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MANUAL
IV YEAR I SEMESTER
DEPARTMENT OF MECHANICAL ENGINEERING
SREE VIDYANIKETHAN ENGINEERING COLLEGE
(AUTONOMOUS)
AFFILIATED TO JNTU ANANTHAPURAMU
SREE SAINATH NAGAR , A. RANGAMPETA
TIRUPATI
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INTRODUCTION TO SIMULATION
The process of building a logical or mathematical model of a system or a
decision problem, and experimenting with the model to obtain insight into
the systems behavior or to assist in solving the decision problem.
Implementing change can be a difficult task for any organization, big or
small. For this purpose modeling of complex systems such as manufacturing
systems is an arduous task. Simulation has gained importance in the past few
years and allows designers imagine new systems and enabling them to both
quantify and observe behavior. Whether the system is a production line, an
operating room or an emergency response system, simulation can be used to
study and compare alternative designs or to troubleshoot existing systems. With
simulation models, how an existing system might perform if altered could
explored, or how a new system might behave before the prototype is even
completed, thus saving on costs and lead times. Modeling and simulation are
emerging as key technologies to support manufacturing in the 21st century.
However, there are differing views on how best to develop, validate and
use simulation models in practice. Most development procedures tend to be
linear and prescriptive by nature. Several researchers have studied performance
by using simulation techniques with the first uses dating back to at least the
early 1960`s. Even though we have moved beyond the Industrial Age and into
the Information Age, manufacturing remains an important part of the global
economy. There have been numerous efforts to use modeling and simulation
tools and techniques to improve manufacturing efficiency over the last four
decades. While much progress has been made and an increasing number of
manufacturing system decisions are being made based on the use of models,
their use is still sporadic in many manufacturing environments. We believe that
there is a need for pervasive use of modeling and simulation for decision
support in current and future manufacturing systems. There are several
challenges that need to be addressed by the simulation community to realize this
vision.
The Simulation Process for Manufacturing Systems Analysis
The process of simulating manufacturing systems involves the following phases
and steps
A. Model Design:
1. Identify the issues to be addressed.
2. Plan the project.
3. Develop conceptual model.
B. Model Development
4. Choose a modeling approach.
5. Build and test the model.
6. Verify and validate the model.
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C. Model Deployment:
7. Experiment with the model.
8. Analyze the results
9. Implement the results for decision-making.
Most organizations that simulate manufacturing or material handling
systems use a commercial simulation software product, rather than a general-
purpose programming language like C. Furthermore, the two most common
criteria for selecting simulation software are modeling flexibility (ability to
model any system regardless of its complexity or uniqueness) and ease of use.
The major types of simulation software for manufacturing are defined now. A
simulation language is a software package that is general in nature (in terms of
the applications it can address) and where model development is done by
programming. Traditionally, programming meant the development of a
simulation model by writing code, but in recent years there has been a strong
movement toward simulation languages that employ a graphical model-building
approach. In the next wave, simulation languages were developed to speed up
the modeling process by allowing reuse of simulation constructs. These
languages included GPSS, SIMSCRIPT, GASP, SLAM, SIMAN, PROMODEL
and ARENA, AUTOMOD etc.
Manufacturing Systems
Modern high technology manufacturing systems, such as those in the
electronics, semiconductor, aerospace, and automotive industries, can be
extremely complex. The complexity of these systems is due to factors such as:
multiple part types made in the same facility/line, numerous manufacturing
steps (300-500 steps is not uncommon), batch processing, very complex
equipment which leads to high levels of preventive maintenance and downtime,
multiple levels of subassemblies, just to name a few. This complexity combined
with the high cost of setting up and maintaining such a system necessitates the
use of formal models of the system, rather than just relying on experience or
simple rules of thumb for performance evaluation and decision making.
