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Version
1.0
Arena Tutorial 10
Lean Models
Part 1
Copyright 2010
All rights reserved
Mark Polczynski
mhp.techforge@gmail.com
This
tutorial
Batch
processing at
its worst
Each operation
receives
production order
from Production
Control
Operation pulls
parts from
stockroom
Operation sends
parts to
stockroom
Arena model
for batch
processing
Production Control
sends a Production
Order for a batch of
Type 2 parts
Operation 1 works
on a batch of
Type 1 parts
Operation 2
converts Type 1
parts into
Type 2 parts
Operation 1
creates Type 1
parts
Queue
1
Operation 1
sends Type 1
parts to the
Stock Room
Arena Tutorial 10 - Lean Models - Part 1
Production
Order 2 stored
in Queue 1 of
the Match
module
batch of
parts allowed
to move to
queue 2
Production
Order 2 arrives
in queue 1
10
Queue 2
for lower
input
Production
Order 2
Queue 1
for upper
input
11
Operation 2
works on
individual parts12
Send Type 2
parts to the
Stock Room
Arena Tutorial 10 - Lean Models - Part 1
13
Simulation just
after start of
run
Production order
for Type 2 parts
has arrived
Operation 1 is
filling batch of 10
Type 1 parts
Arena Tutorial 10 - Lean Models - Part 1
14
Operation 1 is
working on
parts
7 parts in
Operation 2
queue
Operation 2 has
completed 2 of the
batch of 10 parts
Operation 2 is
working on one
part
Arena Tutorial 10 - Lean Models - Part 1
15
Operation 2
complete and batch
of 10 Type 2 part
sent to Stock Room
Completed
batch of Type
2 parts
Arena Tutorial 10 - Lean Models - Part 1
16
17
Im working as
fast as I can,
you capitalist
lackey!
18
Single piece
continuous flow
with customer
pull
Big Brother to
Rasputin:
Uncle Joe wants a
couple of pizzas
Production
Control
Operation 1
Operation 2
Customer
19
Ready
yet?
Ready
yet?
Ready
yet?
Chill out!
Im almost
done!
Single piece
continuous flow
with customer
pull
20
Production
Control sends
production
order to
Operation 2
21
Generating the
Production
Order
22
Production
Order
Use duplicate to
generate part
entity
Initiate
work on
parts
Arena Tutorial 10 - Lean Models - Part 1
23
Operation 2
process is same,
except use
Operator 2
resource.
Convert
duplicate
Production
Order into Part
entity
Operation 1
works on
parts
Arena Tutorial 10 - Lean Models - Part 1
24
Where the
Parts come
from
Original Part
moves to
Operation 2
Duplicate Part recirculates to become next
Part worked on
25
Resource utilization
for single piece
continuous flow with
customer pull
Operation 1
starts
immediately
Gaps due to
variation in
operation delay
times
Note: Production is
balanced - same
average delay for
both operations
Operation 2
starts when
Operation 1
finishes the first
part
Arena Tutorial 10 - Lean Models - Part 1
26
One-piece buffer:
Allow upstream operator to push (1) piece into space between operations.
27
Occasionally
see 1 piece in
queue
28
Note: Production is
balanced - same
average delay for
both operations
Gaps disappear
for both
operators
29
Operation 1
spends half its
time waiting
for Operation 2
Effect of doubling
process delay time for
Operation 2
Operation
2 always
busy
30
31
In
FIFO Lane
A FIFO lane can be placed between unbalanced
operations to smooth out flow.
This is a type of buffer where the first piece
put in the buffer is the first piece pulled out.
The opposite type of buffer is LIFO
last in-first-out.
Ou
t
32
Spee
d it
up!
Full
Im going
as fast as I
can
FIFO lane
(5 slots)
Thats
better!
Empt
y
slot
Thanks
33
If FIFO lane is
full, then stop
working on
parts
34
Arena model
with FIFO
lane
Fast
operatio
n
FIOFO Lane
(5 slots)
Arena Tutorial 10 - Lean Models - Part 1
Slow
operatio
n
35
Kanban
card
Production Control
sends kanban card
to Operation 2 to
initiate production
Arena Tutorial 10 - Lean Models - Part 1
36
Previous example:
Operators could
monitor
upstream/downstrea
m operations
This example:
Operation 2 notifies
Operation 1 that it is
ready using a kanban
card
37
Production control
initiates a
production order
with a single
kanban card
One kanban
card initiates
production
38
Operation 2
specifies FIFO
quantity and holds
kanban card until
there is no WIP in
Operation 2.
39
Create a Part
entity and
dispose of the
Kanban Card
entity
Kanba
n card
Part
40
Operation 1
runs about
twice as fast as
Operation 2
41
Origin
al Part
42
Duplicate Part
recirculation
path
Arena Tutorial 10 - Lean Models - Part 1
43
Arena model
with FIFO
lane
Operation 1
idle half the
time
Never
more than
5 parts
44
Operation 1
supplies
Operations 2 and
3 using FIFO
Im going
lanes.
as fast as I
can
Spee
d it
up!
Generi
c Part
entitie
s
More
parts
!!
Arena Tutorial 10 - Lean Models - Part 1
45
Copy
and
Paste
Create kanban
cards for part
types A and B
46
Send kanban
card to
Operation 1
47
Route kanban
cards and assign
part types
48
To FIFO
lane
Route part to
appropriate FIFO
lane
Arena Tutorial 10 - Lean Models - Part 1
49
Arena model
with (2) FIFO
lanes
Never
more than
5 parts
50
Next
tutorial
4. Supermarket Pull
- Restock on Order Point
5. Load Leveling Box
6. Kanban production
- Two-bin kanban system
51
52