Use Cases of Discrete Event Simulation: Appliance and Research

379 Pages·2012·21.52 MB·English

by  Adrian Adewunmi

Use Cases of Discrete Event Simulation
Steffen Bangsow (Ed.)
Use Cases of Discrete
Event Simulation
Appliance and Research
ABC
Editor
SteffenBangsow
Freiligrathstraße23
Zwickau
Germany
ISBN978-3-642-28776-3 e-ISBN978-3-642-28777-0
DOI10.1007/978-3-642-28777-0
SpringerHeidelbergNewYorkDordrechtLondon
LibraryofCongressControlNumber:2012934760
(cid:2)c Springer-VerlagBerlinHeidelberg2012
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Preface
Over the last decades discrete event simulation has conquered many different
application areas. This trend is, on the one hand, driven by an ever wider use of this
technology in different fields of science and on the other hand by an incredibly
creative use of available software programs through dedicated experts.
This book contains articles from scientists and experts from 10 countries. They
illuminate the width of application of this technology and the quality of problems
solved using simulation. Practical applications of discrete event simulation
dominate in the present book.
The practical application of discrete event simulation is always tied to software
products and development environments. The increase in software quality and
increased mastery in handling the software allows modeling increasingly complex
tasks. This is also impressively reflected in the use cases introduced here.
This project began with an inquiry by Mr. Hloska (thanks for the impetus) and
a following discussion in a number of web forums. The response was just
amazing. Within a short time, interested parties had signed up to fill at least
two books.
This was followed by a period of despair. A large portion of the potential
authors had to withdraw their offer of cooperation. The largest part of the discrete
event simulation projects is subject of confidentiality and the majority of
companies are afraid to loose their competitive advantage when reporting on
simulation projects. This makes a real exchange of experience among simulation
experts extraordinarily difficult apart from the software manufacturers sales
presentations.
I would like to thank all authors who contributed to this book.
I also want to especially thank those authors who have agreed to contribute an
article, but did not receive approval for publication from their superiors.

Steffen Bangsow
Contents
1 Investigating the Effectiveness of Variance Reduction Techniques in
Manufacturing, Call Center and Cross-Docking Discrete Event
Simulation Models............................................................................................1
Adrian Adewunmi, Uwe Aickelin
1.1 Introduction...............................................................................................1
1.2 Reduction of Variance in Discrete Event Simulation................................3
1.2.1 Variance Reduction Techniques.....................................................4
1.3 Case Studies...............................................................................................8
1.3.1 Manufacturing System....................................................................8
1.3.2 Call Centre System.......................................................................13
1.3.3 Cross-Docking System.................................................................17
1.4 Discussion................................................................................................22
1.5 Conclusion...............................................................................................23
Authors Biography, Contact............................................................................23
Bibliography....................................................................................................24

2 Planning of Earthwork Processes Using Discrete Event Simulation.........27
Johannes Wimmer, Tim Horenburg, Willibald A. Günthner, Yang Ji,
André Borrmann
2.1 Actual Situation in Earthwork Planning..................................................27
2.2 Analysis of Requirements for DES in Earthworks..................................28
2.3 State of the Art and Related Work on DES in Earthworks......................30
2.4 Modeling and Implementation of a Module Library for the Simulation
of Earthworks..........................................................................................31
2.4.1 Framework for Earthwork Simulations.........................................31
2.4.2 Modeling of Earthwork Processes................................................32
2.4.3 Module Library for Simulation in Earthworks..............................34
2.5 Coupling DES in Earthworks with Mathematical Optimization
Methods...................................................................................................36
2.6 Evaluation and Case Study......................................................................38
2.7 Conclusion...............................................................................................41
Authors Biography, Contact............................................................................42
References.......................................................................................................43
VIII Contents

3 Simulation Applications in the Automotive Industry.................................45
Edward J. Williams, Onur M. Ülgen
3.1 Manufacturing Simulation.......................................................................45
3.2 Automotive Industry Simulation..............................................................45
3.2.1 Overview of Automobile Manufacturing......................................46
3.2.2 Simulation Studies Relative to Production Facility Lifecycles.....47
3.2.3 Data Collection and Input Analysis Issues in Automotive
Simulation.....................................................................................49
3.2.4 Software Tools Used in Automotive Simulation..........................50
3.3 Examples.................................................................................................52
3.4 A Glimpse into the Future of Simulation in the Automotive Industry.....54
Authors Biography, Contact............................................................................55
ONUR M. ÜLGEN - PMC..............................................................................55
EDWARD J. WILLIAMS - University of Michigan-Dearborn......................55
References.......................................................................................................57

4 Simulating Energy Consumption in Automotive Industries......................59
Daniel Wolff, Dennis Kulus, Stefan Dreher
4.1 Introduction.............................................................................................59
4.1.1 INPRO at a Glance.......................................................................59
4.1.2 About the Authors........................................................................60
4.1.3 Motivation.....................................................................................60
4.1.4 Scope of the Proposed Approach..................................................62
4.2 Energy Simulation...................................................................................64
4.2.1 Definition......................................................................................64
4.2.2 Simulating Energy in Discrete-Event Simulation Tools...............64
4.2.3 Principle of Energy Simulation.....................................................65
4.2.4 Process-Oriented Approach to Energy Simulation.......................69
4.3 Conclusion and Outlook..........................................................................84
References.......................................................................................................86

