05 FLEXSIM

CHAPTER 5
FLEXSIM

5.1 Introduction
Generally, the verb to simulate means to mimic or imitate. This takes a broader view

of the verb as it relates to actual applications. Here, to simulate means to mimic or

imitate through experimentation with a model (or representation) of some real system;

however, simulation also involves more than just mimicking or experimenting. It

involves performing such activities as defining, designing, and constructing a model

or representation; defining the experiments to be conducted; collecting and analyzing

data to drive the model; and analyzing and interpreting the results obtained from the

experiments. Therefore to simulate, as referred to in this book, means to partake in a

process that encompasses all of the above activities Simulation is used for a reason it

has to provide a value added return for the people and the financial resources it uses.

Some of that payback is in hard cash while the rest is in soft, intangible benefits.

Defined savings helps everyone especially accountants while the intangible benefits

are appreciated by management. The examples used in this section are based on more

than a thousand simulation projects over a wide variety of applications used in various

business and service sectors.

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5.2 Feasibility Assessment

In the feasibility phase of a project, new concepts are thought of and plans are made

to execute them. It is the optimal time to make changes and identify possible

problems since only a small amount of effort has been expended. Typical savings

during thisphase have ranged from 20 to 40% of the total cost incurred during this

phase. Direct savings have accrued from reducing the time to obtain an accurate

estimate of the cost and benefits of a proposed project. With simulation, the time to

consider and prioritize alternative recommendations is also reduced. Time savings can

be directly calculated from employee cost/hr and the value of a faster time to market

from business projections.

Simulation is only one of a number of tools available for effectively studying dynamic

systems. Other types of tools used extend from directing day to day operations to

planning changes to meet new business opportunities. It is difficult, if not impossible,

to find one tool that easily satisfies the needs of all users across such a wide range of

activities; however, all of these tools share in the objective to improve system

performance as they also share in the data and metrics that drive operations. It is

therefore critical that thetools are able to share information across applications as well

as organizational boundaries. shows the interactions between the various

organizations and the tools that support the operations.The Dynamic Operations block

can be a production line, a plant, a service organization, or even a single operation. It

is this operation that is the focus of the improvement efforts. Understanding its

dynamic behavior and performance measures is the underlying goal. Two forces

directly change the operating characteristics of the system. The first force is the day to

day directives for operation.

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5.3 OBJECTIVES OF SIMULATION IN MANUFACTURING

Perhaps the greatest overall benefit of using simulation in a manufacturing

environment is that it allows a manager or an engineer to obtain a systemwide view of

the effect of “local” changes to the manufacturing system. If a change is made at a

particular workstation, its impact on the performance of this station may be

predictable. On the other hand, it may be difficult, if not impossible, to determine

ahead of time the impact of this change on the performance of the overall system.

In addition to the above general benefit of simulation, there are a number of specific

potential benefits from using simulation for manufacturing analyses,

including:

• Increased throughput (parts produced per unit of time)

• Decreased times in system of parts

• Reduced in-process inventories of parts

• Increased utilizations of machines or workers

• Increased on-time deliveries of products to customers

• Reduced capital requirements (land, buildings, machines, etc.) or operating

Expenses.

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• Information gathered to build the simulation model will promote a greater

understanding of the system, which often produces other benefits.

• A simulation model for a proposed system often causes system designers to think

about certain significant issues (e.g., system control logic) long before they normally

would.

5.4 FlexSim :

FlexSim is a true objectoriented simulation package for manufacturing, material

handling, warehousing, and flow processes marketed by FlexSim Software Products

(Orem, Utah). A model is constructed by dragging and dropping “objects” into the

“Model View” and then editing their parameters using dialog boxes. FlexSim can

model a wide variety of manufacturing configurations, since existing objects can be

fully customized to meet specific requirements. These customized objects can then be

placed in the library for reuse in current or future modeling applications. A model can

also have an unlimited number of levels of hierarchy and use all aspects of object-

oriented technology.

FlexSim provides three-dimensional, prospective-projection model building and

animation by default; however, the user has the option to switch to an orthographic

view or display both views simultaneously.Material-handling devices available in

FlexSim include conveyors (transport and accumulating), forklift trucks, AGVS,

AS/RS, cranes, elevators, robots, and operators. FlexSim provides preempting and

priority processing for capturing details of product movement and processing.The

FlexSim software includes a cost model that allows one to account for the profit for

each part produced and also for the costs associated with machines, labor, work-in-

process, etc.There are an unlimited number of random-number streams available in

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FlexSim. Furthermore, the user has access to 24 standard theoretical probability

distributions and also to empirical distributions. The time to failure of a machine can

be based on busy time, calendar time, or a user-defined event.There is an

“Experimenter” that can be used to automatically make independent

replications for each of a number of different scenarios, and to obtain point estimates

and confidence intervals for performance measures of interest. Furthermore, the

replications can be simultaneously executed across multiple processor cores. A

number of plots are available, including time plots, histograms, bar charts, pie charts,

and Gantt charts.

