1 By Terence James Haydock Manufacturing Cell A simulated response in Arena.

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By Terence James Haydock

Manufacturing CellA simulated response in Arena

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Overview

• Introduction

• Modelling Approach

• Model Layout

• Animation

• Process and Transfer Times

• Tutorial (step by step guide)

• Results

• Summary

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Introduction

Two types of parts arrive at a four-machine system according to an exponential distribution

with a mean of 25 minutes. Eighty percent of the parts entering the system are Part A’s and

the remaining twenty percent are Part B’s.

Parts move through the following stations with the processing times shown below. All

processing times shown are in minutes and follow the triangular distribution.

Aim: To simulate a manufacturing cell in Rockwell Arena.

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Modelling Approach

MODELLING APPROACH

• Part arrivals: Use the Create module to model part arrivals.

• Machines: Use Process modules to model the machines.

• Warehouse: Use the Dispose module to model the warehouse.

• Routes: Use Routes to define the movement paths.

• Process plans: Use the Sequences module to define the part process

plans.

Run the simulation for 80 hours and collect statistics on the machine

utilization and part flowtime.

From To Time (minutes)

Part Arrival Machine 1 2

Machine 1 Machine 2 2

Machine 2 Machine 4 2

Part Arrival Machine 3 2

Machine 3 Machine 2 2

Machine 4 Warehouse 4

Type A Machine 1 ( 18 , 19 , 20 )

Machine 2 ( 18 , 20 , 22 )

Machine 4 ( 18 , 20 , 22 )

Type B Machine 3 ( 15 , 20 , 25 )

Machine 2 ( 25 , 26 , 27 )

Machine 4 ( 20 , 30 , 31 )

Processing Times

Transfer Times

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Model Layout

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Animation Layout

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Step by Step guide

Aim: Visualization if your part through the system and define transfer times.

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Or, right click on row & edit via dialogue box

Double click on row

Aim: define the sequence of your parts through the system and operating times.

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Repeat for Part BAim: define process plans and a triangular distributed time for machine processes

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Provide Set Module

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Aim: Create the arrival of your parts

Aim: Assign attributes to the entities i.e. your parts

Aim: define arrival station

Aim: define route sequence

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Aim: arrival, process and leave of your part, all associated with machine 1

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Aim: arrival, process and leave of your part, all associated with machine 2

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Aim: arrival, process and leave of your part, all associated with machine 3

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Aim: arrival, process and leave of your part, all associated with machine 4

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Aim: send your parts to the warehouse, while also taking count of the flowtime and the number of parts disposed of i.e. manufactured

Aim: provide animation for visual reference

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Report / ResultsAnalyze the results and offer improvements to the model. Here it can be seen that machine 3 has a much lower usage than the rest.

What would you propose to better utilize the system? A different layout/floor plan maybe?

Now you have completed the tutorial your aim is to study and dissect the model to gain further knowledge of the process in play.

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Summary

Rockwell Arena software is a valuable tool for analysing discrete

event simulations. The ability to incorporate variables, recourses

and assign attributes to entities allows the user to simulate real life

processes, in this case a manufacturing cell. Furthermore, by

studying the generated results you are able to offer intelligent

alternatives to the system in order to bring about improvements.

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References

W.D. Kelton et al Simulation with Arena –4th Edition McGraw-Hill 2007