5 Coupling Digital Planning and Discrete Event Simulation Taking the
Example of an Automated Car Body in White Production.......................87
Steffen Bangsow
5.1 The Task..................................................................................................87
5.2 Data Base in Process Designer................................................................88
5.3 Selecting of Level of Detail for the Simulation.......................................88
5.4 Developing a Robot Library Element......................................................90
5.5 Linking, Shake Hands..............................................................................91
5.6 Interface to Process Designer..................................................................92
5.6.1 Automatic Model Generation.......................................................93
5.6.2 Transfer of Processes from Process Planning to Material Flow
Simulation.....................................................................................93
5.7 One Step Closer to the Digital Factory....................................................95
5.8 Result of the Simulation..........................................................................96
Contents IX

5.9 Outlook and Next Steps...........................................................................97
5.10 Company Presentation and Contact.......................................................97
5.10.1 Magna Steyr Fahrzeugtechnik Graz (Austria)..........................97
5.10.2 The Author..............................................................................100
Reference.......................................................................................................100

6 Modeling and Simulation of Manufacturing Process to Analyze End of
Month Syndrome..........................................................................................101
Sanjay V. Kulkarni, Prashanth Kumar G.
6.1 Introduction...........................................................................................101
6.1.1 End of the Month Syndrome.......................................................102
6.1.2 Objective.....................................................................................103
6.1.3 Problem Statement......................................................................103
6.1.4 Modeling and Simulation Concepts............................................104
6.1.5 Software Selected for the Project Work......................................105
6.2 Study of the Process to Be Modeled......................................................105
6.2.1 Process Mapping.........................................................................106
6.2.2 Data Collection...........................................................................107
6.2.3 Machine Wise Data Collection...................................................107
6.2.4 CYCLE TIME (Seconds)............................................................108
6.2.5 Dispatch Plan for the Yamaha Line (GSF-Gear Shifter Fork)....109
6.2.6 Delay Timings in the Processing Line........................................109
6.3 Building a Virtual Model and Achieving “AS IS” Condition................110
6.3.1 Report - As Is Condition.............................................................110
6.3.2 Reports and Analysis..................................................................112
6.3.3 Results.........................................................................................112
6.3.4 Conclusion..................................................................................113
Authors Biography, Contact..........................................................................113

7 Creating a Model for Virtual Commissioning of a Line Head Control
Using Discrete Event Simulation...............................................................117
Steffen Bangsow, Uwe Günther
7.1 Introduction and Motivation..................................................................117
7.1.1 Definitions..................................................................................119
7.1.2 Software in the Loop and Hardware in the Loop Approaches....120
7.1.3 OPC............................................................................................121
7.2 Virtual Commissioning of Line Controls...............................................122
7.2.1 Task and Challenge.....................................................................122
7.2.2 Virtual Commissioning and Discrete Event Simulation.............123
7.3 Use Case................................................................................................124
7.3.1 Virtual Commissioning Simulation Methodology......................124
7.3.2 Virtual Commissioning Tests.....................................................126
7.3.3 Problems during Virtual Commissioning...................................128
7.3.4 Effects of Virtual Commissioning..............................................128
X Contents

7.4 Outlook..................................................................................................128
7.5 Summary................................................................................................128
Company Profile and Contact........................................................................129
References.....................................................................................................129

8 Optimizing a Highly Flexible Shoe Production Plant Using
Simulation....................................................................................................131
F.A. Voorhorst, A. Avai, C.R. Boër
8.1 Introduction...........................................................................................131
8.2 Problem Description..............................................................................132
8.3 System Description................................................................................132
8.4 Modelling Issue.....................................................................................135
8.4.1 Simulation Architecture and Input Data Analysis......................135
8.4.2 Simulation of Shoes Flow...........................................................135
8.4.3 Production Batches Composition................................................137
8.4.4 Simulation of Dynamic Labor Reallocation...............................137
8.4.5 Labor Allocation Modeling.........................................................138
8.5 Simulation Results and Performances Evaluation.................................139
8.5.1 Use-Case One for Assembly Area: Producing Only One
Family of Shoes..........................................................................140
8.5.2 Use-Case Two: Producing Two Shoes Families.........................140
8.5.3 Use-Case Three for Assembly Area: Producing Three Shoes
Families.......................................................................................141
8.5.4 Finishing Area Overall Performances.........................................142
8.5.5 Production Plant Overall Performances......................................143
8.6 Conclusion.............................................................................................144
Authors Biographies......................................................................................144
References.....................................................................................................145

