Workers and Machine Performance Modeling in Manufacturing

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  • 7/24/2019 Workers and Machine Performance Modeling in Manufacturing

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    Volume 8(4) 185-190 (2015) - 185J Comput Sci Syst BiolISSN: 0974-7230 JCSB, an open access journal

    Research Article Open Access

    Jilcha et al., J Comput Sci Syst Biol 2015, 8:4

    http://dx.doi.org/10.4172/jcsb.1000187

    Research Article Open Access

    Computer Science

    Systems BiologyJournal

    of

    Comput

    er

    Science&

    Sy

    stem

    s

    Biolo

    gy

    ISSN: 0974-7230

    Keywords: PVC pipe product; Arena simulation; Waiting time;Troughputs; Capacity utilization

    Introduction

    Industry Perormance improvements arising rom increasedmanuacturing integration continues to be one o the primarycompetitive issues in current days. Faced with ever-increasingchallenges such as the globalization, increased world competition, andincreased customer expectations, companies are pursuing strategies

    to improve their perormance and reduce their costs. Discrete-eventmodeling and simulation (DES) is a popular tool in widely varying fieldsor identiying and answering questions about the effects o changeson processes. Recent research into manuacturing systems integrationhas identified the need or effective positioning o business objectivesdown through the organization and the subsequent measurement operormance in critical areas as key elements o sustainable competitiveadvantage [1-7]. One o the best tools that can indicate the perormanceo any company is simulation sofware. Te simulation sofware can bedivided in to bigger group Simulation Language and Simulators. Tesimulation language is programming based using simulation sofware.Te simulator allows one to build a model o the desired system byusing beore- made modeling constructs [8]. In Simulation, languagesofware the model is developed creating a program syntacticallyor graphically using languages modeling constructs. Tese typeso simulation sofware are very flexible tools but the user needs toknow programming concepts and longer modeling times [8,9]. Tus,simulation can be either discrete event or continuous simulation. Incontinuous model, the state o the system can change continuously overtime. In discrete model, though changes can occur only at separatedpoints in time [10].

    During the past decade, the manuacturing industry has undergonea dynamic transormation. Recently, traditional manuacturers areinherently subject to high-mix, low volume manuacturing as abusiness model [11]. In this paper, discrete event simulation is used tomodel workers and machine perormance in Ethiopia Plastics Industry.Highly industries rely on workers and machine perormance since

    productivity depends on workers and machine availability. A companywill not be able to participate and will not survive in a long-termperspective i employees do not attribute a high significance to such

    organization goals. However, poor workers and machine and machineperormance can be recognized some o the actors are o high loado work, financial stress, and illness. Tereore, workers and machineperormance, as this unction is essential required or huge value to theorganization in maintaining and strengthening its business and revenuegrowth [12-16].

    Multi-skilling o workers can be achieved by cross-training. Cross-training is a process in which workers are trained on the tasks, duties,and responsibilities o multiple tasks in a specific work cell or work area

    [14]. Worker assignment and involvement within a labor-intensive cellis a major role in the perormance o the cell [17]. Te first model assignsmulti-skilled workers to existing cells while the second model finds theoptimal operator assignment within a cell [15]. Te perormance othe workers can be determined rom the arena simulation tools to takean action in line with the other techniques and tools presented in theprevious researches.

    Te problem observed in this case company is the lack o expertsand variation on processing the PVC pipe in adjusting the heattreatment and low capacity utilization o the workshop which causes

    variation to the specified product. During this, the number o recycledproducts is higher per days. Te industry can ail to achieve the goalor efficient and economical production. Capacity includes all resources

    such as machineries, workers etc. o the actory.Tereore, the objective o this paper is to provide industry with a

    complete set o tools, techniques and procedures to allow examining oexisting workers and machine perormance systems. Tese techniques

    *Corresponding author: Kassu Jilcha, Addis Ababa University, Addis Ababa

    Institute of Technology, Addis Ababa, Ethiopia, Tel: +251 913 01774; E-mail:

    [email protected]

    ReceivedMay 05, 2015; AcceptedMay 18, 2015; PublishedMay 20, 2015

    Citation:Jilcha K, Berhan E, Sherif H (2015) Workers and Machine Performance

    Modeling in Manufacturing System Using Arena Simulation. J Comput Sci Syst Biol

    8: 185-190. doi:10.4172/jcsb.1000187

    Copyright: 2015 Jilcha K, et al. This is an open-access article distributed underthe terms of the Creative Commons Attribution License, which permits unrestricted

    use, distribution, and reproduction in any medium, provided the original author and

    source are credited.