Models are intended to support management decisions about the system and
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a single model will often not be capable of supporting all decisions. Rather,
different decisions require different models because various aspects of the
design and operation of the system will be important for the questions being
asked of the model. While spreadsheet and queuing models are useful for
answering basic questions about manufacturing systems, discrete event
simulation models are often needed to answer detailed questions about how a
complex manufacturing system will perform. Simulation models lend
themselves to incorporating additional details about the manufacturing system
and therefore often give more accurate estimates of manufacturing system
behavior than the simpler models mentioned above, but usually at the cost of
more computation. In general, simulation is a practical methodology for
understanding the high-level dynamics of a complex manufacturing system.
Simulation has several strengths including:
Time compression the potential to simulate years of real system
operation in a much shorter time,
Component integration the ability to integrate complex system
components to study their interactions,
Risk avoidance hypothetical or potentially dangerous systems can be
studied without the financial or physical risks that may be involved in
building and studying a real system,
Physical scaling the ability to study much larger or smaller versions of
a system,
Repeatability the ability to study different systems in identical
environments or the same system in different environments, and
Control everything
INTRODUCTION TO PROMODEL
ProModel is a powerful, Windows-based simulation tool for simulating
and analyzing production systems of all types and sizes. ProModel provides the
perfect combination of ease-of-use and complete flexibility and power for
modeling nearly any situation, and its realistic animation capabilities makes
simulation come to life. ProModel is a powerful yet easy-to-use simulation tool
developed specifically for engineers and production managers to help improve
the design and operation of manufacturing systems (for example job shops, flow
shops, assembly lines, Kanban systems, etc.). Benefits of ProModel include:
Elimination of Bottlenecks
Improved Operating Efficiency
Reduced Lead Times
Improved Resource Utilization
Reduced Inventories
ProModel provides Engineers and Managers the opportunity to test new
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ideas for system design or improvement before committing the time and
resources necessary to build or alter the actual system. ProModel focuses on
issues such as resource utilization, production capacity, productivity, and
inventory levels. By modeling the important elements of a production system
such as resource utilization, system capacity, and production schedules, you can
experiment with different operating strategies and designs to achieve the best
results. As a discrete event simulator, ProModel is intended primarily for
modeling discrete part manufacturing systems, although process industries can
be modeled by converting bulk material into discrete units such as gallons or
barrels. In addition, ProModel is designed to model systems where system
events occur mainly at definite points in time. Time resolution is controllable
and ranges from .01 hours to .00001 seconds.
Typical applications for using ProModel include:
Assembly lines
Job Shops
Transfer lines
JIT and KANBAN systems
Flexible Manufacturing systems
Supply chains & logistics
Use of ProModel requires only a brief orientation and virtually no programming
skills. With Pro-Model's convenient modeling constructs and graphical user
interface, model building is quick and easy. All you do is defining how your
particular system operates, mostly through part flow and operation logic.
Automatic error and consistency checking help ensure that each model is
complete prior to simulation. During simulation, an animated representation of
the system appears on the screen. After the simulation, performance measures
such as resource utilization, productivity and inventory levels are tabulated and
may be graphed for evaluation.
OVERVIEWOF PROMODEL
ProModel is a simulation and animation tool designed to quickly yet
accurately model manufacturing systems of all types, particularly supply
chain systems. Engineers and managers find the manufacturing oriented
modeling elements and rule-based decision logic extremely easy to learn and
use. Users are particularly delighted when they discover that ProModel is
capable of modeling their most complex systems. Because it provides such
an intuitive and straightforward approach to modeling, it is also attractive to
professors in engineering and business programs who are interested in teaching
modeling and analysis concepts without having to teach computer
programming.
While most systems can be modeled by selecting from ProModel's complete
set of modeling elements (e.g. resources, downtimes, etc.) and modifying
the appropriate parameters, complete programming capability is also
provided if needed for modeling special situations. Built-in language features
include if-then-else logic, Boolean expressions, variables, attributes, arrays and
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even access to external spreadsheet and text files.
For those who prefer coding complex logic using a programming
language such as C, Pascal or Basic, external subroutines may be dynamically
linked to the model and called from anywhere inside the model at runtime. In
this way, ProModel allows systems analysts and simulation experts to use the
tools they are most comfortable with to provide total flexibility.
