Impact Journal of Technology & Science India

Volume 25, Issue 07 (2010) 78- 82

IMPACT JOURNAL OF TECHNOLOGY & SCIENCE

ISSN 09274 05426

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MODEL BUILDING PROCEDURE FOR NEW PRODUCTION SYSTEM Pathak R. Somani S (*, A, B), Pathak Ravindra (A), Somani S.K. (B) (A) Research Scholar, S Gyan Vihar University, Jaipur,india (B) Professor, Medicaps Institute of Technology & Management, Indore, India Abstract Production system is very important aspect in industry and before making the investment to install the new system or modification in existing system, we can analyze the system performance only by simulation and modeling. This paper provides a method for development of mathematical model for new production system. A mathematical model uses symbolic notation and mathematical equation to present a system. The art of modeling is enhanced by an ability to abstract the essential features of problem, to select and modify basic assumptions that characterize the system and then to enrich and elaborate the model until a useful approximation analysis. -----------------------------------------------------------------------------------------------------------------------------------------------------

1. Introduction industrial societies. Companies and industrial firms, through which production and business operations are In manufacturing sector modeling has gained importance in the past few years and allows engineers to imagine new systems and enabling them to both quantify and observe behavior. If the system is a production line, then importance of Modeling is increased because it can be used to study and compare alternative designs or to troubleshoot existing systems. With simulation models, how an existing system might perform if altered could explore, or how a new system might behave before the prototype is even completed, thus saving on costs and lead times. Modeling and simulation are emerging as key technologies to support manufacturing in the 21st century. However, there are differing views on how best to develop, validate and use simulation models in practice . Production and business systems are key building blocks in the structure of modern It is usually asserted that production and business operations have the potential to strengthen or weaken a companys competitive ability. To remain competitive, companies have to maintain a high level of performance by maintaining high quality, low cost, short manufacturing lead times, and a high level of customer satisfaction. As a result of fierce competition and decreasing business safety usually performed, represent the major sector of todays global economy. Therefore, in the last decade, companies have made continuous improvement in their production and business systems a milestone in their strategic planning for the new millennium.

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margins, efficient and robust production and business operations have become a necessity for survival in the marketplace.

Volume 25, Issue 07 (2010) 78- 82

capability, simulation modeling can be utilized as an important tool in six-sigma.

What Is Modeling: A model is defined as a representation Many industrial engineering subjects, such as operations research, quality control, and simulation, offer robust and efficient design and problem-solving tools with the ultimate aim of performance enhancement. Examples of this performance include the throughput of a factory, the quality of a product, or the profit of an organization. Simulation modeling as an industrial engineering tool for system design and improvement has undergone tremendous development in the past decade. This can be pictured through the growing capabilities of simulation software tools and the application of simulation solutions to a variety of real-world problems in different business arenas. With the aid of simulation, companies have been able to design efficient production and business systems, validate and trade off proposed design solution alternatives, troubleshoot potential problems, improve systems of a system for the purpose of studying the system. Modeling is the process of producing a model. A model is similar to but simpler than the system it represents. One purpose of a model is to enable the analyst to predict the effect of changes to the system. On the one hand, a model should be a close approximation to the real system and incorporate most of its salient features. On the other hand, it should not be so complex that it is impossible to understand and experiment with it. A good model is a judicious Simulation tradeoff between realism and simplicity. the

practitioners

recommend

increasing

complexity of a model iteratively. An important issue in modeling is model validity. Model validation techniques include simulating the model under known input

conditions and comparing model output with system output. Generally, a model intended for a simulation study is a mathematical model developed with the help of simulation software. Models can be classified in mathematical or physical. A simulation model is a particular type of mathematical model of system. Simulation model may be classified in static or Dynamic, deterministic or stochastic and discrete

performance metrics, and consequently, cut cost, meet targets, and boost sales and profits. In the last decade, simulation modeling has been playing a major role in designing, analyzing, and optimizing engineering systems in a wide range of industrial and business applications. Recently, six-sigma practitioners started to recognize the essential simulation role in system design, problem solving, and continuous improvement. System-level simulation in particular has become a key six-sigma tool for representing and measuring the time-based performance of real-world stochastic production and business systems. Examples include six-sigma studies that are focused on enhancing the productivity, quality, inventory, flow, efficiency, and lead time in production and business systems. In these studies, simulation is particularly performance essential evaluation, for system

or Continuous. Static simulation model is representation of system at a particular point in time where as Dynamic simulation represent as they change over time.

Deterministic models have a known set of inputs and in stochastic has one or more random variables as inputs. A discrete system is one which the state variables change only at a discrete set of points in time but a continuous system is one which the state variables change continuously over time.Today, simulation is being used for a wide range of applications in both manufacturing and business

representation,

experimental

operations. As a powerful tool, simulation models of manufacturing systems are used:

design, what-if analysis, and optimization. With such

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To determine the throughput capability of a manufacturing cell or assembly line To determine the number of operators in a labor-intensive assembly process To determine the number of automated guided vehicles in a complex material-handling system To determine the number of carriers in an electrified monorail system To determine the number of storage and retrieval machines in a complex automated storage and retrieval system To determine the best ordering policies for an inventory control system To validate the production plan in material requirement planning To determine the optimal buffer sizes for work-in-progress products To plan the capacity of subassemblies feeding a production mainline For business operations, simulation models are also being used for a wide range of applications: To determine the number of bank tellers, which results in reducing customer waiting time by a certain percentage To design distribution and transportation networks to improve the performance of logistic and vending systems To analyze a companys financial system To design the operating policies in a fast-food restaurant to reduce customer time-in-system and increase customer satisfaction To evaluate hardware and software requirements for a computer network To design the operating policies in an emergency room to reduce patient waiting time and schedule the working pattern of the medical staff To assess the impact of government regulations on different public services at both the municipal and national levels To test the feasibility of different product development processes and to evaluate their impact on companys budget and competitive strategy

