Simulation-based optimization of resources: A case study

Module learning outcomes and professional body learning outcomes tested

The following module learning outcomes and professional body learning outcomes are tested in this assessment:

1. Deploy special techniques and software systems to optimise resources through eliminating waste and prioritising constraints.

2. Demonstrate an in-depth understanding of specialised techniques in resources optimisation and management.

3. Perform critical analysis of operational resources and bottlenecks through using simulation modelling.

A product arrives in a Queue every 14 seconds exponentially distributed and then routed to any one of 3 machines where it is processed for 20 seconds (24 seconds for rework). Machined parts are placed in a common queue and wait to be tested, 20% are found faulty and must be reprocessed. The test time is a constant 9 seconds. Parts passing test enter another Queue and wait to be packaged at an automatic packaging machine.

1. Inter-arrival time for source is Exponential(0,14,1)

2. The Tester has an output of 80% acceptable and 20% faulty by chance

3. Cycle time for box forming machine is Normal (50,2)

4. MTBF for box forming machine is Weibull (151.1, 50, 24.9)

5. MTTR for box forming machine is uniform (20,30)

1. Use a conveyor to route failed flowitems back to the queue.

2. Increase the ‘Increment ItemType’ by 1 each time a flowitem fails, and change the flowitem’s colour according to how many times it fails: 1- green, 2- yellow,

3- red. You will need to use this function ‘inc(itemtype(item),1)’ to change the ItemType each time when a part enters the rework loop.

3. You will get some bonus marks if you include additional FlexSim functions from the Visual object library (e.g. Billboard to show real-time statistics, not compulsory)

4. Save your model as include a brief discussion, snapshots and relevant statistical results from FlexSim in your main report. The main report (including all Part A, B & C) will be submitted to Canvas. All FlexSim models will be submitted to the same Canvas folder.

a) Discuss the main reasons why the company chose to implement DES. You may talk about their problems before using simulation.

b) The benefits that the company has achieved by implementing DES. Whereappropriate, you should include quantifiable evidence such as tables, statistics,  graphs etc. to indicate their improvement after using DES.

c) Discuss the problems they had to overcome in order to benefit the full DES experience.

d) Include and discus, where possible, some simulation layouts and flow diagrams available for this company (multiple materials may be used for the same company, but only one main case study article).

e) Discuss briefly of the DES software that this company has chosen. Include some pictures if available. Don’t

f) Discuss, in your opinion, how this company could improve their operations and business further through using DES.

Overall conclusion for the whole assignment Include an overall conclusion (covering all Part A, B and C) to reflect your overall learning experience in this assignment, including challenges that you managed to overcome.

As this is a group assignment, it is important for each member to peer-assess each other in terms of their effort and contribution in each part of the assignment. This will enable me to reward, if applicable, the right grade according to the individual effort.  Please fill in the following Peer Assessment template and copy it into your main report after the content page:

? Comment on those obstacles, are they common to other similar companies?

? What did the company do in order to overcome them? Were these obstacles related to skills, or company culture perhaps?

? Logic of the discussion Has the report included any picture of their simulation model(s)?

? This depends on which company case study you have chosen. You may have to use multiple articles based on the same company to find suitable model pictures.

? Have you explained the main message of those pictures?

Discussion of the DES software chosen by the company

? Out of so many available software, why did the company chose this one?

? Have you included any information on hardware and cost?

? Have you discussed the unique feature of that software?

? Which industrial applications this software is suitable for?