10CC15 MODELING AND ANALYSIS OF MANUFACTURING SYSTEMS ANSWER KEY Part - A 1.

. Build a system model Understand the important factors in the real system Find a good solution to the model Modify it with knowledge of relevant externalities Find a better solution to the real system

2. A scale model is a physical model, a representation or copy of an object that is larger or smaller than the actual size of the object, which seeks to maintain the relative proportions (the scale factor) of the physical size of the original object. 3. The purpose of a physical model on a smaller scale may be to have a better overview, for testing purposes, as hobby or toy. The purpose of a physical model on a larger scale may be to see the structure of things that are normally too small to see properly or to see at all, for example a model of an insect or of a molecule. 4. Conveyor analysis, AGV Analysis, etc., 5. Any four points o Total facilities power requirements o Interaction between functions o Work space requirements by function o Work flow o Material handling requirements o Physical constraints o Special process requirements o Employee needs (legal requirements) o Power requirements for each piece of equipment or machinery o Lighting requirements o Noise levels in work areas 6. Any four points

Pallet rack including selective, drive-in, drive-thru, double-deep, pushback, and gravity flow Mezzanine including structural, roll formed, racks Vertical Lift Modules Horizontal Carousels Vertical Carousels

7. A generic model constitutes a standard tool with some built-in elements, which can facilitate its adaptation to a particular national education system 8. EST (Empirical Simulation Technique) is a statistical procedure for simulating life-cycle risk analysis of events such as storms and their correpsonding environmental impacts

9. Synchronous Manufacturing is an operational strategy that incorporates lean principles, but adds flexibilty to the process. Where lean manufacturing is oriented toward a repetitive manufacturing environment, synchronous manufacturing applies to low-volume/high mix type of order characteristics. 10. Forward scheduling is taking a job with a number of tasks and allocates those tasks to resources as early as possible when resources the resources allow. Backwards scheduling is taking a job with a number of tasks and allocates those tasks to resources in reverse orders and schedules the task on the resource

PART B 11.(a)(i) One division between models is based on the type of outcome they predict. Deterministic models ignore random variation, and so always predict the same outcome from a given starting point. On the other hand, the model may be more statistical in nature and so may predict the distribution of possible outcomes. Such models are said to be stochastic. A second method of distinguishing between types of models is to consider the level of understanding on which the model is based. The simplest explanation is to consider the hierarchy of organizational structures within the system being modeled. (4) For the given problem assume suitable data to develop the mathematical model. (4) 11. (a)(ii) Types of manufacturing Systems Process or continuous production Mass production Batch production Jobbing production (4) For each types its characteristics (4) 11. (b)(ii) (1) Out of Portion (2) Out of Portion (3) Physical model A physical model (most commonly referred to simply as a model, however in this sense it is distinguished from a conceptual model) is a smaller or larger physical copy of an object. A physical model of something large is usually smaller, and of something very small is larger. A physical model of something that can move, like a vehicle or machine, may be completely static, or have parts that can be moved manually, or be powered. (3*3=9) 11. (b)(ii) First law: WIP Second law: Matter is conserved Third law: the larger the system scope, the less reliable the system Fourth law: Objects decay (Any 4*1=4) 12. (a)(i) Line Balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity. A constraint slows the process down and results if waiting for downstream operations and excess capacity results in waiting and absorption of fixed costs.

A production line is a set of sequential operations established in a factory whereby materials are put through a refining process to produce an end-product that is suitable for onward consumption; or components are assembled to make a finished article. Objectives: To minimize the total amount of unassigned or idle times at the work station. To eliminate bottlenecks, ensuring a smoother flow of production. To determine the optimal number of work stations and operations in each station. To maintain the morale of workers since the work content of the different workers will not be of great difference. (4+4=8) 12. (a)(ii) Out of Portion (8) 12. (b)(i) (1) Batch Manufacturing: Batch production is a technique used in manufacturing, in which the object in question is created stage by stage over a series of workstations. Batch production is common in bakeries and in the manufacture of sports shoes, pharmaceutical ingredients (APIs), inks, paints and adhesives. (2) Flexible Manufacturing: A flexible manufacturing system (FMS) is a manufacturing system in which there is some amount of flexibility that allows the system to react in the case of changes, whether predicted or unpredicted. (3) Just In Time Manufacturing: Just in time (JIT) is a production strategy that strives to improve a business return on investment by reducing in-process inventory and associated carrying costs (3*3=9) 12. (b)(ii) (1) By using number parts in the storage buffers. (2) By using Number parts moving in the workstation (3) By using effectiveness of the workstations. (For 3 point = 7) 13. (a)(i) The objective of a warehouse management system is to provide a set of computerized procedures to handle the receipt of stock and returns into a warehouse facility, model and manage the logical representation of the physical storage facilities (e.g. racking etc.), Manage the stock within the facility and enable a seamless link to order processing and logistics management in order to pick, pack and ship product out of the facility. A warehouse management system, or WMS, is a key part of the supply chain and primarily aims to control the movement and storage of materials within a warehouse and process the associated transactions, including shipping, receiving, put away and picking. (2*4+4=8) 13. (a)(ii)