Volume 25, Issue 07 (2010) 78- 82

To design communication systems and data transfer protocols 2. Model Building Procedure The following procedure was developed based primarily on the steps proposed by Shannon [2] and Banks [1]: Objectives of Production System: Every study should begin with a statement of problem. The analyst must ensure that the problem being described is clearly understood. Setting of Objectives and overall project plan: The objective indicate that it should include the plans for the study in terms of the number of people involved, the cost of the study and the number of days required to accomplish each phase of the work along with the result expected at the end of each stage. Being sure that we have sufficient and appropriate personnel, management support computer hardware and software resources to do the job. Conceptual Model Formulation: Developing a

preliminary model either graphically (e.g. block diagram or process flow chart) or in pseudo-code to define the components, descriptive variables, and interactions (logic) that constitute the system. Selecting the factors to be varied, and the levels ofthose factors to be investigated, i.e. what data need to be gathered from the model, in what form, and to what extent. Agreeing the required outputs of the experiment Data Collection: Identifying and collecting the input data needed by the model. Defining the data sources and standardizing the formatting. Model Translation: Models require a lot of information storage and computation so formulating the model in an appropriate simulation language and coding the data. Verification: Concerns the simulation model as a reflection of the conceptual model.Does the simulation correctly represent the data inputs and outputs. Validation: Provides assurance that the conceptual model is an accurate representation ofthe real system. Can the

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model be substituted for the real system for the purposes of experimentation? Final Experimental Design: Designing an experiment that will yield the desired information and determining how each of the test runs specified in the experimental design is to be executed. Experimentation: Executing the simulation to generate the desired data and to perform sensitivity analysis. Analysis and Interpretation:Drawing inferences from the data generated by the simulation runs. Implementation and Documentation: Reporting the results, putting the results to use,recording the findings, and documenting the model and its use 4. Conclusion

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(a) It is impossible or extremely expensive to observe certain processes in the real world, e.g., next year' cancer statistics, performance of the next space shuttle, and the effect of Internet advertising on a company's sales. (b) Problems in which mathematical model can be formulated but analytic solutions are either impossible (e.g., job shop scheduling problem, high order difference equations) or too complicated (e.g., complex systems like the stock market, and large scale queuing models). (c) It is impossible or extremely expensive to validate the mathematical model describing the system, e.g., due to insufficient data.

The model proved to be an effective design and planning tool. The model was an integral part of the facility design process. It was used as a decision support system to help designers quickly assess the performance of various alternative production configurations and resource

allocations without investment. It is useful for testing, analysis or training where real-world systems or concepts can be represented by a model.

REFRENCE [1] Chance, F., Robinson, J., and J. Fowler, Supporting manufacturing with simulation: model design, development, and deployment, Proceedings of the 1996 Winter Simulation Conference, San Diego, CA, 1996, pp. 1-8. [2] Ycesan, E. And Fowler, J. ,Simulation Analysis of Manufacturing and Logistics Systems, Encylcl opedia of Production and Manufacturing Management, Kluwer Academic Publishers, Boston, P. Swamidass ed. , pp. 6873. Areas of Modeling In general, whenever there is a need to model and analyze randomness in a system, Modeling is the tool of choice. More specifically, situations in which simulation modeling and analysis is used include the following: 697., 2000. [3] Schruben, L., and T. Roeder, Fast simulations of largescale highly congested systems, Transactions of the

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Society for Modeling and Simulation International, Vol. 79, No. 3, 2003, pp. 115-125. [4] Jankauskas, L. and S. McLafferty, BESTFIT, Distribution fitting software by Palisade Corporation. Proceedings of the 1996 Winter Simulation Conference, 1996, pp. 551-555. [5] Law, A.M. and M.G. McComas, Pitfalls to avoid in the simulation of manufacturing systems. Industrial Engineering, Vol. 31, 1989, pp. 28-31,69. [6] Law, A.M. and D.W. Kelton. Simulation Modeling and
rd

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Analysis (3 Ed.), McGraw-Hill, New York, 2000. [7] Chong, S., Sivakumar, A., and Gay, R. (2002) Design, Development and Application of an Object Oriented Simulation Toolkit for Real-time Semiconductor Manufacturing Scheduling. Proceedings of the 2002 Winter Simulation Conference, pp. 1849-1856. [8] Jackson, M., and Johansson, C. (1997) Real Time Discrete Event Simulation of a PCB Production System for Operational Support. Proceedings of the 1997 Winter Simulation Conference, pp. 832-837. [9] Katz, D., and Manivannan, S. (1993) Exception Management on a Shop Floor Using Online Simulation. Proceedings of the 1993 Winter Simulation Conference, pp. 888-896. [10] Muller, D., Jackman, J., and, Fitzwater, C. (1990) A Simulation-based Work Order Release Mechanism for a Flexible Manufacturing System. Proceedings of the 1990 Winter Simulation Conference, pp. 599-602. [11] Peters, B., Smith, J., Curry, J., LaJimodiere, C., and, Drake, G. (1996) Advanced Tutorial Simulation-based Scheduling and Control. Proceedings of the 1996 Winter Simulation Conference, pp. 194-198. [12] Rogers, P., and Gordon, R. (1993) Simulation for Real-Time Decision Making in Manufacturing Systems. Proceedings of the 1993 Winter Simulation Conference, pp. 866-874.

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