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Solving Manufacturing Problems Using Simulation Modeling

Ebook

The curriculum of the Faculty of Management includes courses that focus on the use of simulation modeling programs in production management. This book is intended to be used as part of these subjects. The book can also be used in English-language studies or courses jointly implemented by universities from diff erent countries.
The specific objectives of the lessons are for students to gain the ability to use simulation programs, to learn the methodology of researching the improvement of production processes using these programs, and to strengthen the concepts of management and organization of production. Some of the issues also relate to production logistics, including internal transportation and storage systems.
The book consists of sixteen chapters. The layout of each chapter from the 1st to the 15th is similar. It includes an identifi cation of the aim of the exercise, a description of the problem to be analyzed, a description of the objects and tools used, the building of the simulation model, assumptions for carrying out the simulation, and guidelines for performing an analysis of the solutions obtained. In the [1, 3, 5, 6, 8-11, 13, 15] exercises, the Tecnomatix Plant Simulation software, version 15, was used, and in the [2, 4, 7, 12, 14] exercises, the FlexSim 20.1.3 software was used. Inthe 16th exercise, the Production Line - Car Factory computer game, educational version, was used. For this reason, the layout of Exercise 16 is slightly diff erent.

Introduction 11

1. Modeling of production ﬂow 13

1.1. Purpose of the exercise 13

1.2. Description of the problem/process 13

1.3. Used objects/tools 13

1.4. Structuring of the model 15

1.4.1. Structuring of the model – Applying ParallelStation object 15

1.4.2. Structuring of the model – Applying AssemblyStation object 16

1.4.3. Structuring of the model – Applying Conveyor and TransferStation objects 16

1.4.4. Structuring of the model – Applying FlowControl object and SankeyDiagram tool 18

1.4.5. Structuring of the model – Model the work of employees 18

1.5. Assumptions for the performance of the simulation 19

2. Mapping material ﬂows in a production processes 21

2.1. Purpose of the exercise 21

2.2. Description of the problem/process 21

2.3. Used objects/tools 21

2.4. Structuring of the model 23

2.4.1. Structuring of the production process model – Basic objects 23

2.4.2. Structuring of the production process – Process ﬂow 24

2.5. Assumptions for the performance of the simulation 28

2.6. Guidelines for the analysis 28

3. Modeling manufacturing of bulk and liquid products31

3.1. Purpose of the exercise 31

3.2. Description of the problem/process 31

3.3. Used objects/tools 31

3.4. Structuring of the model 33

3.4.1. Structuring of the manufacturing process model – Basic objects 33

3.4.2. Structuring of the manufacturing process model – Adding Tank and Mixer object 34

3.4.3. Structuring of the manufacturing process model – Adding discrete objects and conveyors 36

3.5. Assumptions for the performance of the simulation 38

3.6. Guidelines for the analysis 38

4. Modeling production of ﬂuid products. Fluid library 39

4.1. Purpose of the exercise 39

4.2. Description of the problem/process 39

4.3. Used objects/tools 40

4.4. Structuring of the model 40

4.5. Assumptions for the performance of the simulation 44

4.6. Guidelines for the analysis 44

5. Modeling failures in the production processes45

5.1. Purpose of the exercise 45

5.2. Description of the problem/process 45

5.3. Used objects/tools 45

5.4. Structuring of the model – Basic objects 45

5.4.1. Structuring of the model – Basic settings parameters for failures 47

5.5. Assumptions for the performance of the simulation 48

5.5.1. Assumptions for the performance of the simulation – Machine maintenance 48

5.5.2. Assumptions for the performance of the simulation – Machine availability 49

5.5.3. Assumptions for the performance of the simulation – Tool change 50

5.6. Guidelines for the analysis 50

6. Using the Resource analysis tools to analyze production processes51

6.1. Purpose of the exercise 51

6.2. Description of the problem/process 51

6.3. Used objects/tools 51

6.4. Structuring of the model 51

6.4.1. Structuring of the manufacturing process model – Characteristics of the facilities CostAnalyzer and EnergyAnalyzer 53

6.4.2. Structuring of the manufacturing process model – Methods implementation 53

6.4.3. Structuring of the manufacturing process model – Adding basis model 54

6.5. Assumptions for the performance of the simulation 56

6.5.1. Energy analyzer 56

6.5.2. Cost analyzer 57

6.6. Guidelines for the analysis 57

6.6.1. Analysis of the electricity consumption 57

6.6.2. Cost analysis 58

7. Optimization of the company’s assortment – quantity production plan59

7.1. Purpose of the exercise 59

7.2. Description of the problem/process 59

7.3. Used objects/tools 59

7.4. Structuring of the model 60

7.4.1. Building a production model – Construction of a production area with the set of basic characteristics 60

7.4.2. Building a production model – Setting the characteristics of the production plan 61

7.4.3. Building a production model – Deﬁning basic parameters of the production process 62

7.4.4. Building a production model – Setting the limitation of the availability of the machine working time fund 63

7.4.5. Building a production model – Deﬁning the method of determining the income from the implementation of a given production program 63

