FAKULTI TEKNOLOGI KEJURUTERAAN MEKANIKAL

DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MANUFACTURING SYSTEM

BMMP 3814 REV : 01

BMMP 3814 MANUFACTURING SYSTEM

Multi-Products Simulation Using ARENA

DEVAKI A/P MANOGARAN B071610137

NURNIQMAH BINTI AZIZ B071610740

NAME OF GROUP MEMBERS

&
MATRIX NUMBER

COURSE 3 BMMD 1/1

DATE 25/3/2019

MS NUR FARAH BAZILAH BINTI WAKHI ANUAR

NAME OF INSTRUCTOR

EXAMINER’S COMMENT VERIFICATION STAMP

TOTAL MARKS

REV NO DESCRIPTION
DATE OF REVISION
01 Contents reviewed after 5 years
12/2/2019
 EXPERIMENT 2

Multi-Products Simulation Using ARENA

1.0 LEARNING OUTCOMES:

At the end of the laboratory experiment, student will be able to:

ii Simulate multi product manufacturing system using ARENA simulation software.
iii Use advance process module in ARENA simulation software.
iiii Examine system performance from simulation results output.

2.0 INTRODUCTION

This simulation is designed to demonstrate manufacturing system with multi product. Students
will need to model the system and relate their knowledge in simulating a random process time
and a random arrival time. Ideally, a resource is available 100%, but in reality resources usually
will be unavailable due to a variety of reasons such as a tool breaking on a machine. Failure will
be introduced in this simulation and will affect resource utilization. The complete running
simulation will generate historical data from which the students will examine the performance of
the system. The simulation is computerized simulation using ARENA simulation software.

3.0 THEORY

ii Manufacturing System.
iii Modeling and Simulation.
iiii Concepts in Discrete-Event Simulation
ivi ARENA Basics
4.0 SIMULATION DATA

You are a manager that responsible for the Paint Shop of a Toy Manufacturing Company
(TMC) want to build a model of your current painting process. Your objective is to increase
output to meet additional demand. You would like to use the model to look for bottlenecks and
test changes to the system.

The Paint Shop processes two different toy part types. The part types enter a paint shop
from an inventory store where they undergo several different processes before exiting the
system. The time between arrivals for the first Part Type, a toy boat, is exponential with a mean
of 5 minutes. The time between arrivals for the second Part Type, a toy truck, is exponential with
a mean of 8 minutes.

Both part types then enter a Paint Preparation process where they must size one of two
operators in order to complete the preparation process. Once the Prep operator has been seized,
the parts require anywhere from 2 to 8 minutes to process. Priority is given to toy boats.

After the preparation step, the parts must be painted in a Paint Booth. This process takes
exactly 2.5 minutes and can process one part a time. Parts are processed first come, first served.
The paint Booth must be cleaned after 25 paint processes. This cleaning process can take
anywhere from 15 to 20 minutes, but usually requires 17 minutes.

Once a part has been painted, a single inspector determines if the part was painted
correctly. This inspection can take anywhere from 2 to 4 minutes, but usually requires 3 minutes.
It is estimated that 90% of the toy parts pass the inspection.

Once a part is inspected, it will exit the system. Run the model for 8 working hours. The
base time units should be minutes.

Examine part cycle-time statistics, number in queue statistics, resources statistics and
frequency statistics.
5.0 PROCEDURES

Steps for simulating using ARENA software:

5.1 Develop ARENA logic model

5.2 Develop the modules in ARENA simulation software.

Note: If the Advanced Process panel is not available in project bar, add by click
File Template Panel Attach AdvancedProcess.tpo

5.3 Input data (Entities, Attributes, Resources, Queues, etc.).

5.4 Define setup parameter.

5.5 Run simulation.

5.6 Generate reports.

5.7 Analyze the reports.

6.0 RESULTS

Present the simulation flowchart and results gain from ARENA simulation experiment
performed in the laboratory.

7.0 DISCUSSIONS

Refer to the results of the simulation. Determine:

i. The bottleneck of the system.

The bottleneck in the system is the seize paint booth. It is because have the larger number of
waiting maximum value which is 9 compared to the other process.

ii. Number of input for Toy Part Type.

The number of input for toy boat is 94.

The number of input for toy truck is 46.

iii. Number of output for Toy Part Type

The number of output for toy boat is 84 while the number of output for toy truck is 41.
iv. Average time for each Toy Part Type spend in the system.

Average time -Toy Boat: 20.4118

-Toy Truck: 22.8721

v. Average value added time for each Toy Part Type.

Average value added time -Toy Boat: 10.4002

-Toy Truck: 10.6097

vi. Average waiting time for each Toy Part Type.

Average waiting time -Toy Boat: 10.0116

-Toy Truck: 12.2624

vii. Utilization for each resource.

Inspector = 0.7781 = 77.811%

Paint Booth = 0.6565 = 65.65%

Prep Operator = 0.7029 = 70.29%

viii. Queue for each resource (average waiting time, max waiting time, average number of
part waiting and max number of part waiting).

Queue Average Maximum Average Maximum

waiting waiting number of number of
time time part waiting part waiting

Inspect toy 3.3946 10.5766 0.8911 5

Seize Paint 5.1316 20.7291 1.5362 9

Booth

Seize Prep 2.9262 28.0007 0.9663 6

Operator

ix. Frequency of Paint Booth failure during the working hours.

The frequency of Paint Booth - Failures =5

- Average time = 16.7883 minutes

x. Percentage of busy time, idle time and maintenance time for Paint Booth.

Percentage busy time = 65.56%

Idle time = 16.86%

Maintenance time = 17.49%

8.0 CONCLUSIONS

The ARENNA simulation software is one of the software that can simulate the multi-product
manufacturing system. From this lab session student will familiar using ARENA simulation
software. Next, the student is able to use advance process in ARENA software simulation
software and develop the ARENA logic model. We can determine the entities, attributes,
resource, queues in each system. Furthermore, we can determine the bottleneck, the waiting time
for each product, and we can know the failures in the system before we produce the product in
the system. In addition, we can simulate the process that can generate the waiting time to
produce each type of product. We also can examine the system performance from the simulation
results output.

9.0 REFERENCES

ii Lecture Notes 1 - 7
iii Banks, J., Carson II, J.S., Nelson, B.L. and Nicol, D.M. (2010). Discrete-Event System
Simulation, 5th Edition. Pearson
iiii Kelton, David W., Sadowski, Randall P., Sturrock, David T. (2007). Simulation with
Arena. McGraw Hill
ivi Altiok, T. and Melamed, B. (2007). Simulation Modeling and Analysis with
ARENA.Academic Press
vi Allen-Bradley, Rockwell Software. ARENA Course Manual (2010). Rockwell
Automation