a
paint booth has significantly reduced the delay at the paint shop but slightly increased the
delay at the polishing area, because speeding up an operation increases congestion
downstream. The overall effect on gear flow times, however, is a slight reduction.
Figure 5.1 Simulation results for the Modified Gear Manufacturing Job Shop Model
5.2 COMPARISON OF RESULTS
In the Table 5.1, its visible that Painting operation after modification has a delay of just 16
minutes compared to 44 minutes initially. This improvement is not visible in Resource
23
Utilization, see Table 5.2. Initially Resource Utilization of Paint Booth was 44% but after
improvement, it came down to 29% because the number of Paint Booth has increased by one.
But the improvement caused to reduce to Gear Flow time of all types of Gears, Table 5.3.
GEAR DELAYS AT OPERATION LOCATIONS
Initial
Suggestion
Drilling
0.6656
0.6556
Milling
14.6109
14.619
Painting
44.8111
16.082
Polishing
3.0743
8.945
Suggestion
Drilling M/C
8.98
8.98
Milling M/C
12.48
12.48
Paint Booth
44.8
29.86
Polishing Worker
29.88
29.86
Fork Truck
37.63
37.42
Suggestion
G1
240.46
203.02
G2
153.2
141.93
G3
105.16
103.93
24
CHAPTER 6
CONCLUSION
The given Job Shop System was modeled in Arena Simulation software and the results were
generated. After analyzing the results, it was noticed that the waiting time in paint shop was
more compared to other stations. So a suggestion was made to increase the number of paint
booth by one. The results before and after improvement were compared. And it was found
that the waiting time in paint shop is increasing but the utilization of that station is
decreasing. The acceptance or rejection of this suggestion depends on the organization
policies. If they are ok with sacrificing the utilization of a machine compared to waiting time,
they can go ahead with this suggestion. They have to consider the cost of machine operation
and loss due to huge waiting time in a station. The trade-off lies there.
Again lot of suggestions can be made in this system, by removing some machines in a station
which has less utilization so that we can increase the utilization and we can save money in
operating the machine. We can also consider changes in the assumptions a and b.
25
REFERENCE
[1]. David Kelton W., Randall P. Sadowski, Deborah A. Sadowski. 2001. Simulation with
Arena (2nd ed.), McGraw Hill.
[2]. R. Tavakkoli, M., Daneshmand Mehr. 2005. A Computer Simulation Model for Job Shop
Scheduling Problems Minimizing Makespan, Computers & Industrial Engineering, 48,
811823.
[3]. Rahime Sancar E. & Arslan O. 2009. Simulation Analysis of Lot Streaming in Job Shops
with Transportation Queue Disciplines, Simulation Modelling Practice and Theory,
17,442453.
[4]. Tayfur Altiok & Benjamin Melamed. 2007. Simulation Modeling and Analysis with
Arena (2nd ed.), Elsevier Inc.
26