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You are on page 1of 52

What We’ll Do ...

• Model 5.1: • Model 5.2:

Electronic assembly/test system

– Modeling approaches – Stations, Transfers, Pictures

Enhanced electronic assembly/test

• Model 5.3:

– Resources, Resource States, Schedules – Saving statistical data – Output Analyzer (data display only)

Enhancing the animation

**– Queues, Entity Pictures, Resource Pictures – Adding Plots and Variables
**

Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs

5-2

What We’ll Do ... (cont’d.)

• Input analysis

– – – – – – – Specifying input distributions, parameters Deterministic vs. random input Collecting and using data Fitting input distributions via the Input Analyzer No data? Nonstationary arrival processes Multivariate and correlated input data

Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs

5-3

**Electronic Assembly/Test System (Model 5.1)
**

Part A Prep Part A

EXPO(5) TRIA(1,4,8)

Rework

20%

Scrapped

80%

Sealer

9%

EXPO(45)

**Arrivals Part B Prep Part B
**

Batches of 4 EXPO(30) TRIA(3,5,10) Part A TRIA(1,3,4) Part B NORM(2.4,0.5)

91%

Salvaged and Shipped

Shipped

• Produce two different sealed elect. units (A, B) • Arriving parts: cast metal cases machined to accept the electronic parts • Part A, Part B — separate prep areas • Both go to Sealer for assembly, testing — then to Shipping (out) if OK, or else to Rework • Rework — Salvage or Scrap

Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs

5-4

Part A

• Interarrivals: expo (5) minutes • Transit times between all stations:

2 min.

**• Go to Part A Prep area
**

• Go to Sealer

– No wait for person, cart to transfer — parts have their own feet (relax this assumption in Chapt. 7) – Process = (machine + deburr + clean) ~ tria (1,4,8) – Process = (assemble + test) ~ tria (1,3,4) min. – 91% pass, go to Shipped; Else go to Rework

**• Rework: (re-process + testing) ~ expo (45)
**

– 80% pass, go to Salvage/Ship; Else go to Scrap

Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs

5-5

go to Salvage/Ship. 5-6 . expo (30) min.5) min. • Transit times between all stations: 2 min. though at same station – 91% pass.4.10) – Process = (assemble + test) ~ norm (2.5. . different from Part A. Else go to Scrap Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs • Rework: (re-process + test) = expo (45) min. 0. Else go to Rework – 80% pass.Part B • Interarrivals: batches of 4. go to Shipped. • Go to Part B Prep area • Go to Sealer – Process = (machine + deburr +clean) ~ tria (3.

salvaged/shipped parts. transfers) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5-7 . Animation • Start empty & idle.Run Conditions. scrapped parts • Animation: – Queues. busy/idle resources as before – Entity movement between stations (2 min.000 minutes • Output: – – – – Utilization of all resources Number in each queue Time in each queue Cycle time (flowtime) separated out by shipped parts. Output. run for 2.

data structures. Scrap Transfer times: Route Attribute Sealer Time assigned at Arrival (parts have different times at the Sealer station) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5-8 . Salvage. represent logic This model: – – – – – – Separate Arrive modules for two part types Separate Server modules for each Prep area Inspect modules for Sealer and Rework Depart modules for Shipping. modules.Developing a Modeling Approach • Define submodels. • • • control logic Appropriate level of detail — judgment call Often multiple ways to model.

physical station Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5-9 . landing pads” • Each Station has a unique name • Station marker: • Can separate logical station. transfer generally • Provide animation “launching.Stations • Up to now: • Station: no (zero) transfer times between stations — realistic?? Physical location for an activity (or a group of activities) • Way to model entity flow.

Station Transfers • Send an entity from one station to another • Modeling options: – – – – – Connect (zero time) Route (possibly positive time. communications) Transporters Conveyors • Animation facility for each transfer option – For Route: Route object from Animate toolbar Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .10 . no constraints) Resource-constrained (freeway.

Salvage. for Sealer and Rework) Depart (three. and Scrap) Simulate • Right mouse button — repeat last action Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .11 . for Shipping.Roughing Out the Model • New model window • Attach Common Panel • Place modules – – – – – Arrive (two) Server (two. for Prep Areas) Inspect (two.