ProModel also provides several built-in distribution functions which, in
conjunction with streams, return random values according to a statistical
distribution. To aid the user in selecting an appropriate distribution for a data
set, Stat::Fit is included with ProModel. Stat::Fit is a curve fitting software
that fits analytical distributions to user data.
Model development is completely graphical and ob- ject-oriented. To the
extent possible, all input is provided graphically with information being
grouped by object type and presented in a "spreadsheet-like" format for
quick and intuitive access. For example, when you define a machine you can
define its icon, capacity, downtime characteristics, input and output rules,
desired output statistics, etc. ProModel complies with GUI standards, which
means that individuals familiar with other standard Windows programs such as
word processing or spreadsheets will have no trouble learning how to use
ProModel. This data input approach minimizes the learning curve for
beginners and maximizes the efficiency for modifying large and complex
models.
A unique feature in ProModel is the ability to bring up a pop-up menu
depending on the current context that prompts the user in defining any
statement or expression. This enables any expression or statement to be
entered using only the mouse. It also eliminates the need to remember
variable or other element names that you wish to reference by allowing you to
select them from a list box.
Quick and convenient online documentation is available through
ProModel's integrated Help system and online tutorials. The Help system uses
the Windows Help system that allows maximum flexibility for looking up
anything from command syntax to descriptions of model building modules.
ProModel also provides tutorials that contain quick lessons on how to
build models, how to run models and access output reports and how to model
various applications with the software.
To further reduce model development time, ProModel provides model
merging capabilities to allow several individuals to be working separately on
different sections of a large model. Additionally, frequently defined cells or
even commonly used decision logic may be stored as submodel templates
which eliminate the need to "re- invent the wheel" with every model. These
templates can even have specially designated parameters that may be changed
by the user.
Animation development is integrated with the model definition. A major
drawback of many simulation soft- ware products is that animation
development is independent from simulation model development. This makes
it time consuming and inconvenient for engineers to use animation as a
validation/verification tool. ProModel integrates system definition and
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animation development into one function. While defining routing locations,
conveyors, AGV paths, etc., you essentially develop the animation layout.
The layout screen is a virtual screen that can be scaled to an actual factory
layout.
Simulation results are informative and may be displayed in tabular or
graphical form. Many simulation software products require special commands
to generate statistics that are difficult to interpret for non- simulationists.
ProModel allows quick and convenient selection of reports and provides
automatic tabular and graphical reports on all system performance measures.
Output reports from several simulation runs can even be compared on the same
graph.
ProModel runs on any standard 486 computer with Windows 3.x, Windows
NT or Windows 95 operating systems. Most engineers, managers, and
professors have easy access to IBM or compatible computers with VGA
graphics capabilities. ProModel does not require any special graphics cards or
special monitors. This makes it convenient and cost effective for companies
and academic institutions that have standard microcomputers. ProModel also
runs on LANs (Local Area Networks).
MODELLING ELEMENTS
The modeling elements of ProModel provide the building blocks for
representing the physical and logical components of the system being
modeled. Physical elements of the system such as parts, machines, or resources
may be referenced either graphically or by name. Names of modeling
elements may be any word containing up to 80 alphanumeric characters.
Following is a brief description of each of these elements (see Figure 1).
Figure 1: ProModel's Modeling Elements
LOCATIONS
Routing locations are fixed places in the system (e.g. machines, queues,
storage areas, work stations, tanks, etc.) to where parts or entities are routed for
processing, storage or simply to make some decision about further routing.
Routing locations may be either single unit locations (e.g. a single machine)
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or multi-unit locations (e.g. a group of similar machines performing the same
operation in parallel).
Routing locations may have a capacity greater than one and may have
periodic downtimes as a function of clock time (e.g. shift changes), usage time
(e.g. tool wear), usage frequency (e.g. change a dispenser after every n
cycles), change of material (e.g. machine setup) or based on some user defined
condition. Routing locations may be assigned input and output rules. Input
rules are used for selecting what entity to process next while output rules are
used for ranking entities (i.e. FIFO, LIFO, user-defined) in a multi-capacity
location.
