Assignment 2

Group Project
Virtual Production

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 Door manufacturing
Introduction
A door manufacturer is building a new manufacturing line where they will produce six different door
variants. The doors can be large or small and either black, red, or green as illustrated in Figure 1.
However, many of the details are unknown and you will have to make assumptions and
simplifications of the line.

Figure 1: Door variants

Objective:
Your objective is to build a model that incorporates all details listed below and has no late parts while
maintaining a low WIP.

Equipment
The company have provided a list with the operations being purchased. For each step relevant data
will be provided, such as processing time for the different variants, availability, MTTR and set-up
time.

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Door parts
The doors that will be produced are:

• smallBlack
• smallRed
• smallGreen
• largeBlack
• largeRed
• largeGreen

Layout and operations

Build the simulation model according to the flowchart in Figure 2, add buffers if needed. The buffers
have a dwell time of 10 seconds, the exception is the drying after Op70 which has a dwell time of 8
hours. The capacity is up to you to decide but you are aiming for the minimum amount of WIP. Every
automatic station has an availability of 95 % and MTTR of 10:00 minutes. Whenever a station breaks
it needs an operator to repair it and every manual station needs an operator to perform the work.

At the quality control in Op80 there is a 2% risk that a door will be scrapped and an 8% risk that it
requires rework. When a door needs rework an AGV is needed to transport it to the rework and
another AGV is needed to transport it back to Op90.

Op80 uses an erlang distribution with a mean of 2:00, a standard deviation of 20, lower limit of 20
and an upper limit of 8:00. Op 60 has a different erlang distribution depending on if the door is large
or small. For a small door the mean is 11:00, standard deviation of 1:40, lower limit of 6:00 and an
upper limit of 20:00. For large doors it is the same except that the mean is 12:00 instead.

Each door variant has its own FGI storage where finished doors are stored and every 24 hours, 20 of
each door variant is moved to the drain. If a FGI storage runs out of doors, and cannot deliver, a
variable is increased by one for each non-delivered door. Your goal is to never have a late door.

To calculate how many stations are needed in each operation step you can use this formula.
𝑃𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑡𝑖𝑚𝑒
( )
𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦
𝑁𝑢𝑚𝑂𝑝 =
𝐴𝑐𝑡𝑢𝑎𝑙 𝑑𝑒𝑚𝑎𝑛𝑑
For Op10 this calculation is (660/0,95)/420 = 1,65 rounded up this is 2 stations. The 600 is the
processing time in seconds, 0.95 is the 95 % availability and 420 is the actual demand in seconds.

In Op30 there is a set-up time of 2:00 depending on if the door is small or large. In Op70 there is a
setup time of 1 hour depending on which colour the door has. The easiest way to create an attribute
is to do it in the source table attribute. You first need to write something in the attribute column, for
example attribute, before you can open it. Then create two attributes named Size and Colour of the
datatype string. This can then be used by the operations to determine if a set-up is needed or not.

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 Figure 2: Flowchart of the simulation model

smallBlack smallRed smallGreen largeBlack largeRed largeGreen

Op10 10:00 10:00 10:00 11:00 11:00 11:00
Op20 6:30 6:30 6:30 6:30 6:30 6:30
Op30 7:30 7:30 7:30 7:30 7:30 7:30
Op40 16:40 16:40 16:40 16:40 16:40 16:40
Op50 2:00 2:00 2:00 2:00 2:00 2:00
Op60 11:00 11:00 11:00 12:00 12:00 12:00
Op70 31:00 31:00 31:00 31:00 31:00 31:00
Drying 8:00:00 8:00:00 8:00:00 8:00:00 8:00:00 8:00:00
Op80 2:00 2:00 2:00 2:00 2:00 2:00
Rework 1:00:00 1:00:00 1:00:00 1:00:00 1:00:00 1:00:00
Op90 5:00 5:00 5:00 5:00 5:00 5:00
Op100 6:00 6:00 6:00 6:00 6:00 6:00

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Aiming for higher grade
This describes the project scope (additionally) in order to get the 4 or 5 of the course. However, you
don’t need to implement all of the points below in order to get a higher grade, but it is a good indication
of what can be done in order to achieve a higher grade.
The following points are expected for a higher grade:
• Code: Very well-structured and well commented program code. The code is “general” and
flexible and no or few lines use “hard-coded” logic with for example object names. Instead
lists, anonymous identifiers and user attributes are used
• Selected tasks more from the list of additional tasks and/or selected tasks marked with a
“higher grade” in the project specification (e.g. operators).
• Low average WIP.
• A very good presentation of the project.
• Additional tasks.

Additional tasks that can be solved for higher grade:

1. In addition to the repair and processing jobs in the previous model the workers will also have
to move material between Op10_1 (and Op10_2) and a buffer before Op20 manually i.e.,
carry the parts between. The aim is to use as few workers as possible, and they are not
allowed to perform the same job. For example, if worker 1 is performing the processing in
Op70 no other worker is allowed to perform the processing in Op70 or if a worker is
performing the repair for Op60_1 no other worker is allowed to perform the repair for
Op60_1. You should still have no late products. However, you may add a buffer if necessary.
The placement of the workplaces is important and should be placed near the stations, but
the orientation is up to you, see the figures for examples. In order to make sure you have as
few workers as possible you need to analyze the workers.

2. Create a function that assign the availability and MTTR to all stations from a datatable at the
start of the simulation. Only one failure is allowed to be on any one station and all valid
values for availability and MTTR must be considered. If the station does not have a failure i.e.
the row for that station does not have any values the failure must be removed from the
station. If you change the values in the datatable the machine values should also change
without having to open the machine.

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 3. Making sure that parts aren’t mixed between different batches that may cause long
unnecessary sequence-dependent setups. See the picture below for example of want you
want to avoid.
4. Make so that the AGVs also make the transport between Op80 and DrainScrap. You can’t add
any more AGVs.
5. Pull logic from FGI to the beginning of the production line to avoid blocking and minimize WIP
in the system.
6. You make improvements outside of the scope with a good technical solution, this can also lead
to higher grades.

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