Add… button – Attribute: Sealer Time (type it in) – Value: TRIA(1.12 .Part A Arrive Module • Main dialog (default what’s not mentioned) – Enter Data • Station: Part A Arrive (type it in — first mention) – Arrival Data – Leave Data • Time Between: EXPO(5) (pull-down list) • Mark Time Attribute: Arrival Time (type it in) • Station: Part A • Route Time: 2 Prep (type it in) • Assign subdialog (button).4) (pull-down list) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .3.

0. except: – – – – – Station: Part B Arrive Batch Size: 4 Time Between: EXPO(30) Leave Data Station: Part B Prep Attrib.Part B Arrive Module • Same as for Part A Arrive.13 .5) • Each arrival creates four separate entities – Quadruplets separated at birth – Flow independently – Independent Sealer Time values assigned Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .4. Sealer Time Value: NORM(2.

etc. Resource Statistics.4.14 . subdialogs (Queue.Part A [B] Prep Server Modules • Exploit pull-downs where possible (Station • Main dialog – Enter Data names.5. Resource.8) [TRIA(3. Attribute names) for earlier definitions • Station: Part A Prep [Part B Prep] (pull-down) TRIA(1.) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs • Station: Sealer (type) • Route Time: 2 5 .10)] – Server Data – Leave Data • Process Time: • Accept defaults for Resource name.

Sealer Inspect Module • Main dialog – Enter Data • Station: Sealer (pull-down) – Server Data • Process Time: Sealer Time (attribute.15 . must type in) • Failure Probability: 0.09 (type) • Station: Shipping (type) • Route Time: 2 (type) • Station: Rework (type) • Route Time: 2 (type) – Pass Inspection Leave Data – Fail Inspection Leave Data Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .

Rework Inspect Module • Main dialog – Enter Data • Station: Rework (pull-down) – Server Data • Process Time: EXPO(45) (type) • Failure Probability: 0.2 (type) • Station: Salvaged Parts (type) • Route Time: 2 (type) • Station: Scrap (type) • Route Time: 2 (type) – Pass Inspection Leave Data – Fail Inspection Leave Data Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .16 .

and Scrap – Enter Data Shipping.Depart Modules • Three separate modules: Parts. Salvaged • Main dialog for Shipping (others are similar) • Station: Shipping (pull-down) select (accept default counter name) – Count • Individual Counter: – Tally • Individual Tally: select • Attribute: Arrival Time (accept Interval default selection) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .17 .

18 .0) Initialize everything between replications Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . Munchkin • Length of Replication: 2000 and Test – Replicate • Accept defaults for – – – – Date (computer clock) Number of Replications (1) Beginning Time (0.Simulate Module • Specify termination rule (among other things) • Main dialog – Project • Title: Electronic Assembly • Analyst: Mr.

maybe click ―corners‖ for polyline route. orientation (just accept all defaults. hit OK) – Cursor changes to crosshairs – Click in beginning station. click in ending station – Repeat for all Routes to be animated (right click) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .Animated Routes • Paths to display entities during transfers • Animate panel.19 . Route button – Not necessary for numerical results – Just for animation to connect Stations – Route dialog for appearance.

Run • Check (if desired) • Go (will automatically pre-Check if needed) • Pause • Fast Forward – Step – Double-click on things to see status (debug) – Even faster: Run/Setup…/Mode/Batch Run (No Animation) before running – Find button to help find errors • . remove toolbars during run (they return) • Full-screen mode: Run/Setup…/Miscellaneous Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .20 .

a.. Discrete Change (a. max. number of observations or final value – For 95% confidence interval on steady-state (long-run) expected average – May not have enough data (see Chapter 7 . time-persistent).out • Half Width column: – Columns for averages.21 .Viewing the Results • When done. Counters areas (if present in model) – Uses Notepad or other viewer in separate window – Also saves as text file model_name.k. asked if you want to see numerical results (text) • Tally..) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . min.

Resource Failures Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . Resource States.22 .Enhanced Model (Model 5.2) • A Story – Original model shown to production manager – Pointed out that this is only the first shift of a two-shift day — on second shift there are two operators at Rework (the bottleneck station) – Pointed out that the Sealer fails sometimes • Need: • Uptimes ~ exponential. mean 2 hours • Repair times ~ exponential. mean 4 minutes Schedules.