7.5. Assumptions for the performance of the simulation 64

7.6. Guidelines for the analysis 65

8. Using assembly line balancing to improve production processes67

8.1. Purpose of the exercise 67

8.2. Description of the problem/process 67

8.3. Used objects/tools 68

8.4. Structuring of the model 69

8.4.1. Structuring of the manufacturing process model – Making a table of process¬ing times 69

8.4.2. Structuring of the manufacturing process model – Mapping the manufacturing process 71

8.4.3. Structuring of the manufacturing process model – Adding objects representing workplace 71

8.4.4. Structuring of the manufacturing process model – Building a system for gathering information 71

8.5. Assumptions for the performance of the simulation 73

8.6. Guidelines for the analysis 74

9. Using the U-shaped structure to improve the production line 75

9.1. Purpose of the exercise 75

9.2. Description of the problem/process 75

9.3. Used objects/tools 76

9.4. Structuring of the model 77

9.5. Assumptions for the performance of the simulation 78

9.6. Guidelines for the analysis 79

10. Using the Bottleneck Analyzer tool to identify bottlenecks 81

10.1. Purpose of the exercise 81

10.2. Description of the problem/process 81

10.3. Used objects/tools 81

10.4. Structuring of the model 83

10.4.1. Structuring of the manufacturing process model – Basic objects 84

10.4.2. Structuring of the manufacturing process model – Machine failure settings 85

10.4.3. Structuring of the manufacturing process model – Shift schedule and employees 86

10.4.4. Structuring of the manufacturing process model – Lockout zone 87

10.5. Assumptions for the performance of the simulation 87

10.6. Guidelines for the analysis 88

11. Using the Experiment Manager tool to improve production processes89

11.1. Purpose of the exercise 89

11.2. Description of the problem/process 89

11.3. Used objects/tools 90

11.4. Structuring of the model 91

11.4.1. Building a production process model – Picking a potato pallet from the ware¬house and their transport to the production line 92

11.4.2. Building a production process model – Cutting, frying and salting fries 93

11.4.3. Building a production process model – Packing in bags and packing in collec¬tive packages 93

11.4.4. Building a production process model – Transport of ﬁnished products to the warehouse 94

11.5. Assumptions for the performance of the simulation 95

11.6. Guidelines for the analysis 96

12. Using the Experimenter tool to improve the production processes. 97

12.1. Purpose of the exercise 97

12.2. Description of the problem/process 97

12.3. Used objects/tools 98

12.4. Structuring of the model 99

12.5. Assumptions for the performance of the simulation 101

12.6. Guidelines for the analysis 101

13. Using the GAWizard tool in improving the production processes 103

13.1. Purpose of the exercise 103

13.2. Description of the problem/process 103

13.3. Used objects/tools 105

13.4. Structuring of the model 107

13.4.1. Structuring of the production process model – Creation of ﬂow objects and deﬁning variables 107

13.4.2. Structuring of the production process model – Lenses hardening process 107

13.4.3. Structuring of the production process model – Adding workers 108

13.4.4. Structuring of the production process model – Use of methods 109

13.5. Assumptions for the performance of the simulation 111

13.6. Guidelines for the analysis 111

14. Using the Optimizer tool to improve the production processes113

14.1. Purpose of the exercise 113

14.2. Description of the problem/process 113

14.3. Used objects/tools 115

14.4. Structuring of the model 115

14.4.1. Structuring of the production process model – Basic objects 115

14.4.2. Structuring of the production process model – Creation of ﬂow objects 117

14.4.3. Structuring of the production process model – Working week schedule 120

14.5. Assumptions for the performance of the simulation 120

14.6. Guidelines for the analysis 120

15. Building a production process model123

15.1. Purpose of exercise 123

15.2. Description of the problem/process 123

15.3. Used objects/tools 123

15.4. Structuring of the model 125

15.5. Assumptions for the performance of the simulation 126

15.6. Guidelines for the analysis 127

16. Simulation of the manufacturing process in the automotive industry using computer game Production Line – Car Factory 129

16.1. Purpose of the exercise 129

16.2. Description of the problem/process 129

16.3. Used objects/tools 129

16.4. Structuring of the model 130

16.4.1. Structuring of the manufacturing process model – Choice of production line location 131

16.4.2. Building of the manufacturing process model – Key workstations 131

16.4.3. Building of the manufacturing process model – Enabling ﬂow between stations 132

16.4.4. Structuring of the manufacturing process model – Attachment of material re¬sources 132

16.4.5. Building of the manufacturing process model – Additional functions133

16.5. Assumptions for the performance of the simulation 133

16.6. Guidelines for the analysis 133

List of tables135

List of ﬁgures 137

Tytuł: Solving Manufacturing Problems Using Simulation Modeling
Autor: Cezary Szwed, Justyna Smagowicz
ISBN: 978-83-8156-737-4, 9788381567374
Data wydania: 2025-06-25
Format: Ebook
Identyfikator pozycji: e_4i9d
Wydawca: Oficyna Wydawnicza Politechniki Warszawskiej