    Abstract

    This paper deals with the workers and machine performance measurements in manufacturing system. In

    simulating the manufacturing system, discrete event simulation involves the modeling of the system as it improves

    throughput time and is particularly useful for modeling queuing systems. In modeling this system, an ARENA simulation

    model was developed, veried, and validated to determine the daily production and potential problem areas for the

    various request levels in the case company (Ethiopia Plastic Factory). The results obtained show that throughput

    time in the existing system is low because of occurrence of bottlenecks, and waiting time identied. Therefore,

    some basic proposals have been drawn from the result to raise awareness of the importance of considering human

    and machine performance variation in such simulation models. It presents some conceptual ideas for developing a

    worker manager for representing worker and machine performance in manufacturing systems simulation models.The company workers and machine performance level is raised by identifying the bottle neck area. They were

    recommended to amend the main basic bottle necks identied.

    Workers and Machine Performance Modeling in Manufacturing System

    Using Arena SimulationKassu Jilcha*, Esheitie Berhan and Hannan Sherif

    Addis Ababa University, Addis Ababa Institute of Technology, Addis Ababa, Ethiopia

    http://dx.doi.org/10.4172/jcsb.1000187http://dx.doi.org/10.4172/jcsb.1000187
  • 7/24/2019 Workers and Machine Performance Modeling in Manufacturing

    2/6

    Citation: Jilcha K, Berhan E, Sherif H (2015) Workers and Machine Performance Modeling in Manufacturing System Using Arena Simulation. J

    Comput Sci Syst Biol 8: 185-190. doi:10.4172/jcsb.1000187

    Volume 8(4) 185-190 (2015) - 186J Comput Sci Syst BiolISSN: 0974-7230 JCSB, an open access journal

    helps in applying simulation system model which could be used asbeore an existing system is altered or a new system built, to reducethe chances o ailure to meet specifications, to eliminate unoreseen

    bottlenecks, to prevent under or over-utilization o resources, and tooptimize system perormance.

    Material and Methods

    Te study was conducted by considering different materials

    and methods to achieve the goal o this study. Te literature reviews

    and arena sofware applications were utilized to come up with good

    solution. Simulation, in particular discrete event simulation, has

    still not gain industries wide acceptance as decision support tool or

    perormance evaluation. Te researchers have provided the example o

    the application o discrete event simulation in evaluating perormance

    o a production line in the case company. Te data was collected rom

    an Ethiopian Plastic industry production line and the simulation model

    is built using arena sofware simulation. A simulation model providesa visual animation o the line to see how product will flow through

    the line. An ARENA simulation model was developed, verified, and

    validated to determine the daily production and potential problem

    areas or the various production levels in the plastic industry.

    Discussion and Results

    Production process flow

    In general, there are 5 main workshops in Ethiopia plastic industry.Raw materials in the orm o garden hose and master batch are supplied byoreign countries like Asia and in domestic like Elsewady Cables Ethiopiaand directed to raw material store or storing and quality checking.

    Tey will be sent to two operating process continuous and injectionsection and turn on heat treatment and take the melted plastic withscrew thread then orced into mold. Te bundle will be prepared byhauloo. Afer the product is finished it will be inspected and thenpackaging will be done. Finally; the product will be kept in finishingstorage as shown in Figure 1. Te other process is continues (extrusion)process flow which begins at raw material receiving, and balling unitmachine as indicated by Figure 2.

    Data analysisTe collected data through the means o interviews, direct

    observation and company document review were analyzed. FittingInput Distribution through the input analyzer is used to identiy fittedstatistical distribution [18]. It is used to evaluate the distributions

    Receiving

    production

    orders

    Raw material

    RequisitionProperly

    mounting mold

    Machine

    setup

    parameters

    Full hopper with

    raw materialTurn on

    heater

    Turn on motor

    granule plasticmelted and move

    screw thread

    Open molted and

    product take off

    Meltedplastic

    Finished

    product

    Packing,

    labeling,

    stamping

    ShippingQuarterly

    checked

    yes

    No

    Recycle

    Reject

    Take corrective action

    Figure 1:Injection process ow.

    Raw material (garden

    hose & master batch

    receiving from store)

    Mini storeFilter and

    stablizerMixer

    Spine

    conveyor

    HopperExtruder

    machine

    Vacuum

    tank

    Cooling

    tankNumbering stamp

    machine tank

    Take off

    Balling unit

    machine

    Figure 2:Continuous (extrusion) process ow diagram.

    http://dx.doi.org/10.4172/jcsb.1000187http://dx.doi.org/10.4172/jcsb.1000187
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    Citation: Jilcha K, Berhan E, Sherif H (2015) Workers and Machine Performance Modeling in Manufacturing System Using Arena Simulation. J

    Comput Sci Syst Biol 8: 185-190. doi:10.4172/jcsb.1000187

    Volume 8(4) 185-190 (2015) - 187J Comput Sci Syst BiolISSN: 0974-7230 JCSB, an open access journal

    Model formulation

    In modeling design the type o analysis is perormed on workers

    and machine perormance. Te products that are selected are the one

    those most ofen produced. Tey are considered as one o the main

    products o Ethiopia Plastic Industry in this case company. Te working

    period in Ethiopia Plastic Industry is five days and a hal day withineight working hour consideration. Tis means the working days rom

    Monday to Friday 8:00 working hours and on Saturday 4:00 working

    hours are utilized in the company. Te three models or the arena

    simulations are workers distribution models, continuous extrusion

    models, and injection models as shown in Figures 4-6.