Two special types of locations that provide movement as well as
performing holding and operation functions are queues and conveyors. A
queue mimics the behavior of waiting lines, including the movement of entities
through the line. Conveyors are accumulating or non- accumulating and have a
particular speed and load spacing. Conveyors may be configured together to
provide conveyor networks.
New to ProModel 4.0 is the ability to model the continuous flow of liquids and
other substances into and out of tanks or similar vessels. Also, when
combined with discrete-event simulation, ProModels continuous modeling
capability makes it possible to model the exchange between continuous
material and discrete entities (e.g. when you place liquid into a container).
Other uses include modeling high-rate, discrete part manufacturing systems.
ENTITIES (PARTS)
Parts or entities refer to the items being processed in the system. These
include raw materials, piece parts, assemblies, loads, WIP, finished products,
etc. Entities of the same type or of different types may be con- solidated into
a single entity, separated into two or more additional entities or converted to
one or more new entity types.
Entities may be assigned attributes that can be tested in making decisions or
for gathering specialized statis- tics. The graphic of an entity can be changed
as a result of an operation to show the physical change during the animation.
PATH NETWORKS
Path networks are optional and define the possible paths that entities and
resources may travel when moving through the system. Path networks consist
of nodes connected by path segments and are defined graphically with simple
mouse clicks. Multiple path networks may be defined and one or more
resources and/or entities may share the same network. Movement along a path
network may be defined in terms of distance and speed or by time. Path
distances are automatically computed based on the layout scale defined by the
user.
There are three types of path networks: passing, non- passing, and crane. A
passing network is used for open path movement where entities and resources
are free to overtake one another. Non-passing networks consist of single-file
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tracks or guide paths such as those used for AGVs where vehicles are not able
to pass. Crane networks define the operating envelope and interface points for
bridge cranes.
RESOURCES
A resource may be a person, tool, vehicle or other object that may be used to:
Transport material between routing locations. Perform an operation on
material at a location
Perform maintenance on a location or other resource that is down.
Resources may be either static or assigned to a path network for dynamic
movement. A special type of dynamic resource is a crane. Built-in decision
rules can be used for allocation of resources and for prioritization of part pick-
up and delivery. Motion characteristics of resources such as empty and full
speeds, acceleration, deceleration, pickup and delivery time can also be
specified.
PROCESSING (ROUTING)
This element defines the processing sequence and flow logic of entities
between routing locations. The operation or service times at locations, resource
requirements, processing logic, input/output relationship, routing conditions,
and move times or requirements can be described using the Processing
element.
Operation times can be defined by constants, distri- butions, functions,
attributes, subroutines, etc. or an expression containing any combination of
these. Opera- tion logic can include IF-THEN-ELSE statements, loops, nested
statement blocks and subroutine calls. Resource related statements such as
GET, USE, and JOINTLY GET with Boolean expressions and built-in
operation statements such as ACCUM, JOIN, and GROUP greatly simplify
otherwise complex logic in describing the processing requirements. Built-in
and user-defined routing rules provide flexibility for modeling all types of
routing conditions.
ARRIVALS (OR PRODUCTION SCHEDULE)
Deterministic, conditional, or stochastic arrivals can be modeled using this
element. External files including production schedules or arrival data can be
read into ProModel in the Arrivals element. Built-in or user de- fined
distributions or spreadsheet created data can be used to define inter arrival
times and quantities.
SHIFTS (OR WORKSCHEDULES)
A powerful feature is the ability to define custom work and break schedules
through ProModel's Shifts module. Work and break schedules are defined
graphically by time of day and day of the week. Resources or locations are
then assigned to a specific shift schedule. In addition, you can define
shift and break logic that controls location and resource behavior when they
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go off-line and what happens once they are off-line.
ADDITIONAL MODELINGELEMENTS
ProModel provides additional modeling elements used in statements and
expressions to define special decision and operating logic in a model. These
elements include variables, attributes, functions, user-defined distributions,
and costing. There are several types of logic elements that may be defined by
the user. Like model elements, names given to these elements may be up to
80 characters in length. Figure 2 shows the menu for accessing these additional
elements. Some of these elements will be discussed in this section
.