23 . Inspect.Schedules • Vary Capacity (number of units) of a resource over time • Alternative to “Capacity” Capacity Type in Server. unavailable Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . Process modules • Arena actually has four automatically defined Resource States. keeps statistics on all: – – – – Idle (as before) Busy (as before) Inactive: capacity reduced to zero Failed: model downtimes.

it defaults to infinity Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . schedule repeats forever • If any duration is empty.) • Server Data area: – For Capacity Type. pick Schedule rather than Capacity (pull-down) – ―Capacity‖ box changes to: • Schedule — name the schedule (defined below) • Choice between Preempt/Ignore/Wait — what if resource is busy when scheduled to go down? (See book. duration) pairs • If all durations are specified.24 .) – Get a new Schedule… button below — push it • Schedule subdialog • Add (capacity.Schedules (cont’d.

Resource Downtimes • Bring one unit of a resource down — other units (if any) still up • Resource… button – Downtime Name – Time Between Downtimes (anything — pull-down for distributions) – Downtime (anything. distribution pull-down) • Can have multiple Downtimes (separate names) for a Resource Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .25 .

the Uptime – Downtime (anything. the Count for uptime If based on Time.26 .Resource Failures • All units of a resource come down • Resource… button – – – – Failure Name Based on entity Count or elapsed Time Preempt/Ignore/Wait for come-down rule If based on Count. distribution pull-down) • Can have multiple Failures (separate names) for a Resource Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .

Saving Statistical Data • Observe.) • How? Statistics module (Common panel) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .27 . maybe save different kinds of data – Non-default output performance measure • e. Tallies. etc. Counters.. “Frequencies” (new) – Export to other applications (spreadsheets. statistical inference • Save records of Time-Persistent data. % of time queue length > 5 – Postprocessing via Output Analyzer • Note that dynamic animated plots disappear when done • Statistical analysis of output data.g.

Add… button for what you want • Time-Persistent area – Subdialog depends on type area (type of stat) – Option to save data to a (binary) file — “name.28 . name could include drive.The Statistics Module • Five different areas. for different kinds of stats • In an area.dat” (including the double quotes). later dialogs react to selection – Select Tally Name • Tallies area • Other areas discussed later . path – Select data object... Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .

available 5 . – Statistics module. 20]. or State Want to know % of time the Rework queue is of length 0.Frequency Statistics • A “finer” description of an output • Record time-persistent occurrence frequency of a • Example: Variable. Expression. (10. 10]. busy MR(resource name): no. general expression • Arena function • Others: NQ(queue name): queue length NR(resource name): no. Frequencies area – Add… button – Expression: Variable.29 – Define categories (Constant or Range) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs . etc. (0.

also accessible via Tools • • menu in Arena Reads binary files saved by Arena Various kinds of output-data display. analysis – For now: just data-display functions • Advisable (not required) — define. then Add…) – List of output files of interest — one model or many – Eases tasks by ―screening‖ for these files only – Save in file called whatever. Open next time Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .dgr.The Output Analyzer • Separate application.30 . maybe save a data group (File/New or .

31 .) • Plot time-persistent data • Moving-average plots – Graph/Plot or – Can overlay several curves (Sensible? Units?) – Options for plot Title. crop axes : “smooth” over time • Barcharts : like Plot. cosmetically different • Histograms of data – Beware: autocorrelation Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs – Moving-average window Value – Exponential smoothing. Forecasting 5 .The Output Analyzer (cont’d. axis Labels.

enhance it a bit • Can pull animation away from model logic in model window – Useful for big models. or closeups of parts of animation Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs – Usually sufficient for verification. impact 5 . validation – More realism.32 . animation.3) • Get “Spartan” generic default animation for many things • Often want to customize.Enhancing the Animation (Model 5. complex animation – Set up Named Views for model logic.

then OK Drag them around on screen Check Rotate box to show entities turning Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .33 .Changing Animation Queues • Lengthen (click. drag. maybe hold shift) • Rotate to re-orient for realism • Change the “form” of the queue from Line (the default) to Point — fixed places for entities – – – – – – Double-click on the queue Select Type to be Point Click Points… button Successively click Add for points.

including: – Arrive: choose different Initial Entity Picture – Server: Change when entering or leaving – Inspect: Change when entering.34 . or ―fail‖ leave Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs • Give desired Picture a name here 5 . ―pass‖ leave. change them in process.Changing the Entity Pictures • Distinguish between entity types. realistically represent batches • Default picture: above Simulate module • Define different picture: Animate… button and subdialog in many modules.

