Anylogic model
Budget: £20 – £250 GBP
Consider a production shop-floor of three different products, namely FP1, FP2 and FP3. At the shop floor, three different types of raw materials (RM) are initially delivered to the site with the arrival rates specified in the Table below. The shop-floor is open 5 days a week and the working hour is between 8:00am to 17:00.
Raw Arrival time materials
RM1 On average once a day
RM2 On average every other day
RM3 Daily
RM4 2 per day
RM5 6 per week
RM6 On average every 2 days
After the materials are arrived at the shop floor, they will be receipted and stored at separate pallet racks, within 10 to 30 minutes and most likely 15 minutes. Then, raw materials are picked from rack stores and moved to pre-assembly machines (PA1 – PA10) to perform some processing on them before the assembly. The rack pick task takes between 5 to 10 minutes for all the raw material types. The pre-assembly routing for each raw material is presented below:
- Routing-1: RM1 and RM2 should join together to be pro-processed with PA1 then PA5
- Routing-2: RM3 requires a pre-process with PA3 and then PA6
- Routing-3: 50% of RM4 should join RM5 and RM6 to be pre-processed with PA2 then
PA7
- Routing-4: the rest of RM4 requires a pre-process with PA4 and then PA8
- Routing-5: Either RM5 or RM6 requires a pre-process with PA9 and then PA10 at the
same time
The cycle-time of PAs are summarised in the following Table:
Raw materials PA1 – PA4 PA5 – PA8 PA9 & PA10
PA machines cycle-times
Random between 2 to 3 hours
Maximum 1.5 and most likely 1.2 and minimum 0.5 hours With the most likely value of 1.5 hours
Cranfield University: School of Aerospace Transport, and Manufacturing
Manufacturing System Modelling Assignment 2021/2022
Next, the assembly machine assembles the final products from the pre-processed materials from different routings – one from each routing is needed. The assembly process takes between 4.0 to 8.0 hours and typically 6.0 hours to be completed.
The assembly design (Raw material composition) for each final product is summarised in the Table below:
Final Routing- Routing- Routing- Routing- Routing- products 1 2 3 4 5
FP1 x x x
FP2 x x x x FP3x xx
After the assembly, the products will be quality checked with an average delay time of 120 minutes. At the quality check stage, there is a 2% probability that the final products do not pass the quality assurance criteria. Assembly machines are required maintenance after 10 complete assemblies. The maintenance activity is performed by the technicians at the shop floor. The maintenance delay is between 1 to 3 hours. There is also a 10% breakdown rate for each assembly machine at the shop floor. For each breakdown, the delay will increase by 50% in addition to the maintenance delay for any repair or replacement.
There are 2 technicians at the shop-floor to perform receipt, storage, pre-assembly, assembly and maintenance works. In addition, there is 1 quality check officers to perform the quality check.
Other assumptions:
Buffers/queues have the maximum capacity with no limit. However, a buffer or queue with more than 10 entity indicates a bottleneck in the system
Please make your own assumptions for any remaining parameters/variables Please note that the ultimate goal of the simulation is to maximise the throughput. Assignment requirements
You are required to create the simulation model in both AnyLogic and Witness software using the DES technique and run the simulation for 1 year. You also need to write a report based on both the simulation models and compare the results.
Raw Arrival time materials
RM1 On average once a day
RM2 On average every other day
RM3 Daily
RM4 2 per day
RM5 6 per week
RM6 On average every 2 days
After the materials are arrived at the shop floor, they will be receipted and stored at separate pallet racks, within 10 to 30 minutes and most likely 15 minutes. Then, raw materials are picked from rack stores and moved to pre-assembly machines (PA1 – PA10) to perform some processing on them before the assembly. The rack pick task takes between 5 to 10 minutes for all the raw material types. The pre-assembly routing for each raw material is presented below:
- Routing-1: RM1 and RM2 should join together to be pro-processed with PA1 then PA5
- Routing-2: RM3 requires a pre-process with PA3 and then PA6
- Routing-3: 50% of RM4 should join RM5 and RM6 to be pre-processed with PA2 then
PA7
- Routing-4: the rest of RM4 requires a pre-process with PA4 and then PA8
- Routing-5: Either RM5 or RM6 requires a pre-process with PA9 and then PA10 at the
same time
The cycle-time of PAs are summarised in the following Table:
Raw materials PA1 – PA4 PA5 – PA8 PA9 & PA10
PA machines cycle-times
Random between 2 to 3 hours
Maximum 1.5 and most likely 1.2 and minimum 0.5 hours With the most likely value of 1.5 hours
Cranfield University: School of Aerospace Transport, and Manufacturing
Manufacturing System Modelling Assignment 2021/2022
Next, the assembly machine assembles the final products from the pre-processed materials from different routings – one from each routing is needed. The assembly process takes between 4.0 to 8.0 hours and typically 6.0 hours to be completed.
The assembly design (Raw material composition) for each final product is summarised in the Table below:
Final Routing- Routing- Routing- Routing- Routing- products 1 2 3 4 5
FP1 x x x
FP2 x x x x FP3x xx
After the assembly, the products will be quality checked with an average delay time of 120 minutes. At the quality check stage, there is a 2% probability that the final products do not pass the quality assurance criteria. Assembly machines are required maintenance after 10 complete assemblies. The maintenance activity is performed by the technicians at the shop floor. The maintenance delay is between 1 to 3 hours. There is also a 10% breakdown rate for each assembly machine at the shop floor. For each breakdown, the delay will increase by 50% in addition to the maintenance delay for any repair or replacement.
There are 2 technicians at the shop-floor to perform receipt, storage, pre-assembly, assembly and maintenance works. In addition, there is 1 quality check officers to perform the quality check.
Other assumptions:
Buffers/queues have the maximum capacity with no limit. However, a buffer or queue with more than 10 entity indicates a bottleneck in the system
Please make your own assumptions for any remaining parameters/variables Please note that the ultimate goal of the simulation is to maximise the throughput. Assignment requirements
You are required to create the simulation model in both AnyLogic and Witness software using the DES technique and run the simulation for 1 year. You also need to write a report based on both the simulation models and compare the results.