Figure 2: More Elements Menu
ATTRIBUTES
Attributes for entities and locations can be defined. They may contain real or
integer values. Location, resource and entity names may also be assigned to
attributes.
VARIABLES
Variables are used for decision making and statistical reporting. The value of a
variable may be monitored over time and displayed at the end of the simulation
as a time series plot or histogram. Variables may hold integer or real values.
Local variables may also be used for quick convenience when defining logic.
ARRAYS
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An array is a matrix of variables representing multiple values. An array may be
one dimensional or multi- dimensional.
MACROS
A macro is a complex expression or set of expressions that can be defined once
and used multiple times as part of a logic statement (i.e. processing, scheduling,
downtime logic). Macros can be helpful in situations where the same bit of
logic is repeated in many places in the model.
SUBROUTINES
A subroutine is a user-defined block of statements that can be passed values
when called and optionally return values when completed. Subroutines may
be referenced in the place of any value or logic. A complex operation
performed several places in a model may be appropriately defined by a
single subroutine.
Arrival Cycles, Table Functions and User
Defined Distributions
Arrival patterns, table functions or user distributions may be defined. For
example, a user defined distribution which returns an operation time of 5
minutes 30 percent of the time and an operation time of 8 minutes 70 percent of
the time can be expressed in the User Distributions element.
EXTERNAL FILES
One of the powerful features of ProModel is the ability to read data from
external text or spreadsheet files or write data to external files. For example,
operation times (even in the form of expressions) from an EXCEL spreadsheet
file can be read into ProModel using this element.
COSTING
With ProModels new Costing feature, you can now make decisions about
your system on a cost basis. New dialogs allow you to monitor costs
associated with locations, entities, and resources during a model run. In
addition, the General Statistics Report now includes Costing statistics,
automatically generated at runtime. For locations, you can find the cost of
operating a location. For resources, the total cost includes the usage cost as
well as the cost of not using the resource. For entities, the total cost includes
the costs incurred at all locations the entity passed through, the costs incurred
by use of resources, and the initial cost of the entity.
SCENARIOS AND RUNTIME INTERFACE
The runtime interface (RTI) is a convenient and controlled environment for
modifying selected model parameters (capacities, operation times, etc.) without
having to change the model data directly. It also provides an
experimental environment, which permits multiple scenarios to be defined
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and simulated. The RTI can be accessed at the beginning of a simulation run
for making modifications for a single run or for saving alternative
modifications as scenarios for doing multiple scenario analysis.
RUNNINGTHE SIMULATION&ANIMATION
Models can be run for specified lengths of time or until all entities have been
processed. Multiple replications may also be specified. Models may be
run with or without animation. The animation is very smooth and it maintains
great resolution at any zoomfactor.
The Views feature allows you to define and then quickly and easily access
specific areas of the model layout. Selecting a view scrolls the layout window
and adjusts the zoom so you see a specific region of the layout regardless
of the layout windows size. Once a view is defined, you can select it while
running the simulation or change the view from within the logic. During the
simulation, you can query the status of resources or the current value of any
logic element. Source level debugging allows you to trace each action with the
option to display the actual source statement that triggered the action. Trace
statements may be confined to a single area of a model. Status lights for
locations change colors to help you see various states such as busy, idle,
down, etc.
The animation screen is a virtual screen that means the animation layout is
limited only by memory in your computer. By turning off the animation, you
can speed up the simulation, run for a while and turn the animation back on.
The simulation clock resolution can be expressed in terms of hours, minutes,
or seconds with a clock resolution of .00001 a second.
OUTPUT REPORTS
By choosing the statistics for resources, locations, entities, variables, etc., users
can customize the output reports. The statistics are written to a results database
which can be exported to spreadsheets. Additionally, graphical reports of the
outputs can be displayed, printed or plotted. These graphs can be
individual or comparative pie charts, histograms, time-series plots, etc. See
Figure 4 for a sample location state graph.