5.5 Sources of Randomness :

We begin with a discussion of common sources of randomness in manufacturing

systems. In particular, the following are possible examples of continuous

distributionsin manufacturing:

• Interarrival times of orders, parts, or raw materials

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• Processing, assembly, or inspection times

• Times to failure of a machine

• Times to repair a machine

• Loading and unloading times

• Setup times to change a machine over from one part type to another

• Rework

• Product yields

Note that in some cases the above quantities might be constant. For example,

processing times for an automated machine might not vary appreciably. Also,

automobile engines might arrive to a final assembly area with constant interarrival

times of 1 minute.There are actually two other common ways in which parts “enter” a

manufacturing system. In some systems (e.g., a subassembly manufacturing line), it is

often assumed that there is an unlimited supply of raw parts or materials in front of

the line’s first machine. Thus, the rate at which parts enter the system is the effective

processing rate of the first machine, i.e., accounting for downtimes, blockage, etc.

Jobs or orders may also arrive to a system in accordance with a production schedule,

which specifies the time of arrival, the part type, and the order size for each order. In a

simulation model, the production schedule might be read from an external file.

plant layout is a very critical part of running an efficient and cost effective business.

All work areas, production lines, material storage facilities, etc. should be designed to

perform to the highest rate and the corresponding shortest cycle time. When designing

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a plant layout it is necessary to take into account all the functions within the business.

The design must include not only the needs for the present business levels but should

also have provisions for future expansion. This is included to avoid frequent and

costly changes to the design as demand increases. Plant Layout is the physical

arrangement of equipment and facilities within a plant.i.e. the grouping of equipment

and operations in a factory for the greatest degree ofefficiency. The Plant Layout can

be indicated on a floor plan showing the distances between different features of the

plant. Optimizing the layout of a plant can improve productivity, safety and quality of

Products. Unnecessary efforts of materials handling can be avoided when the Plant

Layout is optimized. This is valid for:

1. Distances through which the material has to move

2. Distances equipment has to move

3. Distances operators have to move

4. Types of handling equipment needed.

5.6 METHODOLOGY FOLLOWED FOR ANAL YSIS OF THE PROBLEM

5.6.1 Raw Material Requirement

Total raw materials are divided according to their weights and this data is used for

ABC analysis. From this we come to know the importance of each type of material.

This data is helpful to decide raw material policy.

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5.6.2 Understanding of Existing Process Sequence

To design an efficient plant layout understanding of process sequence is necessary.

Forthis the existing manufacturing processes are studied in sequence. The critical

operationsin each process are observed carefully. This will help in redesigning the

process sequence.

5.7 Time Study

The time study has to be carried out at each processing stage. It is done manually

using a stop watch and readings are recorded in time study sheet. The time study helps

in finding out the time required for each process in the sequence. This data willbe

useful in deciding the capacity planning for a new plant. From the time study we also

come to know the bottlenecking stage.

5.8 Layout Designing and Simulation

After studying the process sequence and the time required for each process, the layout

designing is done. The layout is designed by taking into consideration the available

space, interrelation between two successive departments, the importance of each

process and the capacity required to achieve the desired output rate. After designing

the layouts, they are simulated using simulation software, FLEXSIM. The capacity of

each workstation and the bottlenecking locations are understand by observing the

simulation results. From these results a decision is taken, whether to revise the

capacity or not. The revised plant layout is again simulated. The revision is applied in

a progressive manner. After comparing the throughput of each layout, the one having

maximum throughput rate is selected and is proposed to the company for

implementation.

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5.9 SIMULATION OF FACILITY LAYOUTS

Simulation means process of testing an existing or new invention for modification or

use by means of a prototype. Plant designers generally have only two choices: either

physically change the layout of an existing facility and then measure results, or model

the system and measure results to develop the final facility design before making

changes. Plant layout simulation is a tool that uses data to evaluate a current facility

layout and show potential improvement areas. The same data is then used to

objectively evaluate various layout alternatives for new construction, additions, and/or

re-organization

5.9.1 Need of Simulation

Facility layout problems are rather difficult in terms of analytical modeling. When the

number of departments is large, the material flow volumes between departments are

random, and a flexible layout is desired, the problem becomes much more complex

and usually intractable analytically. Therefore, simulation has been used as a

modeling alternative to determine a good layout among a very large number of

alternatives.

5.9.2 Experimental Design And Results

Simulation software is a powerful analysis tool that helps engineers and planners

make intelligent decisions in the design and operation of a system. With the help of

simulation software, we can build a 3-dimensional computer model of a real-life

system, and then study that system in either a shorter time frame or for less cost than

with the actual system.

The simulation software should have the capabilities so that it can be successfully

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used to:

1. Improve equipment utilization.

2. Reduce waiting time and queue sizes.

3. Allocate resources efficiently.

4. Eliminate stock-out problems.

5. Minimize negative effects of breakdowns.

6. Minimize negative effects of rejects and waste.

7. Study alternative investment ideas.

8. Determine part throughput times.

9. Study cost reduction plans.

10. Establish optimum batch sizes and part sequencing.

11. Resolve material handling issues.

12. Study effect of setup times and tool changeovers.

13. Optimize prioritization and dispatching logic for goods and services.

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