    Model verification

    Verification assesses the correctness o the ormal representation

    o the intended model, by inspecting computer code and test runs, and

    perorming consistency checks on their statistics [20]. More specifically,

    verification consists in the main o the ollowing activities:

    Inspecting simulation program logic.

    Perorming simulation test runs and inspecting sample path

    trajectories. In particular, in a visual simulation environment

    (like Arena), the analyst inspects both code printouts as well as

    graphics to veriy (as best one can) that the underlying program

    logic is correct.

    Perorming simple consistency checks, including sanity checks

    as well as more sophisticated checks o theoretical relations hips

    among predicted statistics.

    In simulation modeling, each part o model run with different

    set o inputs and the obtained outputs were compared by using

    throughputs and littles ormula with real outputs.

    Model validation

    Validation activities are critical to the construction o crediblemodels. Te standard approach to model validation is to collectdata (parameter values, perormance metrics, etc.) rom the systemunder study, and compare them to their model counter parts. Teseparameters will prove the validity o the data and simulation.

    Number of replication estimation

    A good design o simulation replications allows the analyst toobtain the most statistical inormation rom simulation runs or theleast computational cost. In particular, minimizing the number oreplications and their length is necessary to obtain reliable statistics.In order to decide the number o replication the model must run some

    initial set o replication so that sample average, standard deviation andconfidence interval are computed. Tis initial set o replication is shownin able 4.

    parameter and calculates a number o measures o the data. o selectwhich type o distribution to use, the authors have compared thesquare error o each distribution. Te larger the square error value, the

    urther away the fitted distribution is rom the actual data. Te data wasanalyzed by using real recorded time rom the operation areas o theselected product in the case company section. Tese data supported theanalysis o validation, verification and number o replication estimationas discussed in the next sections [7].

    Model assumption

    In Ethiopia Plastics Industry, there are three shifs per day. Workersdistribution through the specified time per shifs can be delayed bydifferent kind o incidents. Te actual working time or whole systemis 8:00 working hours per day. Since it is not expected that a personwill work without some interruptions, the operators may take time ortheir personal needs. Assumptions are taken or modeling the variation

    o workers perormance at time to rest, machine ailure, and poweroff. Te model or one shifs are modeled and analyzed. In the studyonly polyvinyl chloride (PVC) pipe line is selected. Raw material isassumed as a constant input, no interruption o operation is occurred incontinuous and random or injection. Te manuacturer working timeis 8:00 working hours per day. Distribution is fitted to input analyzer;it evaluates the distributions parameter and calculates a number omeasures o the data. In order to select which type o distribution isused, the author has compared the square error o each distribution.Te larger the square error value, the urther away the fitted distributionis rom the actual data (19). Tereore the ollowing fit all summaryorders in worker perormance distribution rom smallest to largestsquare error. From the table it can be seen that triangular is the onewith smallest square error and thus it is selected. Line indicates that the

    data normal distribution and the blocks are the actual datas situationhistogram expression when compared to the normal distribution. Tenormal distribution is skewed to the right (ables 1-3, Figure 3 [18,19]).

    s/n Process Distribution Square error

    1 Raw material requisition 3.5+3 BETA (0.3847, 0.648) 0.023693

    2 Machine set up 4.5+3 BETA (0.896, 0.979) 0.004202

    3 Hopper 3.5+3 BETA (1.05, 0.7336) 0.012719

    4 Turn on heater 5.5+3 BETA (11.76, 2.47) 0.000290

    5Turn on motor granular plastic

    melted move to screw thread22.5+3 BETA (11.16, 1.52) 0.001000

    6 Melted plastic forced into mold 5.5+GAMM (0.663, 22.87) 0.011748

    7 Takeoff 4.5+5 BETA (0.928, 11.35) 0.019469

    8 Package 6.5+4 BETA (0.996, 1.44) 0.002769

    Table 1:PVC pipe process time distribution in injection.

    S/n Continuous (extrusion) Distribution Square

    1 Workers distribution TRIA (5.5, 6.8, 7.5) 0.00473

    Table 2:Workers distribution in continuous (extrusion).