Figure 4: A Location State Graph
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OPTIONS
One of the most accommodating features of ProModel is the provision for
customizing the modeling environment to suit the preferences of the user.
Under the View menu, you can zoom in or out, display a grid, refresh the
screen, set default directories for model files, icon library files, or model output
files. You can set and save default settings (i.e. window sizes, appearance).
ProModel also allows you to choose editing preferences for model
development. Default fonts and sizes for text and a choice of long or
abbreviated menu lengths are available. Prompts and added explanations can
also be activated which may assist the novice user. The expert user can benefit
from choosing options that streamline the editing process.
OPTIMIZATION
SimRunner Optimization is an add-on capability for ProModel simulation
software. SimRunner turns your simulation model into an answer machine by
giving you the best answer possible while saving you the most time. The
optimization process takes an existing ProModel simulation model and
performs sophisticated what-if analysis and optimization automatically.
For each optimization project, you tell SimRunner which model to
analyze/optimize, which input factors to change, and how you measure system
simulation performance. You can run two types of projects in SimRunner:
Stage One Optimization Analysis, and Stage Two Simulation Optimization.
A Stage One Optimization Analysis is a factorial design of experiments that
tells you whether or not changing a given input factor is affecting the objective
function, and the significance of the effects. A Stage Two Simulation
Optimization is a multi-variable optimization that tries various combinations
of input factors to arrive at the combination that provides the best objective
function value.
The SimRunner Output report generates three types of data and reporting for
you:
1. Data reports - for import into spreadsheets
2. Analysis reports - for text and word processing reports
3. Charts - for graphical display of results.
Each of these can be printed or exported to other applications using common
clipboard functions.
SUPPLY CHAIN APPLICATIONS
Simulation models have had extreme value in many companies, being used as
decision making and planning tools by managers in supply chain related areas.
ProModel is successful in providing an accurate representation for many players
involved in a single product line. The players may consist of suppliers,
warehouses, customers, retailers, and transportation vehicles. Such issues
facing the players of the organization are fleet sizing, inventory reduction, and
shutdowns and outages. ProModel allows you to create a model, which
addresses these issues in a single model.
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Fleet Sizing
In the effort to correctly size various types of fleets (rail car, truck, ISO, etc.),
models may incorporate variability in transportation times. Seasonal peaks
and dives are easily modeled in addition to vessel maintenance outages.
Rail switching issues involving stoppages and congestion can also be
investigated. Demand increases may be used in a current state model to
determine the need for more vessels and/or how to meet the need with existing
resources. ProModel has been used to meet special seasonal orders without
additional resources, reduce current fleet sizes, and manage the current
transportation resources more effectively.
Inventory reduction
Especially challenging issues in supply chain applications include
capturing the behavior of continuous flow systems with stochastic conditions.
On- screen variables and output statistics modules provide guidance to make
decisions on tank sizing, capacity analysis and impact of variability of supply
on manufacturing units. Benefits include the ability to analyze complex
systems with a holistic perspective, reducing inventory levels by modeling
continuous flow systems at both manufacturing and consumer sites and
determining the needs of campaigning of differing products on the same unit.
Shutdowns and outages
The long and short-term impacts of planned outages have been a problem for
managers. Unplanned and random outages are much worse. Outage issues
not only include manufacturing or customer outages and their various impacts,
but also involve shipping and supply outages. ProModel allows you to
determine the impact of planned shutdowns on remote customer sites as well
as the possibility of shutting down production because of poorly planned,
customer interfaced outages. Models provide flexibility on testing alternate
scenarios, moving and shifting the timing of outages as well as the
durations.
CONCLUSIONS
Until recently, manufacturing companies have not fully benefited from
simulation in making continuous improvements because of the time,
programming ex- pertise, and cost involved in getting useful results. ProModel
is designed for manufacturing companies to fully achieve the benefits of
simulation technology at an affordable price. ProModel is directed toward
making simulation a standard tool in the hands of engineers, managers and
systems analysts just as spreadsheet soft- ware is in the hands of accountants
and financial analysts.
