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MANUFACTURING SYSTEMS
Simulation
Is the process of building a mathematical or logical model of a system or a decision problem
Experimenting with the model to obtain insight into the systems behavior or to assist in solving the decision problem.
Simulation can be used to experiment with new designs or policies prior to implementation, so as to prepare for what may happen.
3.
Entities Part
Attributes Part number, due date Destination, message length Flight number, weight
Communications
Message
Airport
Airplane
Runways, gates
Queues
Queues
New equipment and buildings are required (called green fields). New equipment is required in an old building. A new product will be produced in all or part of an existing building. Upgrading of existing equipment or its operation. Concerned with producing the same product more efficiently. Changes may be in the equipment (e.g., introduction of a robot) or in operational procedures (e.g., scheduling rule employed).
Number and type of machines for a particular objective. Location and size of inventory buffers. Evaluation of a change in product mix (impact of new products). Evaluation of the effect of a new piece of equipment on an existing manufacturing line. Evaluation of capital investments. Manpower requirements planning. Throughput analysis. Makespan analysis. Bottleneck analysis. Evaluation of operational procedures. Evaluation of policies for component part or raw material inventory levels. Evaluation of control strategies
assumptions Can deal with problems not possible to solve analytically Provides an experimental laboratory: possible to evaluate decisions/systems without implementing them Generally easier to understand
time-consuming for complex systems Simulation results /simulated systems are always approximations of the real ones
Problem Definition
Statement of Objectives
SIMULATION SOFTWARE
1st Category Channel purpose language FORTRANC, C + +VB, VB+ + . . ............ . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .many other oriented languages 2nd Category Simulation language
GPSS (1965)SIMSCRIPT (1963)SIMULA GASP (1961)ALGOL SLAM (1979)SIMAN GPSS/4 (1977)SLAM IIAWESIM (1995)GEMS
3rd Category Simulation Packages ARENA (1993)AutoMOD QUEST EXTEND PROMODEL TaylorED WITNESS. . . . . . . . . . .and many more
Webbased simulation
Stage 2
Stage 3
Stage 4
Software selection
Software contract negotiation
Stage 5
Stage 6
Software purchase
SOFTWARE SELECTION
Brainstorming
Self-Evaluation
Note: All ratings shown above are meant as a sample only for demonstration purposes
Simulations shortcomings
1.Simulation in discrete parts manufacturing seldom addresses sustainability issues. 2. Current simulation products do not typically support the modeling of environmental concerns or impacts; e.g., energy consumption or carbon footprint, waste/hazardous materials disposal, and pollution. . 3. Information on alternative manufacturing technologies, processes, and data is not readily available to the simulation analyst to incorporate into models. 4. Regional differences in environmental safety requirements are not represented in simulation environments. 5. Recovery, recycling, and life cycle costs (LCC) of materials are not addressed in design and manufacturing simulations. 6. Simulations do not deal with the usage and disposal practices of product users after sale.
SIMTER - ADVANCED SIMULATION-BASED PRODUCTION DEVELOPMENT TOOL FOR TRADITIONAL MANUFACTURING INDUSTRIES 1 Collaboration of Finnish and Swedish Government
In Finland project participants are VTT technical research centre of finland, visual components and holming works (Industries)
In Sweden- Project Participants are chalmers university of technology , volvo technology and EKA chemicals
The SIMTER project aimed to produce a simulation tool, which would enable joint multi parameter analysis of a production system. Thus, the project focused on producing three sub-tools (LoA, ergonomics, environmental) and integrating them into a single SIMTER tool.
Environmental impacts
LCI data
The data is entered by the user into the SIMTER input database. In the analysis phase, the environmental data and simulation run results are combined in an MS Excel workbook.
Ergonomics
In the SIMTER project, integrated simulation tool developed to maximize production efficiency and to balance manual and automated work subject to ergonomics constraints. Several common and validated methods for evaluating the ergonomics of working postures are employed in the SIMTER tool. These are 1. RULA-Rapid Upper Limb Assessment 2. Ovako Working posture Analysis System 3. ERGOCAN-(Combination of RULA and OWAS)
Environmental Waste
1. energy, water, or raw materials consumed in excess of what is needed to meet customer needs 2. pollutants and material wastes released into the environment, such as air emissions, wastewater discharges, hazardous wastes and solid wastes (trash or discarded scrap) 3. hazardous substances that adversely affect human health or the environment during their use in production or their presence in products
Environmental Metrics
The environmental metrics were adapted from EPA and GreenSCOR (2008) During the development the following metrics were tested
Environmental calculations are based on 1. 2. 3. 4. number of products manufactured Raw materials used machine utilizations scrap and rework rate
If there are any process phases or equipment consuming fuels, the direct CO2 is also calculated.
Toy case processed through following five steps. 1.Assembly 2. Inspection 3. Painting 4. Drying 5. Packing
The product consists of four parts, made from 1. plastics 2. wood 3. iron.
Results
Environmental impact is calculated in an MS Excel workbook
Resource sheet: equipment energy data, simulation run results and energy calculations.
Future Work
1. Refinement of Subtools. 2. Determining the influence of levels of automation on ergonomics, and environmental impacts. 3. Fill the gap between Life Cycle Assessment and conventional process simulation, and identifying the most significant environmental factors to be taken into account. 4. Integration with manufacturing simulation provides a structure not just for measuring performance and environmental metrics, but also for identifying where action can be taken to improve green performance.
References