1. INTRODUCTION
Manufacturing systems often involve multiple processing stages, transportation
delays, assembly operations, and resource constraints. Understanding how these
factors interact can be challenging without analytical tools. Simulation provides a way
to study such systems and evaluate their performance before making real-world
changes.
This project focuses on simulating a dishwasher production system consisting of
workstations, automated guided vehicles (AGVs), a middle storage buffer, and final
assembly. Three types of products (A, B, and C) are produced, each requiring
different part combinations and workstation processing sequences. The objective of
the simulation is to measure:
· Average time a completed dishwasher spends in the system
· Queue buildup in the middle storage area throughout level
· Resource utilization across workstations, AGVs, and assembly staff
The model was developed using Arena Simulation Software, using simple logic
blocks to represent the major activities in the system.
2. SYSTEM DESCRIPTION
The production system begins with customer orders arriving randomly. Each order
belongs to product type A, B, or C and contains a random number of dishwashers.
Each product type requires a specific set of component parts, and each part follows a
predetermined workstation processing sequence.
Once fabricated, parts wait temporarily in a storage area and then are transported by
AGVs to the assembly section. Assembly requires all necessary parts to be present
before a finished dishwasher can be built.
, The flow of activities in the system is summarized below:
Stage Description
Order arrival Random arrival of product requests (Types A, B, C)
Part generation Orders are separated into required part work orders
Workstation
Parts follow routing logic with stochastic processing times
processing
After processing, each work order is duplicated into individual
Cloning of parts
physical parts equal to the order quantity
Transportation AGVs transport parts from storage to assembly
Matching &
Parts are matched and assembled into complete dishwashers
assembly
Exit Finished dishwashers leave the system
3. MODEL DESIGN
The model was built using the following Arena modules:
· Create: Generates incoming orders
· Decide: Assigns order type and routes parts
· Assign: Sets attributes such as product type, quantity, and part type
· Separate: Duplicates entities to represent required part units
· Process: Represents workstation and assembly processing
· Match: Ensures required parts are combined before final assembly
· Record: Measures time in system
Dispose: Removes entities from the system
Manufacturing systems often involve multiple processing stages, transportation
delays, assembly operations, and resource constraints. Understanding how these
factors interact can be challenging without analytical tools. Simulation provides a way
to study such systems and evaluate their performance before making real-world
changes.
This project focuses on simulating a dishwasher production system consisting of
workstations, automated guided vehicles (AGVs), a middle storage buffer, and final
assembly. Three types of products (A, B, and C) are produced, each requiring
different part combinations and workstation processing sequences. The objective of
the simulation is to measure:
· Average time a completed dishwasher spends in the system
· Queue buildup in the middle storage area throughout level
· Resource utilization across workstations, AGVs, and assembly staff
The model was developed using Arena Simulation Software, using simple logic
blocks to represent the major activities in the system.
2. SYSTEM DESCRIPTION
The production system begins with customer orders arriving randomly. Each order
belongs to product type A, B, or C and contains a random number of dishwashers.
Each product type requires a specific set of component parts, and each part follows a
predetermined workstation processing sequence.
Once fabricated, parts wait temporarily in a storage area and then are transported by
AGVs to the assembly section. Assembly requires all necessary parts to be present
before a finished dishwasher can be built.
, The flow of activities in the system is summarized below:
Stage Description
Order arrival Random arrival of product requests (Types A, B, C)
Part generation Orders are separated into required part work orders
Workstation
Parts follow routing logic with stochastic processing times
processing
After processing, each work order is duplicated into individual
Cloning of parts
physical parts equal to the order quantity
Transportation AGVs transport parts from storage to assembly
Matching &
Parts are matched and assembled into complete dishwashers
assembly
Exit Finished dishwashers leave the system
3. MODEL DESIGN
The model was built using the following Arena modules:
· Create: Generates incoming orders
· Decide: Assigns order type and routes parts
· Assign: Sets attributes such as product type, quantity, and part type
· Separate: Duplicates entities to represent required part units
· Process: Represents workstation and assembly processing
· Match: Ensures required parts are combined before final assembly
· Record: Measures time in system
Dispose: Removes entities from the system
