Modeling and Simulation of Nonisothermal Plug Flow Reactor for Methanol Synthesis Via Methyl Acetate Saponification

The design of assembly lines for production operation is deemed crucial to ensure optimal productivity and minimal work in progress. A case study involving investigation of manufacturing assembly line is to be considered for computer based modeling using WITNESS. The objective of this project is to model a manufacturing assembly line for 3 pin power plug using WITNESS and to conduct a sensitivity analysis that would improve the production capability and output rate. The scope of the project is to conduct the corresponding time study for manufacturing assembly line of 3 pin power plug assembly including setup time and operation time. To conduct a simulation project using WITNESS, there are several phases that to be concerned. The phases are established objectives, scope and level of model details, data collection, structuring the model, building the model, testing the model, experimentation, documentation, presentation of result and implementation. The simulation result for manual assembly shows that the number of finished product is 1332 pieces of 3 pin power plug in per day. The total time taken for manual assembly for a 3 pin power plug is 43.2 sec (including handling time and insertion time). The throughput time is 0.72 per minute. The time taken to insert the part by using single station with one arm is 22 second while using two arms it's just required 9 seconds. The throughput time for single station with one arm robot is 0.46 minute per pieces and for two arms is 0.25 minute per pieces. The result from simulation shows great increased on the number of part produces when we introduce automated assembly. In single station with one arm robot, 2085 pieces produces in daily. The production of the plug increased double if compared with manual assembly. While the double arm robot can produces 3839 pieces of power plug daily. From the result, it shows that the single station system with two robot arm yield the best results. It can be concluded that WITNESS is among one of the powerful tools to do a simulation for assembly lines. Therefore further exploration on how to use the software should be enhanced in order to fully utilize the benefit and capability of the simulatio

Modeling of Assembly Line of FinderUnit for Camera

The Dissertation consists of six main divisions excluding Abstract and Appendix. The main divisions are Introduction, Literature Review & Theory, Methodology, Results & Discussion, Conclusion and References. The study was carried out to model the assembly line of finder unit of camera by using WITNESS software. It was also to perform sensitivity analysis in order to propose the best layout, besides, to be familiar with WITNESS software by using its basic and advanced features. Three main measurements were highly evaluated; production rate, throughput time and number of WIP. The study scope was on particular assembly line of the finder unit. It was a component in a camera used to look through when the camera was in hand-to-view position. Simulation role was to evaluate alternatives to support strategic initiatives or support better performance at operational and tactical levels. The following were studied in supporting the project; (a) Manufacturing System, (b) Facility Layout, (c) Manual Assembly Line, (d)Automated Assembly Line, (e) Single Station, (f) Time Study, (g) WITNESS software. There were three types of layouts proposed in the project; in-line manual assembly line, in-line semi-automated assembly line and single station. The method involved during the simulation were introducing the elements, entering the input and output rules, editingthe details of the elements, running the simulation, obtaining the reports and analysis. The main tools used were WITNESSsoftware and stopwatch. Based on the simulation it was found that overall, the setting station was the busiest station for almost all designs compared to other stations. Some of the stations also acquired idle and blocked percentages. The best production rate was produced by Design 1 with additional number of setting station, 27.1 units/hr whereas the throughput time was 2.22 minutes. However, the number of WIP was very high that was 78 units. In conclusion, the modeling of assembling lines was successfully performed within the allocated time. The use of the WITNESS software in the project helped much in modeling and sensitivity analysis. It was recommended for continuation to include more advanced and attractive display features, and improve the current system in term of increasing the production rate and reducing the WIP

Modeling and Simulation of Nonisothermal Plug Flow Reactor for Methanol Synthesis Via Methyl Acetate Saponification

The design of assembly lines for production operation is deemed crucial to ensure optimal productivity and minimal work in progress. A case study involving investigation of manufacturing assembly line is to be considered for computer based modeling using WITNESS. The objective of this project is to model a manufacturing assembly line for 3 pin power plug using WITNESS and to conduct a sensitivity analysis that would improve the production capability and output rate. The scope of the project is to conduct the corresponding time study for manufacturing assembly line of 3 pin power plug assembly including setup time and operation time. To conduct a simulation project using WITNESS, there are several phases that to be concerned. The phases are established objectives, scope and level of model details, data collection, structuring the model, building the model, testing the model, experimentation, documentation, presentation of result and implementation. The simulation result for manual assembly shows that the number of finished product is 1332 pieces of 3 pin power plug in per day. The total time taken for manual assembly for a 3 pin power plug is 43.2 sec (including handling time and insertion time). The throughput time is 0.72 per minute. The time taken to insert the part by using single station with one arm is 22 second while using two arms it's just required 9 seconds. The throughput time for single station with one arm robot is 0.46 minute per pieces and for two arms is 0.25 minute per pieces. The result from simulation shows great increased on the number of part produces when we introduce automated assembly. In single station with one arm robot, 2085 pieces produces in daily. The production of the plug increased double if compared with manual assembly. While the double arm robot can produces 3839 pieces of power plug daily. From the result, it shows that the single station system with two robot arm yield the best results. It can be concluded that WITNESS is among one of the powerful tools to do a simulation for assembly lines. Therefore further exploration on how to use the software should be enhanced in order to fully utilize the benefit and capability of the simulatio