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PROMODEL EXERCISE - 1
Design a layout of a manufacturing system consisting of two CNC machines,
One Incoming queue, and one outgoing queue placed on layout of a
manufacturing system. Consider the capacity of the incoming products as 6 with
the frequency of arrival of product is 11.37min. The product is processed on
CNC machine 1 for 12.86 min and the distribution of the parts as geometric
distribution with a standard deviation of 4 %. Run the simulation for 40 hours
and plot the graphs and print the output results.
Procedure
Step 1 :
Create a New File
Select File New Enter your file name Ok
Step 2 :
Build Background Graphics
- Select Build menu Background Graphics Behind grid
- Edit menu Import Graphic
- Change files of type to windows metafile.
- Click on the file named tutorialback.WMF and click on the open
button.
- Resize the imported graphic to fit in layout window.
Step 3 :
Build locations where work will happen
- Select build Locations
- Add four locations : Incoming queue(capacity 6), Turning centre,
Machining centre and Outgoing conv.
- Place each on screen and add text tables.
Step 4 :
Add an entity
- Select Build Entities
- Add one entity by clicking on the flat plate graphic and rename it as
product.
Step 5 :
Add a Path Network
- Select Build Path Networks
- Left click with mouse near one location.
- Right click with mouse near next location to create a path segment.
- Repeat last two steps, ensuring that path segments start on the end of
previous segment.
- Click on button labeled Interfaces.
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- Click on each node (at end of path segments then click on adjacent
location to create interface.
-
Step 6 :
Add a Machinist
- Select Build Resources
- Add a resources by clicking on the machinist graphic
- Click on the specification button to open the resource specification
dialog box
- Select the path network named Net1
- Click the Ok button.
Step 7 :
Add Processing logic
- Select Build Processing
- After selecting product from the tools window, Click in the layout
on the Incoming queue then the on the Turning center then on the
and finally on the machining center then so on.
- Finish by selecting route to exit
- Add logic lines
- Build Processings Select the product Snap lines to border Draw a
line from incoming queue to turning center Move logic Select the hammer
Move with Resources Select machinist Then free Paste Close Close
the dialogue box Draw a line from turning center to machining center Click
operation Click hammer Wait Keypad Enter some value 12.86 Paste
Close Move logic Move with Resources Machinist Then free Paste
Close Close Draw a line form machining center to conveyer. Operation
Hammer Use Machinist Duration Distribution functions Geometric
Normal Keypad 8.3 Standard dew 4.1 Return paste Close Move
logic hammer move with resources machinist then free paste close
close draw a line from conveyer to outside click route to exit.
Step 8 :
Schedule Product arrivals
- Select Build Arrivals
- In the tools window, click on the entity called product.
- In the layout window, click on the location called incoming queue.
- Change the arrival frequency to 11.37 min.
Step 9 :
Set Options, save model and run
- Select simulation - Options
- Click on the field labeled run hours
- Type in 40 (to run for 40 hours)
- Click on the ok button
- Select simulation Save and Run.
- Options zoom 150%
- Information -status light operating- options zoom-200% - trace
start trace off
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Step 10 :
View simulation results
- After simulation is complete, select yes to view results (note that
entities failed to arrive at incoming queue because of its capacity
limit)
- View graphs and change graphic options machining center, and so
on.
PROMODEL EXERCISE - 2
FantasticDan'sBarbershop
This first lab provides the opportunity to get your feet wet using ProModel.
It leads you through, in full detail, the building of a simple barbershop
simulation. When you are done, you will have built and run your first
simulation model, and learned some of the most important basic
components of a ProModel discrete simulation model.
NOTE: There are many screen captures so that you can see what it should
look like as you build the model.
PROCEDURE
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Your screen will look something
like this but will be a lot less
squeezed
for space. We now have four
windows. Starting from the upper
left corner and working clockwise,
they are: Process, Routing,
Layout, and Tools.
Start in the Process window. We
need to select an entity that our
process works upon. To avoid a
spelling error, Promodel provides
an easy way to examine all of the
Entities that have already been
defined. Simply click on the Entity
button. Make sure that Customer
is highlighted and then click OK.
