Modelling Manufacturing Systems

(MANE 4390 )
Instructor: Dr. Sayyed Ali Hosseini
Lecture #1

http://www.nist.gov/mep/manu
facturers/processimprovements.cfm

Integrated Manufacturing Systems

Modelling Manufacturing Systems

oilrig-supply-chain

Illustration by Chris Gash

Manufacturing and Production Processes

http://pe-energy.com/the-

Where we are and where we want to be

MANE4390 Modelling Manufacturing Systems

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Definition
Manufacturing: Is a process or combination of processes to
transform raw material into something useful.
Manufacturing System: A manufacturing system is a set of
machines, transportation elements, computers, storage buffers,
people, and other items that are used together for
manufacturing. These items are resources.

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Definition
Manufacturing Systems Alternate Terms:
Factory
Production system
Fabrication Facility
Subsets of manufacturing systems, which are themselves systems,
are sometimes called cells, work centers, or work stations .

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Purpose of Manufacturing

To increase shareholder value

To satisfy customer with high quality and minimum cost
To have minimum impact on the environment

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Manufacturing System Function

Product Design
Process Planning
Production Operations (Fabrication and Assembly)
Material flow and facilities layout
Production planning/control
Administrative

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Consequent Needs

Manufacturing Systems Engineering professionals who

understand factories as complex systems.
Tools to predict the performance of proposed factory
designs.
Tools for optimal factory design.
Tools for optimal real-time management (control) of
factories.

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Basic Issues (General Concerns)

Frequent new product introductions.

Product lifetimes often short.
Process lifetimes often short.
This leads to frequent building and rebuilding of factories.
There is little time for improving the factory after it is
built; it must be built right.

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Basic Issues (Quantity, Quality and Variability)

Design Quality
the design of products that give customers what they
want or would like to have
Manufacturing Quality
the manufacturing of products to avoid giving customers
what they dont want or would not like to have (bugs).

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Basic Issues (Styles for Demand Satisfaction)

Make to Stock (Off the Shelf):
items available when a customer
arrives
appropriate for large volumes, limited
product variety, cheap raw materials
Make to Order:
production started only after order
arrives
appropriate for custom products, low
volumes, expensive raw materials
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Basic Issues (Conflicting Objectives)

Make to Stock:
large finished goods inventories needed to prevent stockouts
small finished goods inventories needed to keep costs low
Make to Order:
excess production capacity (low utilization) needed to
allow early, reliable delivery promises
minimal production capacity (high utilization) needed to
keep costs low

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Manufacturing System Types

Fixed Position Layout

Process Layout
Cellular Layout
Product Layout

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Manufacturing System Types

Fixed Position Layout (Low Production Quantity)
Process Layout (Low Production Quantity)
makes low quantities of specialized and customized products
Also includes production of components for these products
Products are typically complex (e.g., specialized machinery,
prototypes, space capsules)
Equipment is general purpose
Plant layouts:
Fixed position
Process layout
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Manufacturing System Types

Fixed Position Layout (Low Production Quantity)

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Manufacturing System Types

Fixed Position Layout (Low Production Quantity)

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Manufacturing System Types

Process Layout (Low Production Quantity)

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Manufacturing System Types

Cellular Layout (Medium Production Quantity)
A mixture of products is made without significant changeover
time between products

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Manufacturing System Types

Product Layout (High Production Quantity)
Multiple workstations arranged in sequence
Product requires multiple processing or assembly steps

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Manufacturing System Types

Product Layout (High Production Quantity)

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A Question?
How does the number of Parts per Hour vs. Number of
Part Types vary with Layout type?

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Comparison Between Manufacturing System Types

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Laws of Manufacturing

Littles Law (WIP = Production rate*Throughput Time)

Mass and Energy are Conserved
Larger Systems are Less Reliable
Law of Material Decay
Complexity Growth N^M
Technology Changes
Randomness of Behavior
Limits of (Human) Rationality
Combine, Simplify, Eliminate to produce Savings

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Manufacturing Models
Physical models
Mathematical (Analytical) Models
Prescriptive
Descriptive
Experimental Models
Simulation Models
Hybrid Models
The key to building useful models is to select proper decision
variables.
The modeler should ask What questions am I trying to
answer? to determine these what the decision variables are
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Physical Models
models developed by architects to illustrate buildings
being constructed
picture is worth a thousand words.
Physical models also include computer generated
models of products, facility or production line layouts,
etc. Rapid prototyping.

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Mathematical Models
A set of mathematical equations or logical relationships
is developed to describe the real system.
Parameters of Mathematical Models

standard production times

time between machine failures
batch sizes are estimated from accounting and other data.

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Descriptive Mathematical Models

a mathematical simulation - give a set of values for the
decision variables,
we turn the model on and the outcomes will be an
estimate of system performance
Can build very realistic models with this approach
We will construct mathematical simulation models in
this course

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Prescriptive Mathematical Models

Mathematical programming models (linear, integer,
nonlinear).
Turn the model on and outcomes will be the answer of
how we should set the decision variables.
Eg. you should assign jobs 2 and 3 to machine 2.
Grow in size when details are incorporated, making
them difficult to solve optimally
We will construct and solve mathematical programming
models in this course

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Solving Prescriptive Mathematical Models

Some models can be solved optimally.
Some models are too difficult to solve optimally and so
heuristic approaches are used.
Heuristic refers to experience-based techniques for problem solving
where an exhaustive search is impractical.
Heuristic methods are used to speed up the process of finding a
satisfactory solution

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Heuristic Versus Optimization Trade-off

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Analytical Models
Represent a more mathematical abstraction of the real
systems.
Do not detailed events that occur.
Eg. Queuing theory, mathematical programming,
heuristics.

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Experimental Models (Simulation Models)

Mimic the events that occur in the real system,
allowing experimentation with operating parameters.
Eg. What is we change the cycle time of machine 1 from
5mins to 4.5mins?

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Models Applications

Optimization
Performance Prediction
Control
Insight
Justification

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Optimization
Finding the best values for decision variables
Optimal batch sizes
Finding minimum cost shipping networks

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Performance Prediction
Checking potential plans and sensitivity
What if a machine breaks
What if a supplier cant supply this month
Helps come up with production plans that are robust

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Control
Aiding the selection of desired control rules
Should jobs be processed according to shortest
processing time or earliest due dates?

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Insight
Providing better understanding of systems

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Justification
aiding in selling decisions and supporting viewpoints

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The Art of Model Building

Model building is an art in which
science comes to solve the
problem.

Problem Definition
Model Form Hypothesis
Model Formulation
Derive System Performance
Verification
Validation
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Model Form Hypothesis

Decide whats in the real system that you need to put

into your model to find answer to the problem.

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Model Formulation

Describing the entities and relationships found in step

2 and expressed them mathematically.

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Derive System Performance

Run model and examine performance parameters,

see if answers/measures you are getting from model make
sense.
If no, then go back to step 2, If yes, then model is ready
for use.

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Verification and Validation

Verification ensures model on paper and model

generated by computer are equivalent.
Validation ensures that model accurately depicts the
real system.

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An Example of Heuristic Method (Example 1.1)

Assign each of the 3 jobs to each of the 3 machines to minimize
total processing time.

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