KJSCE/IT/LY Btech/SEMVII/MS/2019-20

Experiment No.: 10
Title: Simulation of Manufacturing System

Page No:
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Batch:B4 Roll No.:1724012 Experiment No.: 9

Aim: To Implement the model for Manufacturing System using Extend Sim and estimate
system performance

Resources needed: Extend Sim 7

Theory

Problem Statement:
In a manufacturing unit three types of items (numbered as 1, 2, or 3 depending on the type
of item it will be) arrive on an assembly line exponentially with a mean 1.Out of these 25%
are type 1; 50% are type 2 and 25 % are type 3 respectively. At one step of the assembly
process, there are four machines. Two of the machines can work on all three types, but one
of the machines is old and can work on types 1 and 2, and the fourth machine can only work
on type 3. All the machines process one item at a time and take constant time of one unit to
process each item. Plot the utilization of each machine.

Model the problem as a queuing system.

Animate the model in 2D.

Run the simulation till 480 min I,e 8 hours.

Plot and verify the following results

 Length of the queue against the number of jobs exited from the system.

Concepts:

A basic discrete event model

The most common discrete event model involves the handling of one or more waiting lines
or queues, such as those found in supermarkets or factories.

Conceptual Model assumptions:

The Job Shop model represents a business operation where Jobs can be processed.

The assumptions for the model are:

• The model runs for a simulated time of 8 hours (480 minutes)

• Arrival of the items is exponentially distributed with a mean of 1.
• Processing times for jobs are constant (I unit each)
• The blocks come from the Item, Value, and Plotter libraries

Procedure:
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Starting a model and setting simulation parameters

The following steps are typical when starting any discrete event model.
  Open a new model worksheet


  Run > Simulation Setup. In the Setup tab enter the simulation
Give the command
parameters:

o End time: 480
 
o Global time units: minutes
  If they aren’t already open, open the Item, Plotter, and Value libraries



Place an Executive block (Item library) on the top left corner of the model
worksheet

The Executive block does event scheduling and manages discrete event simulations. It must
be present in every discrete event model.

Start small

In building any simulation model, it is easiest to start with a simple subset of the process and
add detail until you arrive at a completed model that approximates the system that‟s being
modelled. This allows you to test at various stages while making the model building process
more manageable.

The following table lists the blocks that will be added to the worksheet and their use in the
model.

Except for the Plotter block from the Plotter library and random number block from value
library, the blocks in the table are from the Item library.

Name (Label) Block Function

Create block (items) Generates items or values, either randomly or on

schedule. If used to generate items, it pushes
them into the simulation and should be followed
by a queue-type block.

Purpose in Manufacturing Model

Generates items that arrive exponentially with mean 1

Set (Item > Properties) Attaches user-assigned properties (attribute,

priority, and quantity) to items passing through.
Purpose in Manufacturing Model

Set property as Type (1, 2, 3)

Queue block (Buffer) Acts as a sorted queue or as a resource pool Queue.

As a sorted queue, holds items in FIFO or LIFO order,
or sorts items based on their attribute or priority.

Purpose in Manufacturing Model

Holds the items based on the type when the machine is available, and releases them one by
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one in first-in, first-out order.

Select Item In (Item > Routing) Selects an input and outputs its item.

Purpose in Manufacturing Model

For merging the inputs (items coming from the buffers) and output one (to a particular
machine).

Select Item Out (Item > Routing) Sends each item it gets to a selected O/P

Purpose in Manufacturing Model

Apply the routing rule (items to be routed to the specified buffer)

Activity block (Machine) Processes one or more items simultaneously.

Processing time is a constant or is based on
a distribution or an item‟s attribute.

Purpose in Manufacturing Model

Processes the items as per the service time i.e. constant

Random Number block Generates random numbers

Purpose in Manufacturing Model

Outputs values to a Set block as per the look up table

Exit (Exit) Removes items from the simulation and counts them
as they leave.

Purpose in Manufacturing Model

Exit the items after being processed from the system.


 on the model worksheet in a
Starting at the right of the Executive block, place the blocks
line from left to right, based on their order in the table.
 
Label the blocks as the system entities.

Enter the dialog parameters and settings for each block

Make the connections

Run the simulation

Verify the results

Animate the model

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Results: (Program printout with output)
Program: (Printed model developed in Extend Sim )

Output: (Printed results i.e. the plotter data)

Questions:

1. Give the significance of Validation and verification in simulation?

Ans:

Significance of Verification:

1.Having the implementation presented to and checked by someone not directly involved in
its development.

2. Tracing the model flow via flow diagram or otherwise to determine if the model is taking
all possible actions in the course of a run (note that this is critical when using components
such as Extend’s Select DE Output block (DE.lix)).

3. Model outputs making sense for various combinations of possible configurations and
input data; it is important in this instance that as much output of expected values as can be
stomached should be incorporated into the model, most typically “long-run” statistical
measures that can be predicted at various points in the model, such as the mean and standard
deviation of time data, item counts, and elapsed time (particularly for catching the common
mistake of using different time units in model components).

4. Dumping data to see if the values are what they should be at simulation end.

5. Including explanatory comments either in block dialogues or in text boxes on Extend’s

work plane.

6. Observing model behavior under animation, a powerful tool to visually check that model
components are behaving as expected; you must be very cognizant that Extend’s animation
is strictly sequential, so actions that occur simultaneously are animated one following the
other – this may require keeping a careful eye on the system clock.

7. Utilizing pause and single step features to interactively probe intermediate system results
(and even change some values) • The Extend Information block (DE.lix) provides the means
for capturing data item by item for facilitating this kind of approach

Significance of Validation:
 Subsystem Validity − A model itself may not have any existing system to compare it with, but it
may consist of a known subsystem. Each of that validity can be tested separately.
 Internal Validity − A model with high degree of internal variance will be rejected as a stochastic
system with high variance due to its internal processes will hide the changes in the output due
to input changes.
 Sensitivity Analysis − It provides the information about the sensitive parameter in the system to
which we need to pay higher attention.
 Face Validity − When the model performs on opposite logics, then it should be rejected even if
it behaves like the real system.
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Outcomes:

Analyze simulation results to reach an appropriate conclusion.

Conclusion:
Thus we implemented the manufacturing system problem in ExtendSim Simulation Software.

Grade: AA / AB / BB / BC / CC / CD /DD

Signature of faculty in-charge with date

References References:

Books/ Journals/ Websites:

1. Jerry Banks, John Carson, Barry Nelson, and David M. Nicol; “Discrete Event System
Simulation”, Fifth Edition, Pearson Education.
2. Jerry Banks, John Carson, Barry Nelson, and David M. Nicol; “Discrete Event System
Simulation”, Third Edition, Pearson Education.
3. ExtendSim 8 Manual (Departmental Library)