Pro-Model Simulation Issues - Report Example

Surname Student’s Name Institutional Affiliation ProModel Simulation Abstract There are of six if not eight major areas of operations which includes milling, drilling, turning and machine grinding. Some other areas include assembly, inspection, washing and station for packaging. This paper aimed at building a model of specific manufacturing system and to use the Pro-model software to explain different aspect of the manufacturing system and recommend the most effective and cost effective production system. The results shows cost minimized product and it recommends more use of the simulation process for easy decision making process. Introduction Manufacturing Companies produces products in steps and each step in production attract cost which consist of both variable and fixed cost. While fixed cost is constant throughout production period, variable cost can be changed depending on various factors the surrounds the type and nature of production machines involves. There are of six if not eight major areas of operations which includes milling, drilling, turning and machine grinding. Some other areas include assembly, inspection, washing and station for packaging (Harrell et al., p23). These particular functions are being directed as the first to the last part being processed reaching in the last stage. In all stages, the company aimed at minimizing cost hence cost minimization is very important in production system and that is the aim of any organization. The cost minimization can be reduced either through cost optimization or modeling. Therefore, this paper aimed at carried out cost modelling using Pro-model software to help in developing a system. It will have major functions of production system through carrying out experimental design to collect data and simulate the result (Harrell et al., p173). The results will help in decision making in the production cost. Major components of ProModel software looks like the figure shown below:- Aims and Objectives The ProModel optimization usually suites a powerful yet simple to use simulation tool that is capable of modeling all manufacturing systems. It is flexible manufacturing modeling system and it can help in supply chain management. The main aim of this report is to build a model of specific manufacturing system and to use the Pro-model software to explain different aspect of the manufacturing system and recommend the most effective and cost effective production system. The ProModel simulation software is a computer based discrete event which is a simulating modelling package for cost in manufacturing sector. Model details The simulation components of manufacturing system include the following aspects:- The first part of the model is arrives at every 30 minutes with starting time at 0. In the second part of the system is reached after every 30 minutes with starting time as 20. While the last part is stating after every 30 minutes with starting time at 40. The major aspect of the model include:- Turning Triangular (6, 8, 12) Milling Triangular (15, 20, 25) Drilling Normal mean =7 STD = 2 Grinding Triangular (9, 13, 16) Assembly Normal Mean = 5, STD = 1 Inspection Normal Mean = 8 STD = 3 Washing Normal Mean = 4, STD = 1 Packing Normal Mean = 5, STD = 1 The data was fed into the simulation software to help in building the system. Location In ProModel, locations are describes as fixed places within the systems and they include items like machines system, queues, areas of the storage, work stations among other items. In modeling, location here may include single unit, or multiple location like in this case, we are working with multiple locations. Results of simulation process. The first round of experiment results is shown in the table below:- Type I Type III Type II Avg Parts 0 0 0 0 62 0 69 69 73 70.33333333 5 70 73 71 71.33333333 15 72 74 71 72.33333333 25 73 73 71 72.33333333 50 73 77 73 74.33333333 75 74 76 71 73.66666667 100 75 76 70 73.66666667 120 76 75 73 74.66666667 150 73 77 75 75 170 70 74 78 74 200 71 75 78 74.66666667 250 72 71 76 73 300 74 70 70 71.33333333 350 72 74 76 74 400 71 74 76 73.66666667 450 71 74 75 73.33333333 500 72 74 74 73.33333333 550 72 76 71 73 600 75 75 71 73.66666667 650 72 74 70 72 700 73 75 72 73.33333333 750 73 75 77 75 800 76 73 73 74 850 74 71 67 70.66666667 900 73 76 73 74 950 73 75 71 73 1000 76 77 71 74.66666667 The replica of the experiment Replications Type I Type III Type II WAC Avg Parts 0 0 0 0 0 1 69 69 73 70.33333333 2 71 70 73 71.33333333 3 71 70.67 72 71.22333333 4 71 71.5 71.75 71.41666667 5 70.2 70.4 71.8 70.8 10 70.8 70.6 72 71.13333333 15 71.07 71.2 71.87 71.38 20 71 71.15 71.9 71.35 25 71.24 71.48 71.64 71.45333333 30 71.43 71.6 71.67 71.56666667 35 71.34 71.6 71.74 71.56 40 71.48 71.63 71.7 71.60333333 45 71.6 71.62 71.69 71.63666667 50 71.52 71.54 71.74 71.6 60 71.57 71.52 71.68 71.59 70 71.74 71.44 71.69 71.62333333 80 71.75 71.59 71.59 71.64333333 90 71.8 71.64 71.56 71.66666667 100 71.77 71.52 71.47 71.58666667 The experiment was carried out as per the instruction using ProModel program and the results are recorded in the table below:- Type I 25:- 0 374.2 Type II 28:- 0 206.98 Type III 13:- 0 182.77 The results further reveals that the idle percentage of transport is 54.44% while the semi-skilled is 31.63%. The T full 7, and can be 52.10%. Turning blocked by 0.57%. In this simulation, we mostly used the costing features which can help in decision making on the system based on the cost basis. We are able to monitor the costs associated with every location, entities and resource during a model run. The costing statistics will be produced in this case which will be useful in decision making process. Discussion and Conclusion After the three experiments, the results were graphs to explain the movement of the units against warm up time. The graph below explains the movement. It is important to notice that from the result is that the average parts of the units starts at 60 units while the time is still 0. This shows that time is not the issue but the unit cost which needs to be minimized. The other location modeling results is shown in the table below: Results: Locations Name Scheduled Time (HR) Capacity Total Entries Avg Time Per Entry (MIN) Avg Contents Maximum Contents Current Contents % Utilization Door 2 1 60.03 0.01 0.01 1.00 0.03 0.63 Desk 2 3 24.53 3.84 0.78 2.93 1.10 26.14 DriveThru Line 2 3 23.37 2.07 0.44 2.47 0.43 14.80 DriveThru Window 2 1 23.57 3.00 0.59 1.00 0.70 59.23 The section scenario is through simulation of units against the replica and investigating how the curve moves. The movement of the curve is shown in the table graph below:- Against the replica or the replication it starts at zero showing steep movement of the graph before it flattens at 70. The movement of the graph show how the cost can be reduced in this modeling process of the manufacturing system. This can also be transposed to single capacity and in the process the results below will be produced. Conclusion From the results, quantitative analysis is based on the combined optimization and simulation modeling which indicates that by increasing the volume of materials and increasing the machine hours, we are able to reduce cost by 11.14%. Location and time of material delivery is also very important in this case as they help in measuring performance and cost effectiveness of the production process. Limitation of the model The model is complicated to use and require skilled personnel who are able to interpret the data and use the software in computing the cost reduction in an organization. This is very critical in cost management process and implies that if a skilled personnel is not present the company may not be in a position to use the software. Alternatives There are several alternatives which can be used in decision making process. One of them is to use other cost management tools like excel optimization software which are simple and easy to use. However, ProModel simulation programs gives quicker results compared to other models. Recommendation Until recently, manufacturing companies have not benefited fully from the simulation in improving the decision processes in their organization. The ProModel has been designed specifically to help in improving the decision process and this study recommends the use of Mixed Integer Program (MIP) in modeling the process and ProModel has they are tailored made for manufacturing system decision making process. Work Cited Harrell, Charles, Biman K. Ghosh, and Royce O. Bowden. Simulation using promodel. Boston: McGraw-Hil, 2011. Read More