Modeling of Assembly Line of FinderUnit for Camera

The Dissertation consists of six main divisions excluding Abstract and Appendix. The main divisions are Introduction, Literature Review & Theory, Methodology, Results & Discussion, Conclusion and References. The study was carried out to model the assembly line of finder unit of camera by using WITNESS software. It was also to perform sensitivity analysis in order to propose the best layout, besides, to be familiar with WITNESS software by using its basic and advanced features. Three main measurements were highly evaluated; production rate, throughput time and number of WIP. The study scope was on particular assembly line of the finder unit. It was a component in a camera used to look through when the camera was in hand-to-view position. Simulation role was to evaluate alternatives to support strategic initiatives or support better performance at operational and tactical levels. The following were studied in supporting the project; (a) Manufacturing System, (b) Facility Layout, (c) Manual Assembly Line, (d)Automated Assembly Line, (e) Single Station, (f) Time Study, (g) WITNESS software. There were three types of layouts proposed in the project; in-line manual assembly line, in-line semi-automated assembly line and single station. The method involved during the simulation were introducing the elements, entering the input and output rules, editingthe details of the elements, running the simulation, obtaining the reports and analysis. The main tools used were WITNESSsoftware and stopwatch. Based on the simulation it was found that overall, the setting station was the busiest station for almost all designs compared to other stations. Some of the stations also acquired idle and blocked percentages. The best production rate was produced by Design 1 with additional number of setting station, 27.1 units/hr whereas the throughput time was 2.22 minutes. However, the number of WIP was very high that was 78 units. In conclusion, the modeling of assembling lines was successfully performed within the allocated time. The use of the WITNESS software in the project helped much in modeling and sensitivity analysis. It was recommended for continuation to include more advanced and attractive display features, and improve the current system in term of increasing the production rate and reducing the WIP

Manufacturing Processes Management with Usage of Simulation Tools

Simulace výrobních procesů pomáhá optimalizovat výrobu, logistiku a další systémy, díky čemuž dochází ke snižování nákladů a racionalizaci vnitropodnikových procesů. Využitím diskrétní simulace programu Witness Power with Ease se v diplomové práci optimalizuje logistický tok materiálu ve společnosti Hella Autotechnik, s.r.o. Práce přibližuje metody a jednotlivé fáze tvorby modelu včetně jeho validace a navrhuje vylepšení, díky kterému by mělo dojít ke snížení nákladů na dopravní služby o 24 400 Kč měsíčně.By optimizing the logistics, production and other systems the simulation can reduce costs and rationalise business processes. By use of discrete simulation in software Witness Power with Ease is in this diploma thesis optimised logistical flow of material in the company Hella Autotechnik, s.r.o. The thesis introduces methods and particular phases of creating the model including its validation. The proposal in the diploma work suggests the improvement to lower the costs for the transportation services by 24,400 CZK per month.

Grid-enabling FIRST: Speeding up simulation applications using WinGrid

The vision of grid computing is to make computational power, storage capacity, data and applications available to users as readily as electricity and other utilities. Grid infrastructures and applications have traditionally been geared towards dedicated, centralized, high performance clusters running on UNIX flavour operating systems (commonly referred to as cluster-based grid computing). This can be contrasted with desktop-based grid computing which refers to the aggregation of non-dedicated, de-centralized, commodity PCs connected through a network and running (mostly) the Microsoft Windowstrade operating system. Large scale adoption of such Windowstrade-based grid infrastructure may be facilitated via grid-enabling existing Windows applications. This paper presents the WinGridtrade approach to grid enabling existing Windowstrade based commercial-off-the-shelf (COTS) simulation packages (CSPs). Through the use of a case study developed in conjunction with Ford Motor Company, the paper demonstrates how experimentation with the CSP Witnesstrade and FIRST can achieve a linear speedup when WinGridtrade is used to harness idle PC computing resources. This, combined with the lessons learned from the case study, has encouraged us to develop the Web service extensions to WinGridtrade. It is hoped that this would facilitate wider acceptance of WinGridtrade among enterprises having stringent security policies in place