35 .3) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .plb file). must edit/create/read – – – – – Double-click on default picture above Simulate Make sure Default picture is selected (depressed) Copy. select desired picture from scrolling • Reference point — where entity moves. sits • Application: “hidden” batches (Model 5. hit << button • Double-click to edit (for artists only) • Open Picture library (. select the copied picture Select name from Value pull-down to rename copy Either window.Changing the Entity Pictures (cont’d.) • After defining names.

indicate state (Idle.) • Adjust size — Size Factor • Multiple-capacity resources – Multiple seize points (Rework resource.Changing Resource Pictures • Realism.plb files) • Seize point — place for realism (layers. Model 5.3) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs – Example: Sealer resource in Model 5. Busy.36 .3 5 . edit similarly to entity pictures – Artwork – Picture libraries (.) • Double-click. etc. etc.

of plot points to display at a time Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .37 .Adding Plots and Animated Variables • Animate module from Common panel • Select Data Object to observe • Select Information to display (depends on Data Object selected) – Alternative: Animate toolbar buttons. but Animate module is easier • Check off mode(s) of display (default: – For Plots: all) • Have to guess at Max Y (maybe revise after run …) • History Points = no.

Distributions • Structural modeling: what we’ve done so far • Quantitative modeling – Logical aspects — entities. need to observe system’s operation. etc. – Numerical. distributional specifications – Like structural modeling.Input Analysis: Specifying Model Parameters. take data if possible Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . resources. paths.38 .

“draw” or “generate” values from to drive simulation – Transfer.a. fixed values • Random (a. Processing times – What distribution? What distributional parameters? – Causes simulation output to be random.k. processing times (?) model as a distribution.Deterministic vs. too Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs • Don’t just assume randomness away — validity 5 . Random Inputs • Deterministic: nonrandom.39 . stochastic): – Number of units of a resource – Entity transfer time (?) – Interarrival. Interarrival.

boring – System might not exist – Data available on the wrong things — might have to change model according to what’s available – Incomplete. ―dirty‖ data – Too much data (!) • Sensitivity of outputs to uncertainty in inputs • Match model detail to quality of data • Cost — should be budgeted in project • Capture variability in data — model validity • Garbage In.Collecting Data • Generally hard. Garbage Out (GIGO) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . expensive.40 . frustrating.

41 .Using Data: Alternatives and Issues • Use data “directly” in simulation – Read actual observed values to drive the model inputs (interarrivals. …) – All values will be ―legal‖ and realistic – But can never go outside your observed data – May not have enough data for long or many runs – Computationally slow (reading disk files) – ―Draw‖ or ―generate‖ synthetic observations from this distribution to drive the model inputs – We’ve done it this way so far – Can go beyond observed data (good and bad) – May not get a good ―fit‖ to data — validity? Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs • Or. part types. fit probability distribution to data 5 . service times.

42 . also accessible via Tools menu in Arena – Fits distributions.Fitting Distributions via the Arena Input Analyzer • Assume: – Have sample data: Independent and Identically Distributed (IID) list of observed values from the actual physical system – Want to select or fit a probability distribution for use in generating inputs for the simulation model – Separate application. gives valid Arena expression for generation to paste directly into simulation model Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs • Arena Input Analyzer 5 .

43 . empirical. empirical distribution • Continuous vs.) • Fitting = deciding on distribution form (exponential. distribution • “Best” fit from among several distributions Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs • H0: fitted distribution adequately represents the data • Get p value for test (small = poor fit) 5 . …) – Assess goodness of fit via hypothesis tests • Fitted “theoretical” vs.Fitting Distributions via the Arena Input Analyzer (cont’d. discrete data.) and estimating its parameters – Several different methods (Maximum likelihood. moment matching. etc. gamma. least squares.