(4*2=8)

13.(b)(i) AGVS towing vehicle AGVS unit load carriers AGVS pallet trucks AGVS forklift trucks AGVS light-load transporters AGVS assembly-line vehicles (Any 4*2=8) 13. (b)(ii) (1) Picker to Part: This particular method is very common and found in most warehouse environments. The process involves a storage area, a picking area and a material handing system that is used to refill the picking locations from the storage area, which can be forklift based or more specialized such as gravity flow racks. (2) Part To Picker :The part to picker method employs the same physical locations as the previous method; storage area, picking area and a material handling system that moves the items from the storage area to the picking area. The difference with this method is that the picking area is made up of a series of picking bays. The items are moved from the storage area and delivered to the picking bays. (3) Sorting System: The sorting process including the requirement for a picking area, a storage area, replenishment of the picking area and a sorter. This method uses automatic material handling system consisting of multiple conveyors and a number of sorting devices. (4) Pick to Box: Pick to box is similar to the sorting solution as it uses the same elements; a picking area, a storage area, replenishment of the picking area and a sorter. The picking area is organized so that there are a number of picking zones connected by a conveyor system. (4*2=8) 14. (a)(i) Monte Carlo methods (or Monte Carlo experiments) are a class of computational algorithms that rely on repeated random sampling to compute their results. Monte Carlo methods are often used in computer simulations of physical and mathematical systems. Procedures : Step A. Construct a simulated universe of cards or dice or some other randomizing mechanism whose composition is similar to the universe whose behavior we wish to describe and investigate. The term universe refers to the system that is relevant for a single simple event. Step B. Specify the procedure that produces a pseudo-sample which simulates the real-life sample in which we are interested. Step C. If several simple events must be combined into a composite event, and if the composite event was not described in the procedure in step B, describe it now. Step D. Calculate the probability of interest from the tabulation of outcomes of the resampling trials. (2+6=8) 14. (a)(ii) A waiting line system (or queuing system) is defined by two elements: the population source of its customers and the process or service system itself.

(2+6=8) 14. (b)(i) Purpose: From a theoretical point of view, the process modeling explains the key concepts needed to describe what happens in the development process, on what, when it happens, and why. From an operational point of view, the meta-process modeling is aimed at providing guidance for method engineers and application developers. (1) Coverage Activity-oriented Product-oriented Decision-oriented Context-oriented Strategy-oriented (2) Alignment Strategic processes Tactical processes Implementation processes (3) Granularity Granularity refers to the detail level of the process model and affects the kind of guidance, explanation and trace that can be provided. High granularity limits these to a rather coarse level of detail whereas fine granularity provides more detailed capability. (For 3 point = 8) 14. (b)(ii) Simulation is the imitation of some real thing available, state of affairs, or process. The act of simulating something generally entails representing certain key characteristics or behaviors of a selected physical or abstract system. Goals of Simulation System, Throughput under average and peak loads; System cycle time (how long it take to produce one part); Utilization of resource, labor, and machines; Bottlenecks and choke points; WIP storage needs; Effectiveness of scheduling systems; Effectiveness of control systems. (2+6=8)

15. (a)(i) A Petri net (also known as a place/transition net or P/T net) is one of several mathematical modeling languages for the description of distributed systems. A Petri net is a directed bipartite graph, in which the nodes represent transitions (i.e. events that may occur, signified by bars) and places (i.e. conditions, signified by circles). Petri nets can be used by both practitioners and theoreticians. Thus, they provide a powerful medium of communication between them: practitioners can learn from theoreticians how to make their models more methodical, and theoreticians can learn from practitioners how to make their models more realistic. (2+2+ Explanation (4)=8) 15. (a)(ii) The concepts of DBR actually preceded the Five-Focusing-Steps and the notion of the "throughput world" in the development of the TOC paradigm. While the DBR method is much simpler than the older Optimized Production Technology (OPT) algorithm and the recent Advanced Planning and Scheduling (APS) systems, for many production environments, especially those not currently or consistently dominated by an active internal bottleneck, an even simpler method can be adopted.

(4+4=8) 15. (b)(i) 1. Balance the flow, not capacity 2. The level of utilization of a non-bottleneck resource is determined not by its own potential but by some other constraint in the system. 3. Utilization and activation of a resource are not synonymous or the same thing. 4. An hour lost at a bottleneck is an hour lost for the entire system. 5. An hour saved at a non-bottleneck is just a mirage. 6. Bottlenecks govern both throughput and inventory in the system. 7. Transfer batch may not and many times should not be equal to the process batch. 8. A process batch should be variable both along its route and in time. 9. Set the schedule by examining capacity and priority simultaneously and sequentially.(9*0.9=8) 15. (b)(ii) We represent a model using an event graph. Event graphs provide a representation for the static simulation algorithm to work on, and transformations on event graphs can be used to improve simulation performance.

Using this notation, we can build a model that simulates a simple waiting line with one server (e.g., a ticket booth at a theater, the drive-in window at a fast-food restaurant, etc.). (7)