KAILAS SREE CHANDRAN M100447ME

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A Job Shop producing 3 types of Gears; G1, G2, G3.

Job Shop consists of o Arrival Dock

o Milling Workstation

o Drilling Workstation

o Paint Shop

o Polishing Area

o Shop Exit

Gear Jobs arrive in batches of 10 units. Their inter-arrival times are uniformly distributed between 400 and 600 minutes.

Of arriving batches, 50% are G1, 30% are G2, 20% are G3.

Each gear type has different operation sequence.

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Gears are transported by Two trucks running at a constant speed of 100 feet/minute.

Each truck can carry only one gear at a time.

Transport Procedure: ◦ The Transport starts from Arrival Dock

◦ When a job is complete at a location, the gear is placed into an output buffer.

◦ A transport request is made for a truck, and the gear waits for the truck to arrive.

◦ Among the two trucks, the preference will be for the one which is closest to the requested location.

◦ The transported job is placed in the input buffer of next station.

◦ After all operations, the finished gear departs from the job shop via the Shop Exit.

ARRIVAL DOCK

MILLING

WORKSTATION

DRILLING

WORKSTATION

PAINTING SHOP

POLISHING AREA

SHOP EXIT

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FOUR Milling Machines

THREE Drilling Machines ONE Worker

TWO Spray Booths

GEAR TYPE OPERATION SEQUENCES PROCESSING TIME(Minutes)

G1

Milling 35

Drilling 20

Painting 55

Polishing 15

G2

Milling 25

Painting 35

Polishing 15

G3

Drilling 18

Painting 35

Polishing 15

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ARRIVAL DOCK

MILLING

WORKSTATION

DRILLING

WORKSTATION

PAINTING SHOP

POLISHING AREA

SHOP EXIT

G1

G2

G3 7

Arrival

Dock

Milling

Station

Drilling

Station

Paint

Shop

Polishing

Area Shop Exit

Arrival

Dock 100 100 250 250 550 Milling

Station 100 300 400 150 300 Drilling

Station 100 300 150 400 500

Paint Shop 250 400 150 300 400 Polishing

Area 250 150 400 300 200

Shop Exit 550 300 500 400 200 8

FROM TO

Units in feet

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Transporter(Truck) speed is same for both loaded and empty.

The freed transporter stays at the destination station until requested by another station.

The Job Shop works for 24 hours a day in 3 shifts at 8 hours each.

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Gear Job Arrivals Gear Transportation

Gear

Pro

cess

ing

Gear Departure

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Inter Arrival time: Uniform 400 & 600 minutes. Entities per arrival: 10.

Gear type proportion: G1=0.5, G2=0.3, G3=0.2.

Reference for Operations Sequence.

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Station Name: Arrive Dock Transporter name: Fork Truck Transporter preference: Smallest Distance

Transporter destination: By Sequence Transporter speed: 100 feet/minute

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Station Name: Milling Station

Transporter name: Fork Truck

Resource: Milling Machine Process time: From Sequence

Transporter name: Fork Truck Transporter preference: Smallest Distance

Transporter destination: By Sequence Transporter speed: 100 feet/minute

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Station Name: Milling Station

Transporter name: Fork Truck Departure from Job Shop

Recording Flow Time

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23

0

10

20

30

40

50

Drilling Milling Painting Polishing

0.6656

14.6109

44.8111

3.0743

Wait

ing T

ime(M

inute

s)

Gear delays at operation locations

24

0

10

20

30

40

50

Drilling

M/C

Milling

M/C

Paint Booth Polishing

Worker

Fork Truck

8.98 12.48

44.8

29.88

37.63

Uti

lizati

on, %

Resource Utilization

25

0

50

100

150

200

250

G1 G2 G3

240.46

153.2

105.16

Flo

w T

ime, M

inute

s

Gear Flow Time (by Type)

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0.6656

14.6109

44.8111

3.0743

0

10

20

30

40

50

Drilling Milling Painting Polishing

Wait

ing T

ime(M

inute

s)

Gear delays at operation locations

GEAR DELAYS AT OPERATION LOCATIONS

Initial Suggestion

Drilling 0.6656 0.6556

Milling 14.6109 14.619

Painting 44.8111 16.082

Polishing 3.0743 8.945

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RESOURCE UTILIZATION

Initial Suggestion

Drilling M/C 8.98 8.98

Milling M/C 12.48 12.48

Paint Booth 44.8 29.86

Polishing Worker 29.88 29.86

Fork Truck 37.63 37.42

Increase the number of Paint booth from two to three.

GEAR FLOW TIME

Initial Suggestion

G1 240.46 203.02

G2 153.2 141.93

G3 105.16 103.93

Tayfur Altiok & Benjamin Melamed. 2007. Simulation Modeling and Analysis with Arena (2nd ed.), Elsevier Inc.

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David Kelton W., Randall P. Sadowski, Deborah A. Sadowski. 2001. Simulation with Arena (2nd ed.), McGraw Hill.

R. Tavakkoli, M., Daneshmand Mehr. 2005. A Computer Simulation Model for Job Shop Scheduling Problems Minimizing Makespan, Computers & Industrial Engineering, 48, 811–823.

Rahime Sancar E. & Arslan O. 2009. Simulation Analysis of Lot Streaming in Job Shops with Transportation Queue Disciplines, Simulation Modelling Practice and Theory, 17,442–453.

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