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1.

PROBLEM STATEMENT
A machine shop processes two job types. The shop has two identical machines. A
job is processed on only one of the machines. The first type 1 job arrivals are
exponentially distributed with a mean of 10 minutes. The type 2 job arrivals are
exponentially distributed with a mean of 6 minutes. The machine processing times
are triangularly distributed (4, 8, 12) minutes for job type 1 and between (2, 5, 8)
minutes for job type 2.
After processing on the machine both types of jobs go to a single inspection station.
The inspection time follows a Normal distribution with mean of 4.5 minutes and
standard deviation of 1.5 minutes for type 1 and uniformly distributed between 1
and 3 minutes for type 2 jobs. The probability that a part will fail the inspection is
10 percent and is independent of the job type. The failed jobs are rejected and
leave the shop. The transfer time between every pair of stations (including arrival
and departure station) is 1 minute. Job type 1 has higher priority over job type 2
both at machines and inspection queue (there is only one common queue for both
machines).
The machines must be shut down and serviced for 10 minutes after every 20
consecutive jobs. The inspector requires a 15-minute coffee break 2 hours into the
shift and a 30-minute lunch break four hours into the shift and the second coffee
break six and half hours into the shift (for 8 am shift the first coffee break will be at
10 am, lunch at noon and the second coffee break at 2:30 pm). You must show
different pictures for the two job types.
A. ASSUMPTIONS
a. As there are two identical machines, we have assumed that machine
capacity is 2.
b. As the work shop runs for 3 shifts, we have assumed that there is no
overlap of time for any shift.
c. Typically, the day starts at 8am and runs till 8am next day covering
three shifts. (8:00am to 4pm, 4pm to 12am, 12am to 8am).
d. As the work shop runs only for 5 working days, I have run the machine
for 120 hours (24 hrs each day X 5 days)
B. OBJECTIVE:
a. To run the Simio model meeting the requirements as stated in problem
statement.
b. To run 20 replications for the model with 120 hours span.
c. To determine the following.
i. The number of completed jobs
ii. The number of rejected jobs
iii. The flow time of (only) jobs passing inspection
iv. The number of jobs waiting in the machine queue
v. The number of jobs waiting in the inspector queue
vi. The machine and inspector utilization
2. PROCEDURE
A) Created two model entities as job1 and job2 with respective source1 and
source2.

B) Created two servers as machine and inspection


C) Created two sinks as accepted and fail.
D) All the objects are connected using time path with default as 1min.
E) Defined two real state variables as:
i) MACHINEPROCESSINGTIME
ii) INSPECTIONPROCESSINGTIME
F) Following characteristics are assigned for job1 at source1
i) Statements assignment as ModelEntity.Priority and set value as 1.
ii) Statements assignment as ModelEntity.MACHINEPROCESSINGTIME and set
value as Random.Triangular(4, 8, 12)
iii) Statement assignment as ModelEntity.INSPECTIONPROCESSINGTIME and
set value as Random.Normaldistribution (4.5, 1.5)
G) Following characteristics are assigned for job1 at source2
i) Statements assignment as ModelEntity.Priority and set value as 2.
ii) Statements assignment as ModelEntity.MACHINEPROCESSINGTIME and set
value as Random.Triangular (2,5, 8)
iii) Statement assignment as ModelEntity.INSPECTIONPROCESSINGTIME and
set value as Math.max(Random. Uniform(1,3), 0)
H) Following characteristics are assigned for machine server
i) Set Processing time as ModelEntity.MACHINEPROCESSINGTIME
ii) Set ranking as smallest value first and set as Modelentity.Priority.
I) Following characteristics are assigned for inspection server
i) Set Processing time as ModelEntity.INSPECTIONPROCESSINGTIME
ii) Set ranking as smallest value first and set as Modelentity.Priority.
J) Set the reliability logic processing count, count 20 and minutes - 10
J) Create the schedule as defined below
START
TIME
8:00
AM
10:15
AM
12:30
PM
2:45 PM
4:00 PM
6:15 PM

DURATI
ON

VAL
UE

CO
ST

1.75
hours

END
TIME
10:00
AM
12:00
PM

2 hours

2:30 PM

4:00 PM

6:00 PM

8:00 PM

2 hours

1.25
hours
2 hours
1.75
hours

8:30 PM

2 hours

10:45
PM

1.25
hours

10:30
PM
12:00
AM

12:00
AM
2:15
AM
4:30
AM
6:45
AM

2 hours

2:00 AM

1.75
hours

4:00 AM

2 hours

6:30 AM

1.25
hours

8:00 AM

K) For inspection server, assigned capacity type as work schedule and work
schedule as standard schedule.
L) Set the replications as 20 and time length as 120 hours. (5days)

3. Program Difficulties:
A) Assigning two processing times for same server for different jobs is
difficult without creating real states
B) Prioritizing the jobs based on types.
C) Assigning work schedules.
4. Results

PARAMETER REQUIRED ORIGINAL SYSTEM

The number of completed jobs


The number of rejected jobs
The flow time of (only) jobs passing inspection
The number of jobs waiting in the machine
queue
The number of jobs waiting in the inspector
queue
The machine and inspector utilization
5. Analysis of Results:
Comparing Original model and Embellishment model:
1) Number of entities created in the original model are 1,932
Number of entities created in the Embellishment model are 1912
2) Simulated resource utilization in original model
Machine: 81.54%
Inspection: 89.4%
Simulated resource utilization in Embellishment model
Machine: 80.84%

VALUE
OBSERVED
1715
195
74.8mins
12.63
4.23
81.54 & 89.4

Inspection: 88.4%
3) Original Model:
Number in the system in Job Type 1 = 2.69
Number in the system in Job Type 2 = 17.61
Embellishment Model:
Number in the system in Job Type 1 = 8.86
Number in the system in Job Type 2 = 3.32

4) Time in System (Minutes)


Original Model:
Job Type 1 = 26.6295
Job Type 2 = 104.8710
Embellishment Model:
Job Type 1 = 80.1619
Job Type 2 = 20.1290
6. Conclusion:
Based on the Simio results for the original model where the high priority is given to
job1, the results show that the model behaves in a better way with effective
utilization of machines and inspectors and with minimal waiting time for the job
completion. On the other hand, in the embellishment model, the time in system has
been considerably increased with long queue formation at machine and inspection.
The number of entities served are also high in model one competitively to
embellishment mode.