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Newiln
 Problem Question
A foundry employs 18 molders to process incoming orders wh
ich arrive on average every hour, exponentially distribute
d. The foundry runs on a 8 hour day, five days week schedu
le. Thirty percent of the incoming orders are new and Seve
nty percent are repeat orders. New order requires a patter
n which is made in the pattern shop taking 72±24 hours, un
iformly distributed. Patterns for repeat orders must be lo
cated and cleaned and takes 5±3 hours. Orders vary in size
from 6- 24 components, uniformly distributed. The weight o
Frequency components0.13
f the individual 0.37
varies 0.35 0.15
according to the follow
ing table.
Weight of part 5 15 32 35
Weight Distribution

Molding time is 2mins per Kg weight of the component. The

due date for orders is determined by the total molding tim
e plus variable flow time, which typically ranges from40 t
 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18

3 Jobs: Selection
Variable
Arrival
Pattern
Moulding Lead Time
Rate
1.PatternUD(72,24)
VLT=UD(100,60)
1.New:
1.Order Selection
Exponential
Size:
Distribution
UD(15,9)
2.Moulding
2.Old:
2.Weight/Part
Mean: UD(5,3)
1hr
3.Variable Lead Time
1. R<0.13; wt=5before
Shipment
2. R<0.50; wt=15
3. R<0.85;
2 Type wt=32
Customers
4. R>0.85; wt=35
1.Old
2.New
MT=2*wt*os/60
 Start

Initialize
3

A Customer Arrives

Determine Arrival Time o

f next Customer

No Is any Serv Yes

er Free?

Add Customer to Queue Make Server busy

2 1
 1

No Is the Moul Yes Determine Time for finding Patter

Determine Pattern making time.
d Old? n

Determine Order Size

Generate Random Number

Determine Moulding Ti Yes No

R<0.13
me
Yes No
R<0.5

Determine Moulding Time Yes

R<0.85

Determine Moulding Ti No
me

Determine Moulding Tim

e

Determine Service Time and Service C

ompletion time

2
 2

AT NMI SCT
E

ES

Update Clock to next Arri Compute and Print Statis Update clock to Service c
val Time tics ompletion Time

3 STOP Make Server Free

Is Anyo
Yes
ne Wai
ting

No Make Server Busy. T

ake next Customer f
rom Queue and upd
ate Queue Length
2

1
 Start

I, CS, CT, Q, Ser=0, K, IA

T, AT, R, PT, OS, MT, VF
T, ST, ES=80, SST, SSCT,
SCT, L, BIG=100000, mins
ct=BIG

I++
4

IAT=ED(λ)=ln(1-R)/ λ
AT(I)=CT+IAT

K=1

No Yes
K++ Is Ser(K)=0 1

Yes
K<=18

No
Q++

3
 1

Ser(K)=1, CS++,
R=Generate Random Number

Yes R<0. No
PT(CS)=UD(72,24) PT(CS)=UD(5,3)
3

OS(CS)=UD(15,9)
R=Generate Random Number

MT(CS)=(2*OS(CS)*5)/ Yes No
R<0.13
60
Yes No
R<0.5

MT(CS)=(2*OS(CS)*15)/60 Yes
R<0.85

MT(CS)=(2*OS(CS)*32)/ No
60

MT(CS)=(2*OS(CS)*35)/6
0
VFT(CS)=UD(100,60), SST(CS)=CT,
ST(CS)=PT(CS)+MT(CS)+VFT(CS),
SSCT(K)=SST(CS)+ST(CS), SCT(CS)=S
SCT(K)

2
 2

K=1

Is
No
SSCT(K)<minsc
t
Yes

Minsct=SSCT(K)

L=K

K++

Yes K<=18

No

3
 3

AT SCT
NMIE

ES
CT=AT(I) CT=SCT(CS)

I++ Compute and Print Statis Ser(L)=0

tics

Yes
4 Q>0 Q--
STOP

No
K=L
SSCT(L)=BIG
Minsct=BIG

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