9 Simulation and Highly Variable Environments: A Case Study in
a Natural Roofing Slates Manufacturing Plant........................................147
D. Crespo Pereira, D. del Rio Vilas, N. Rego Monteil, R. Rios Prado
9.1 Introduction............................................................................................147
9.1.1 Sources of Variability in Manufacturing: A PPR Approach........148
9.1.2 Statistical Modelling of Variability..............................................150
9.2 Case Study: The Roofing Slates Manufacturing Process........................150
9.2.1 Process Description......................................................................151
9.2.2 The PPR Approach to Variability................................................153
9.3 The Model...............................................................................................155
9.3.1 Conceptual Model........................................................................155
9.3.2 Statistical Analysis.......................................................................159
9.3.3 Model Implementation and Validation........................................166
9.4 Process Improvement..............................................................................171
9.4.1 New Layout Description..............................................................171
9.4.2 New Layout Simulation...............................................................173
Contents XI

9.5 Discussion and Conclusions...................................................................174
Integrated Group for Engineering Research - Authors...................................175
References......................................................................................................176

10 Validating the Existing Solar Cell Manufacturing Plant Layout and
Pro-posing an Alternative Layout Using Simulation.............................178
Sanjay V. Kulkarni, Laxmisha Gowda
10.1 Introduction.......................................................................................180
10.1.1 Problem Statement...............................................................180
10.1.2 Purpose................................................................................180
10.1.3 Scope....................................................................................180
10.1.4 Objective..............................................................................181
10.1.5 Methodology........................................................................181
10.2 System Background..........................................................................182
10.2.1 Plant Layout Details.............................................................182
10.2.2 Description of Process.........................................................182
10.3 Model Building and Simulation........................................................184
10.3.1 Assumptions of the Model...................................................184
10.3.2 Simulation Model................................................................184
10.3.3 Model Verification...............................................................188
10.3.4 Model Validation.................................................................188
10.3.5 Simulation Model Results and Analysis..............................189
10.4 Simulation Experiment.....................................................................191
10.5 Analysis and Discussion...................................................................191
10.5.1 Performance Measures.........................................................191
10.5.2 Cost Analysis.......................................................................193
10.5.3 Summaries of Simulation Experiments................................194
10.6 Conclusions.......................................................................................195
10.7 Future Scope.....................................................................................196
Authors Biography, Contact.......................................................................196
References..................................................................................................198
APPENDIX................................................................................................198

11 End-to-End Modeling and Simulation of High-Performance
Computing Systems...................................................................................201
Cyriel Minkenberg, Wolfgang Denzel, German Rodriguez, Robert Birke
11.1 Introduction.......................................................................................201
11.2 Design of HPC Systems....................................................................202
11.2.1 The Age of Ubiquitous Parallelism......................................202
11.3 End-to-End Modeling Approach.......................................................203
11.3.1 Traditional Approach...........................................................204
11.3.2 Taking the Application View...............................................205
11.3.3 Model Components..............................................................206
11.3.4 Tools: Omnest......................................................................207
11.4 Computer Networks..........................................................................207
11.4.1 Network Topologies.............................................................207
XII Contents

11.4.2 Indirect Networks: Fat Trees................................................209
11.4.3 Meshes and Tori...................................................................212
11.4.4 Dragonflies...........................................................................213
11.4.5 Deadlock..............................................................................214
11.5 Case Study 1: PERCS Simulator......................................................214
11.5.1 PERCS Project.....................................................................214
11.5.2 PERCS Compute Node Model and Interconnect.................215
11.5.3 Plug-In Concept...................................................................217
11.5.4 Sample Results.....................................................................219
11.6 Case Study 2: Venus.........................................................................221
11.6.1 Tool Chain...........................................................................221
11.6.2 Workload Models................................................................226
11.6.3 Network Models..................................................................227
11.6.4 Sample Results.....................................................................230
11.7 Scalability.........................................................................................231
11.7.1 Parallel Discrete Event Simulation......................................232
11.7.2 Parallel Simulation Support in Omnest................................233
11.7.3 Venus...................................................................................234
11.8 Conclusion........................................................................................237
Authors Biography, Contact.......................................................................238
References..................................................................................................239

12 Working with the Modular Library Automotive....................................241
Ji(cid:284)í Hloska
12.1 Creating and Managing User-Defined Libraries in Plant
Simulation.........................................................................................241
12.2 Modular Libraries in Plant Simulation...............................................246
12.3 German Association of the Automotive Industry and the
Modular Library ‘Automotive’.........................................................246
12.3.1 Structure of the Modular Library ‘Automotive’...................247
12.3.2 General Principles of the Functionality.................................249
12.4 Structure of Objects of the Modular Library ‘Automotive’...............251
12.5 Examples of Simple Models Using Point-Oriented Objects from
the Modular Library ‘Automotive’....................................................253
12.5.1 Model of a Kanban System...................................................254
12.5.2 Model of Body Shop Production Line..................................262
12.6 Conclusion.........................................................................................275
Authors Biography, Contact.......................................................................276
References..................................................................................................276

13 Using Simulation to Assess the Opportunities of Dynamic Waste
Collection...................................................................................................277
Martijn Mes
13.1 Introduction.......................................................................................277
13.2 Related Work....................................................................................279