    S/n Process Distribution Square error

    1 Mixer 9.5+11 BETA (0.789, 0.848) 0.000365

    2 Hopper 4.5+6 BETA (1.37, 0.815) 0.000534

    3 Extruder 1.5+2 BETA (1.33, 1.42) 0.000121

    4 Vacuum 4.5+WEIB (0.873, 1.9) 0.003243

    5 Cooling 3.5+4 BETA (1.52, 0.678) 0.001297

    6 Number of stamps TRIA (1.5, 3.2, 4.5) 0.00112

    7 Takeoff 2.5+4 BETA (0.934, 0.903) 0.0001232

    8 Balling 9.5+6 BETA (0.935, 0.836) 0.001245

    Table 3:PVC pipe process time distribution in continuous (extrusion).

    Figure 3:Input analyzer distribution histogram.

    http://dx.doi.org/10.4172/jcsb.1000187http://dx.doi.org/10.4172/jcsb.1000187
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    Citation: Jilcha K, Berhan E, Sherif H (2015) Workers and Machine Performance Modeling in Manufacturing System Using Arena Simulation. J

    Comput Sci Syst Biol 8: 185-190. doi:10.4172/jcsb.1000187

    Volume 8(4) 185-190 (2015) - 188J Comput Sci Syst BiolISSN: 0974-7230 JCSB, an open access journal

    Figure 4: Workers distribution model.

    Figure 5:Continuous extrusion model.

    Figure 6: Injection model.

    http://dx.doi.org/10.4172/jcsb.1000187http://dx.doi.org/10.4172/jcsb.1000187
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    Citation: Jilcha K, Berhan E, Sherif H (2015) Workers and Machine Performance Modeling in Manufacturing System Using Arena Simulation. J

    Comput Sci Syst Biol 8: 185-190. doi:10.4172/jcsb.1000187

    Volume 8(4) 185-190 (2015) - 189J Comput Sci Syst BiolISSN: 0974-7230 JCSB, an open access journal

    For PVC pipe continuous extrusion production line initialreplication (no) is 6 and the initial hal width (ho) is 21.40. Assumingthat the h= 0.25, taking 95% Confidence Level.

    DF= n-1= 6-1= 52

    2

    21,1 / 2

    sn t n a

    h

    2

    2

    2

    3.97n 6 1,1 0.05 / 2

    0.25t

    2 22

    2 2

    3.97 3.97n 0.025, 5 (2571)2 * 1, 666

    0.22 0.25t =

    By considering this equation the number o replications is 1,666

    Conclusion

    In this study worker and machine perormance in manuacturingsystem using simulation has been used. Te simulation is done by usingArena sofware. Te perormance measure used is throughput and it isdirectly related to waiting time; work in process, resource or capacityutilization. Simulation models were built or the continuous (extrusion)and injection workshops separately and finally a model is preparedor the purpose o conducting the computer based simulation. Teproblems identified are the throughput time rom the existing system islow because o occurrence o bottlenecks, and waiting time identified.Workers agent should be assigned on the machinery and workersperormance to ocus on each operating system due that the numbero recycle products can be reduced. Otherwise, the company continues

    like this or a long time and it will be difficult or them to compete intodays market. Tereore, to improve the existing perormance o thecompany, resource utilization improvement is a mandatory.

    References

    1. Suer GA (1996) Optimal Operator Assignment and Cell Loading in Labor-

    Intensive Manufacturing Cells. Computers & Industrial Engineering 31: 155-

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    137-147.

    Workshop Replication Number out (hr) Total time (hr) WIP per (hr)

    Continues (extrusion )

    1 1.903 0.4014 0.7691

    2 1.909 0.4484 0.8588

    3 1.904 0.4697 0.8977

    4 1898 0.4014 0.6691

    5 1899 0.7484 0.8588

    6 1.904 0.5497 0.9977

    Mean 1,902.83

    Half width 21.40

    Standard deviation 3.970

    Injection mold

    1 2.424 9.5589 26.134

    2 2.453 7.3193 19.4321

    3 2.447 8.2891 23.0371

    4 2.460 6.5589 22.897

    5 2.452 7.2165 15.465

    6 2.448 8.4356 25.786

    Mean 2,447.33

    Half width 34.84

    Standard deviation 12.323

    Workers shift time

    1 150 2.9167 0.4404

    2 151 2.9167 0.4413

    3 151 2.196 0.4420

    4 151 2.134 0.4303

    5 151.40 2.5674 0.4405

    6 151.33 2.214 0.412

    Mean 150.95

    Half width 1.08

    Standard deviation 0.5013

    Table 4:Number of replication.

    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