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Lab2b 2022 L

The document describes a simulation model of an electronic assembly and test system using Arena. The key elements are: 1) The system includes processes for part preparation, assembly, testing, rework, and shipping. Random variables model processing times and failure rates. 2) The rework station has variable worker capacity on two shifts to monitor its queue length. 3) Statistics like the rework queue levels and downtime of the sealer machine will be collected using Arena modules to analyze the system.

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Nguyễn Hiếu
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29 views

Lab2b 2022 L

The document describes a simulation model of an electronic assembly and test system using Arena. The key elements are: 1) The system includes processes for part preparation, assembly, testing, rework, and shipping. Random variables model processing times and failure rates. 2) The rework station has variable worker capacity on two shifts to monitor its queue length. 3) Statistics like the rework queue levels and downtime of the sealer machine will be collected using Arena modules to analyze the system.

Uploaded by

Nguyễn Hiếu
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Simulation with Arena

An Electronic Assembly and Test System


PART B

Book: Simulation with Arena 4th Ed, David Kelton


Chapter 4

Dr. P.H.Tram, Mar 2020


Lab Objectives
- Learn “Basic Process” modules: Process, Decide, Assign,
Record, Resource, Schedule
- Learn “Advanced process” modules: Failure, Statistics
An Electronic Assembly and Test System
Sealer
Part A Prep Part A TRIA Rework Scrapped
(1,3,4) 20%
EXPO(45)
Part A Part B
EXPO(5) WEIB
9% 1st shift: 1 Salvaged &
(2.5, 5.3) 80% shipped
TRIA (1,4,8) worker
2nd shift: 2
workers
Part B Prep 91%
Machine
Part B uptime ~
EXPO (120) Shipped
EXPO(30)
Batch of 4 Time to
repair ~
TRIA Time unit: minute
EXPO (4)
(3,5,10) Working hours: 16h/day (2 shifts)
Each station: 1 worker/shift
Additional system features
- Random variables follow
known probability
distributions:
+ Parts arrival time
+ Processing time
+ Defective part ratio
+ Machine uptime (failure)
- Parts arriving in batch
- Different part types have
different processing times
- Operator schedule
Run set-up
- Number of replication: 1
- Replication length: 10 days
- Hours per day: 16 (2 shifts)
- Base time unit: minutes
Third trial
- Modify the simulation model with resource scheduling and machine
failure

- Try to improve the system:


+ Monitor the WIP overtime at the rework station by plotting chart →
decide which shift needs to increase number of workers
+ Increase the number of workers at the rework station at the chosen
shift
+ Conclude on the number of racks should buy at the rework area (each
rack holds 10 assembles)
Arena concepts
System features Arena modules

Machine failure <Resource data module>

Data definition
<Failure data module>
(Advanced Process)

Operator schedule <Resource data module>


<Schedule data module>
Arena - Statistics Collection
Required statistics Arena report Arena modules

Status of rework queue Frequencies < Statistic data module>


(frequency that the queue has 0, (Advanced process)
0-10,10-20… items)

Amount of time Sealer is in a fail Frequencies < Statistic data module>


state (Advanced process)

Version 16:
<Frequency>
(Input Output)
Arena Built-in Variables

Arena Built-in Variables Meaning

NQ([process name.Queue]) Number in Queue of the queue of


certain process

Process name.WIP WIP in the Process (number in Q


+ number being processed)
Schedule data module → Resource schedule

- We create a schedule named “Rework schedule” for the resource in the rework process
- Choose Schedule type “Capacity”
- Right click on the “durations”, choose “Edit via Dialog” to give details of the schedule:Add
(capacity, duration) --> the first 8 hours (1st shift): 1 worker, the next 8 hours (2nd shift): 2 workers
Schedule data module → Resource schedule

You can also double


click on the
“duration” to use the
Graphical
Schedule Editor to
edit the information
(except when the
time duration is not
integer or is a
random variable)
Failure data module → Resource failure

- The failure data module is in the Advanced Process Panel (File > Template Panel>Attach→
Arena/Template/AdvancedProcess.tpo)
- We create a Failure named “Sealer Failure” for the sealer process
- Choose Failure type “Time”
- Key in Uptime and Downtime distribution
Resource data module → schedule and failure

At the “Rework process”, choose:

- Type: “Based on schedule”


- Capacity: Choose “Rework Schedule” in the dropdown list
- Schedule rule: “Ignore”
Resource data module

At the “Sealer process”, choose:

- Type: “Fixed capacity”


- Capacity: “1”
- Failure: Double click and choose “Sealer Failure” in the dropdown list of
failure name. Failure rule: wait
Arena “Schedule rule”
Scheduled Scheduled
Break start Break end

Preempt Break time

Wait Entity processing Break time


(BT<<PT) time

Ignore Break time


(BT>>PT)

12 noon 1 pm

(*) During break time, resource capacity is reduced


This rule is applied similarly for machine failure
Statistic data module

- Give a name for the statistics


- Choose type of the statistics to be collected. If it is Frequencies statistics,
choose the frequency type (value/state)
- Enter the Expression of the variable to be recorded (Use Expression builder)
- Enter collection period, report label. If you specify an output file, then each
individual observation is written to an output file.
Statistic Data module
More about statistics collection
- Tally statistics: taking the average, minimum, or maximum from a list of
numbers (discrete-time)

- Time-persistent statistics: taking the (time) average, minimum, or maximum


of a plot of something during the simulation (continuous-time)

- Counter statistics: accumulated count of something

What statistics is it: average total time in system, average queue length, WIP,
number entities left the system
More about statistics collection
- Instantaneous Utilization: Time weighted average of [number of units busy/
number of units scheduled at that point in time] over the whole run. (When
there is no capacity scheduled, utilization at that time is zero)

- Scheduled Utilization: Time-average of number of units busy over the whole


run/ Time-average of number of units scheduled over the whole run

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