. spreadsheet. ..) – Must be plain ASCII text (save as text or export) – Data values separated by white space (blanks. word processor.Data Files for the Input Analyzer • Create the data file (editor. tabs.44 . basic summary of data To see data file: Window/Input Data menu • Open data file from within Input Analyzer • Can generate “fake” data file to play around – File/Data File/Generate New … menu Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . linefeeds) – Otherwise free format – – – – File/New menu or File/Data File/Use Existing … menu or Get histogram.

The Fit Menu • Fits distributions. Ctrl+V) over into simulation model – May include ―offset‖ depending on distribution – Gives results of goodness-of-fit tests • Chi square. if the the fitted distribution is truly ―the truth‖ ―Small‖ p (< 0.05 or so): poor fit (try again or give up) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . Kolmogorov-Smirnov tests • Most important part: p-value.45 . always between 0 and 1: Probability of getting a data set that’s more inconsistent with the fitted distribution than the data set you actually have. does goodness-of-fit tests • Fit a specific distribution form – Plots density over histogram for visual ―test‖ – Gives exact expression to Copy and Paste (Ctrl+C.

ranked: Window/Fit All Summary or Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .) • Fit all Arena’s (theoretical) distributions at once – Fit/Fit All menu or – Returns the minimum square-error distribution • Square error = sum of squared discrepancies between histogram • frequencies and fitted-distribution frequencies Can depend on histogram intervals chosen: different intervals can lead to different ―best‖ distribution – Could still be a poor fit.The Fit Menu (cont’d. though (check p value) – To see all distributions.46 .

47 . Value) • Continuous: Arena will linearly interpolate within the data range according to these pairs (so you can never generate values outside the range. or intentionally Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .The Fit Menu (cont’d. which might be good or bad) – Empirical distribution can be used when ―theoretical‖ distributions fit poorly.) • “Fit” Empirical distribution (continuous or discrete): Fit/Empirical – Can interpret results as a Discrete or Continuous distribution • Discrete: get pairs (Cumulative Probability.

g. gamma) – Bounded (e. normal) – Positive (e. variances Simulation model sensitivity analysis Outliers..g.. exponential. uniform) Some Issues in Fitting Input Distributions • Consider ease of parameter manipulation to • • affect means.• Not an exact science — no “right” answer • Consider theoretical vs.48 . multimodal data – Maybe split data set (see textbook for details) Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .g. empirical • Consider range of distribution – Infinite both ways (e. beta..

some (bad) options: – Interview ―experts‖ • Min.49 . Max: Triangular Uniform – Mode can be different from Mean — allows asymmetry – Interarrivals — independent.No Data? • Happens more often than you’d like • No good solution.. Max: Uniform • Avg. Mode. stationary • Exponential— still need some value for mean – Number of ―random‖ events in an interval: Poisson – Sum of independent ―pieces‖: normal – Product of independent ―pieces‖: lognormal Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 . % error or absolute error: • Min.

50 Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs . etc. valleys can mask important behavior – Can miss rush hours.Nonstationary Arrival Processes • External events (often arrivals) whose rate varies over time – – – – Lunchtime at fast-food restaurants Rush-hour traffic in cities Telephone call centers Seasonal demands for a manufactured product • It can be critical to model this nonstationarity for model validity • Good model: – Ignoring peaks. Nonstationary Poisson process 5 .

Nonstationary Arrival Processes (cont’d.51 . rate = 45/30 = 1. 11 …) Several ways to estimate rate function — we’ll just do the piecewise-constant method – Divide time frame of simulation into subintervals of time over which you think rate is fairly flat – Compute observed rate within each subinterval – Be very careful about time units! • Model time units = minutes • Subintervals = half hour (= 30 minutes) • 45 arrivals in the half hour.) • Two issues: • – How to specify/estimate the rate function – How to generate from it properly during the simulation (will be discussed in Chapters 8.5 per minute Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs 5 .

52 .Multivariate and Correlated Input Data • Usually we assume that all generated random observations across a simulation are independent (though from possibly different distributions) • Sometimes this isn’t true: • Ignoring such relations can invalidate model • See textbook for ideas. references Simulation with Arena — Chapter 5 — Modeling Basic Operations and Inputs – A ―difficult‖ part requires long processing in both the Prep and Sealer operations – This is positive correlation 5 .

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