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Republic of the Philippines

Tarlac State University


College of Engineering and Technology
Department of Industrial Engineering

Simulation of Hollow Blocks Manufacturing


IE-522 System Simulation

Submitted by:
Oween R. Santiago
Ma. Carine L. Arellano
Edward Jonas E. Pineda
Bea Patricia Feliciano
Reymon Bautista
Franchesca Sico
Ma. Pamela Buenaventura
LJ Anne Sadang
IE-5D

Submitted to:
Engr. Dianna Joy Soriano
Instructor

May 10, 2019


Table of Contents

I. ABSTRACT

II. LOCATIONS

III. ENTITIES

IV. RESOURCES

V. PROCESSING

VI. ARRIVALS

VII. RESULTS

VIII. INTERPRETATION OF RESULTS

IX. CONCLUSION
I. ABSTRACT

In this study, block manufacturing process is investigated using simulation as a tool to optimize

resource utilization and aim to determine the time consumed in making a hollow block. Actual

observations in the manufacturing were done. As a result, from the observations the researchers

accumulate the data they need to simulate the system. Hollow blocks manufacturing used these

resources to produce their products (raw materials, concrete mixer, molding machine, belt

conveyor). Using simulation software, the locations, entities, resources, arrivals, and processes

used were defined and results from the simulated data where given and discussed. Using simulation

it increases the efficiency of producing hollow blocks from 450 in manual process to 1854 hollow

blocks when simulated the manufacturing industry.


II. LOCATIONS

Routing locations are fixed places in the system (e.g. machines, queues, storage areas, work

stations, tanks, etc.) to where parts or entities are routed for processing, storage or simply to

make some decision about further routing.

The location used in this study are the following:

 Raw Materials – the main components of making a hollow block are sand, gravel, water

and “lahar”.

 Mixer or Concrete Mixer – a machine that use to mix the components to form a hollow

block. A cement mixer is strongly recommended for block making. The standard mix

for Concrete Blocks is 1:3:5, 1-part cement to 3 parts sand & 5 parts stone aggregate, by

volume.
 Molding Machine - Fixed Brick Molding Machine Usable Auto Concrete brick making

machine can make concrete block, gravel, ballast, course sand, small sand, fly ash, lime,

spent brick, spent tile.

 Belt Conveyor – is the carrying medium of the molded blocks going to the curing section.

Conveyors are durable and reliable components used in automated distribution and

warehousing, as well as manufacturing and production facilities.

 Curing - begins immediately after placement in the conveyor so that the concrete may

develop the desired strength and durability.

 Finished Product – location where the finished hollow blocks were placed.
III. ENTITIES

Parts or entities refer to the items being processed in the system. These include raw materials,

piece parts, assemblies, loads, WIP, finished products, etc. Entities of the same type or of different

types may be consolidated into a single entity, separated into two or more additional entities or

converted to one or more new entity types.


IV. RESOURCES

A resource may be a person, tool, vehicle or other object that may be used to:

• Transport material between routing locations.

• Perform an operation on material at a location

• Perform maintenance on a location or other resource that is down.


V. PROCESSING

This element defines the processing sequence and flow logic of entities between routing

locations. The operation or service times at locations, resource requirements, processing logic,

input/output relationship, routing conditions, and move times or requirements can be described

using the Processing element.

The resource will start at the storage of raw materials then will proceed to the first process

which is the molding. After in the molding machine, it will go the mixer then proceed once again

to the molding machine. The resource will then put the work-in-process material to the conveyor

and will proceed to the curing section. After curing, the finished product is ready to be ship and

sell.
VI. ARRIVAL

Deterministic, conditional, or stochastic arrivals can be modeled using this element. External

files including production schedules or arrival data can be read in the arrivals element.

The arrival of the entity or the raw material is ten (10) minutes exponentially distributed
VII. RESULT

VIII. INTERPRETATION OF RESULT

The flow of simulation of hollow blocks manufacturing starts at the raw material which is the

sand, gravel, water and “lahar”. The raw material will undergo to the mixer or concrete mixer to

mix all the components of a hollow blocks to be followed by the molding machine and after the

molding process, the molded hollow blocks will be carried by a conveyor to transfer the ongoing

unit to the curing process to permit complete moisturisation till it become a finished product. The

Total product produce in 600-minute or 10 hours simulation time is 1854 hollow blocks.

The average time of the ongoing units to the molding machine is 14.99 minutes and its

utilization is 77.33%. The raw material will be mixed to the average time of 24.12 minutes and

goes to the conveyor in 15.86 minutes and the curing process average time per entry is 9.95

minutes.
IX. CONCLUSION

Pro Model Simulation is designed for manufacturing industries to achieve the benefits at an

affordable price and the best of it. So, a simulated manufacturing industry not only speed up the

process but also increases the output. Given the processing time of the new simulated hollow

blocks making it can produce up to 1,854 hollow blocks as compared to the manual process that

make up to 450 to 500 hollow blocks.

In addition, Pro Model utilizes an optimization tool called Sim Runner that performs

sophisticated “what-if” analysis by running automatic factorial design of experiments on the

model, providing the best answer possible.

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