A framework to predict energy related key performance indicators of manufacturing systems at early design phase

Increasing energy prices, growing market competition, strict environmental legislations, concerns over global climate change and customer interaction incentivise manufacturing firms to improve their production efficiency and minimise bad impacts to environment. As a result, production processes are required to be investigated from energy efficiency perspective at early design phase where most benefits can be attained at low cost, time and risk. This article proposes a framework to predict energy-related key performance indicators (e-KPIs) of manufacturing systems at early design and prior to physical build. The proposed framework is based on the utilisation and incorporation of virtual models within VueOne virtual engineering (VE) tool and WITNESS discrete event simulation (DES) to predict e-KPIs at three distinct levels: production line, individual workstations and the components as individual energy consumption units (ECU). In this framework, alternative designs and configurations can be investigated and benchmarked in order to implement and build the best energy-efficient system. This ensures realising energy-efficient production system design while maintaining predefined production system targets such as cycle-time and throughput rate. The proposed framework is exemplified by a use case of a battery module assembly system. The results reveal that the proposed framework results meaningful e-KPIs capable of supporting manufacturing system designers in decision making in terms of component selection and process design towards an improved sustainability and productivity

Layout Optimization of a repair facility using discrete event simulation

Technological advancements in the field of simulation have enabled production managers to model and simulate their facilities under various scenarios, in order to optimize system performance. In particular the reconfiguration of factory layouts can be time consuming and expensive; Discrete Event Simulation (DES) can be used to model and assess various scenarios to assist production managers with layout planning. Significant benefits can be achieved through the use of DES for factory layout optimization including: decreased lead times, reduced manufacturing costs, efficient materials handling and increased profit. This paper presents the development of a DES model in WITNESS for the analysis and factory layout optimization of a repair facility. The aim of the model is to allow decision makers to assess various layouts and configurations with a view to optimize production. The model has been built with a link to an Excel spreadsheet to enable data input and the visualization of Key Performance Indicators (KPIs). Specific functions have been built into the simulation model to set and save new layouts within Excel to facilitate layout optimization. The model will be used to optimize the factory configuration

A framework to predict energy related key performance indicators of manufacturing systems at early design phase

Increasing energy prices, growing market competition, strict environmental legislations, concerns over global climate change and customer interaction incentivise manufacturing firms to improve their production efficiency and minimise bad impacts to environment. As a result, production processes are required to be investigated from energy efficiency perspective at early design phase where most benefits can be attained at low cost, time and risk. This article proposes a framework to predict energy-related key performance indicators (e-KPIs) of manufacturing systems at early design and prior to physical build. The proposed framework is based on the utilisation and incorporation of virtual models within VueOne virtual engineering (VE) tool and WITNESS discrete event simulation (DES) to predict e-KPIs at three distinct levels: production line, individual workstations and the components as individual energy consumption units (ECU). In this framework, alternative designs and configurations can be investigated and benchmarked in order to implement and build the best energy-efficient system. This ensures realising energy-efficient production system design while maintaining predefined production system targets such as cycle-time and throughput rate. The proposed framework is exemplified by a use case of a battery module assembly system. The results reveal that the proposed framework results meaningful e-KPIs capable of supporting manufacturing system designers in decision making in terms of component selection and process design towards an improved sustainability and productivity

Simulation of Industrialised Building System components production

The construction of IBS building should starts with the production of the IBS components and the production process is the main activity concerned in the IBS production plant. Having an optimum production line to manufacture the required IBS elements within targeted time and limited number of reusable steel mould is very important. In this study, workstation organization method has been adopted in the production of IBS component of beam and column. Witness 2001 simulation software has been used to model and simulate the most optimum production line set up. Here, two production lines set up have been proposed to complete the production of IBS beam and column between two and three months time with limited number of reusable steel mould to supply for the construction of medium size single storey IBS housing project ranging from 100 to 300 units. A contingency production line set up which able to complete the production of required IBS components within a month time with increased number of reusable steel mould has also been proposed. Number of resources such as workstation, tool, storage area and labour has been determined from the proposal. The proposed production line can be applied in the planning and cost estimating of IBS production plant set up