22
Next, we will use the same
shortcut to select where we will do
the processing/routing. First we
will get the routing from the
Customer line so make sure that
Customer_line is highlighted and
click OK.
There isn't an operation that needs
to be done in the line other than to
move to Dan when Dan has an
opening so we will leave the
Operation field blank.
We need to say that the Customer
entity is routed from the Customer
Line to Dan though. This is done
in the Routing window.
First click on the Output button of
the Routing window and make sure
that Customer is highlighted, then
click OK. This indicates that a
customer after going through the
line is still a customer and isn't
changed into something else.
23
Next we enter the Destination of
a customer leaving the line which
is Dan.
Notice how this is represented
graphically by the red arrow. A
customer leaves the line to go to
Dan for service.
We also need to include the
processing (or cutting of a
customer's hair) by Dan. Go to the
Process Window, and select a
customer as an entity and a
location of Dan. Start this by
hitting enter to create a new row
in the Process window.
Next, we need to enter a
description of the operation that
Dan performs.
24
The customer ends up waiting until
Dan finishes cutting his or her
hair. Not surprisingly, we will be
using the WAIT command. Recall
that we said that we would use a
uniform distribution between 8
and
10. This is described in Promodel
by the mean and the half range so
it is entered as U (9,1).
Putting it together, we can enter it
as
WAIT U (9,1) in the
operation field.
You can also use another tool called
the logic builder to help with the
syntax. To get to this, click on the
Operation button, then on the
button in the editor window
that comes up. To input the
uniform distribution, click the
Time button. Distribution
Functions are located under the
Logic Elements section.
The result will be this entry in the
Process Window. Next we need
to enter the routing for a
customer.
When a customer finishes getting
his or her haircut, the customer
EXITS the system. Not
surprisingly, this is exactly the way
it looks in the Routing window.
Notice how to block in the Process
window corresponds to one or
more blocks in the Routing
window.
In more complex cases, we may
find it help to use the File|View
Text command to examine the
routing
and processing of entities.
25
Okay, we are getting close to the
finish line. Our next step is to
define the arrival of customers (or
entities) to the system.
Notice that the Occurrences
and Frequency columns do not
have dialog boxes associated
with them. You need to enter
this information manually.
This includes even defining the
triangular distribution for the
interarrival times. Note: Logic
Builder can be accessed for the
Frequency column by right-
clicking on the box.
Our last step is to select the
Simulation Options
26
We will define and use the other
options later but for now just set
the length of the run to 8 hours.
While poor Dan doesn't take a
break, at least he only puts in an 8
hour day.
Be sure that the Output Path
is defined as your save
location.
Finally click run. (If you
haven't saved already,
ProModel will prompt you to
do so.)
After it finishes running, there is a
dialog box asking if you want to
see the results. Click Yes.
27
Of course your results can be
(and probably should be) slightly
different from mine.
We can click on the above buttons
to see some graphical
representations
of the results.
Note the ProModel 2002 (version
6.0) has a default result screen that
is different from the one shown in
the cell to the right. To switch to
the old style output format click
options in Tools menu in
ProModel. Switch from Output
Viewer 3DR to Output Viewer.
Scrolling down we can see more
of the General report of the
simulation results.
Congratulations! You have done your first discrete simulation.
28
Questions
For the Fantastic Dan Barbershop, run the simulation model for a whole year (250 days, 8 hours
each day) and type the answers to the following questions for class discussion. The questions
will be collected on Tuesday come prepared to discuss your results. Be sure to identify where
you found the information for each of the following questions:
1. On average how many customers does Dan serve each day?
2. What is the average number of customers waiting to get a haircut? What is the maximum?
3. What is the average time spent by a customer in the salon? What is the maximum time
spent in the salon?
4. On average, how busy is Dan? Is it satisfactory?
5. How many chairs should Dan have for customers waiting for a hair cut?
6. If Dan could take exactly nine minutes for each haircut, will it improve the situation?
7. Whats the relationship between Average Minutes Wait For Res, etc. and Average
Minutes Blocked?