Introduction Objective

Simulation has become more interesting tool for many companies in developed/developing countries to use in different types of production systems analysis. Additionally, simulation can be used for operational and not only in the planning or designing phases. Recent advances in simulation software has allowed to expand its usefulness beyond a purely design function into operational use. The objective is to use the simulation software for the operational support used for scheduling, daily resource allocation, and process monitoring. In manufacturing facility many possible ways to integrate the simulation services between different areas. Today many of the companies integrated with ERP systems, warehouse management systems or at least real time database systems to maintain the material flow. The Process power of simulation Control software can be used to connect with the Flow System external systems, Design Integration which further utilized to Simulation study the real system. Services Of course it needs some integration Value Supply between these Creation Chain systems. This is the basic idea behind this Different areas to apply for Operational Support work, how we can implement this methodology in order to solve many shop floor problems to quickly respond to the customers and also to compensate all the uncertainties and disturbances in the system. Another application of such a system, when implementing a model in allocating resources in terms of people, machines and other resources at a

terminal. Because the containers come from different places everyday, this will create more problems and complicated if we dont know how to allocate them properly. Simulating this layout can help to find different storage policies in terms of space and cost of operation. And also it will be easier to find the alternative resource allocation procedures. In other terms the simulation tool is helping us to forecast the model in operational use.

Simulation and its Importance

We have the powerful simulation software available which can handle the specific requirements in order to solve the complex systems for real time monitoring. And additional programming really performs to solve specialized computations such as scheduling and many other possibilities to customize the model. Flexsim simulation software is a window based application Database Server environment. The basic powerfulness comes from its object-oriented technology. It has Development Inventory built by using the of Supplier Reduction current technologies and gives all the power, flexibility and interconnectivity of Material Process todays tools. In Control (Cost Reduction) Flexsim all Shop floor Control animation is OpenGL and boasts incredible virtual reality animation. It has the possibility to show all the different views during the model running phase. We can see the different areas where simulation can be used for real time analysis. Beyond these different areas of applications, it is important to focus on a specific element to implement the solution. This simulation server has its own database to integrate between different elements. The goal of current work is to implement the features those are available in the Flexsim Software to design the model to use it for an operational support in a real time environment. The initial condition of the model is the data retrieved from the Company information system usually MPS system. The data has to be retrieved and updated into the simulation model based on the requirement. The objective of this work will be designed to allocate the target-oriented teams, and also to study the stability of the system by considering few cases. (a) New orders into the system, which are not in the MPS system. (b) Allocating target oriented teams based on the forecast (c) Continuous monitoring and sending alerts to the concerned department The number of runs has to be performed for a particular set of data by changing different parameters. Finally the model could be used to analyze the whole system in order to incorporate value addition, financial and costing aspects as well as the expansion of the model to include other parts of the production process.

METHOD Model Study

The method is to connect the Simulation model to the company information system (MPS system). If we can define the manufacturing system as a block diagram, in which there are three main modules defined in the diagram Simulation Study

Forecasted Data

Production System

A Simulation study module, in which the whole manufacturing system can be modeled in terms of resources, processes, flow items etc., A Production system module is the manufacturing facility, where the production work involves. A Forecasting module is the section where it analyzes the updated data from the simulation result as well as historical data to be compared to enhance the production system.

The interaction between the Simulation module and the Production System module is an important factor here. The Simulation model has to be updated as per the real system. This can be updated by connecting simulation model with the database of the company information system. Based on the production schedule the time between the simulation runs can be maintained. And it is possible to check any time by running the model at condensed time. The results from the simulation model can be analyzed, but how this forecast information be presented? This would be possible by means of sending the information to the concerned departments before the time. For this there are few possible solutions either sending to the web browser to display the related information (either image or tabular Simulation Database format) or can make it as an Server Server understandable form and send it to the different departments. Web The computer running with simulation Server is always contacted with the company MPS system to update the information about the material flow. The simulation server can be able to send the simulated information to the web server or network server where this Various Departments server has been connected to the other systems in the production department. Nowadays many companies are doing resource allocation manually by estimating the present situation and deciding where to work and who should work where? It also helps to support in analyzing the scheduling problems. We can incorporate the scheduling into the simulation model and see how the behavior of the production system in order to make decisions. The effect on system stability and resource allocation would give an overall cost reduction in a long run of the

production. Many other internal disturbances can be studied and make an alert before the production as well as while running the production. These alerts can be sent directly to the concerned department. We can even test for an order that is not in the MPS system, whether we can able to deliver before the deadline or not? At another instance if few workers will be absent on a particular day within a week, we dont know how this affects the system stability, these kinds of uncertainties can be included into the Simulation model and tests can be made.

Results and Benefits

The forecasted data can be used in allocating the target oriented teams and all possible alerts in the production facility could be sent to their desktops using the intranet where the people can make the quick decisions. The real time monitoring is possible in all departments so that the adjustments would be made. In scheduling the work, the decisions can be easily taken in day by day production. It is advisable to use simulation software in operational use in order to compensate the internal disturbances as well as uncertainty in demand. The centralization can be achieved in terms of better overall visualization and very simpler interfaces to enterprise systems which lead to E-manufacturing environment. Flexsim is designed to support a seamlessly integrate simulation software in any manufacturing company. We have an advantage that Flexsim uses Microsoft C++ compiler, so in addition it is possible to support all the latest distributed technologies providing by the Microsoft. The real time operational use of simulation enables to continuously improve their operations while realizing all cost parameters. Other benefits as a result from the simulation model as an operational use are: Improved system planning and design Graphical display of simulation results Easy identification of causes of operational problems Under-utilization of resources can be easily identified Simulation alerts can be sent online to the departments Enhanced maintenance of operations at various levels