Use Cases of Discrete Event Simulation

Transcription

1 Use Cases of Discrete Event Simulation

2 Steffen Bangsow (Ed.) Use Cases of Discrete Event Simulation Appliance and Research ABC

3 Editor Steffen Bangsow Freiligrathstraße 23 Zwickau Germany ISBN e-isbn DOI / Springer Heidelberg New York Dordrecht London Library of Congress Control Number: c Springer-Verlag Berlin Heidelberg 2012 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. Exempted from this legal reservation are brief excerpts in connection with reviews or scholarly analysis or material supplied specifically for the purpose of being entered and executed on a computer system, for exclusive use by the purchaser of the work. Duplication of this publication or parts thereof is permitted only under the provisions of the Copyright Law of the Publisher s location, in its current version, and permission for use must always be obtained from Springer. Permissions for use may be obtained through RightsLink at the Copyright Clearance Center. Violations are liable to prosecution under the respective Copyright Law. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. While the advice and information in this book are believed to be true and accurate at the date of publication, neither the authors nor the editors nor the publisher can accept any legal responsibility for any errors or omissions that may be made. The publisher makes no warranty, express or implied, with respect to the material contained herein. Printed on acid-free paper Springer is part of Springer Science+Business Media (

4 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

5 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 Reduction of Variance in Discrete Event Simulation Variance Reduction Techniques Case Studies Manufacturing System Call Centre System Cross-Docking System Discussion Conclusion Authors Biography, Contact Bibliography Planning of Earthwork Processes Using Discrete Event Simulation Johannes Wimmer, Tim Horenburg, Willibald A. Günthner, Yang Ji, André Borrmann 2.1 Actual Situation in Earthwork Planning Analysis of Requirements for DES in Earthworks State of the Art and Related Work on DES in Earthworks Modeling and Implementation of a Module Library for the Simulation of Earthworks Framework for Earthwork Simulations Modeling of Earthwork Processes Module Library for Simulation in Earthworks Coupling DES in Earthworks with Mathematical Optimization Methods Evaluation and Case Study Conclusion Authors Biography, Contact References... 43

6 VIII Contents 3 Simulation Applications in the Automotive Industry Edward J. Williams, Onur M. Ülgen 3.1 Manufacturing Simulation Automotive Industry Simulation Overview of Automobile Manufacturing Simulation Studies Relative to Production Facility Lifecycles Data Collection and Input Analysis Issues in Automotive Simulation Software Tools Used in Automotive Simulation Examples A Glimpse into the Future of Simulation in the Automotive Industry Authors Biography, Contact ONUR M. ÜLGEN - PMC EDWARD J. WILLIAMS - University of Michigan-Dearborn References Simulating Energy Consumption in Automotive Industries Daniel Wolff, Dennis Kulus, Stefan Dreher 4.1 Introduction INPRO at a Glance About the Authors Motivation Scope of the Proposed Approach Energy Simulation Definition Simulating Energy in Discrete-Event Simulation Tools Principle of Energy Simulation Process-Oriented Approach to Energy Simulation Conclusion and Outlook References Coupling Digital Planning and Discrete Event Simulation Taking the Example of an Automated Car Body in White Production Steffen Bangsow 5.1 The Task Data Base in Process Designer Selecting of Level of Detail for the Simulation Developing a Robot Library Element Linking, Shake Hands Interface to Process Designer Automatic Model Generation Transfer of Processes from Process Planning to Material Flow Simulation One Step Closer to the Digital Factory Result of the Simulation... 96

7 Contents IX 5.9 Outlook and Next Steps Company Presentation and Contact Magna Steyr Fahrzeugtechnik Graz (Austria) The Author Reference Modeling and Simulation of Manufacturing Process to Analyze End of Month Syndrome Sanjay V. Kulkarni, Prashanth Kumar G. 6.1 Introduction End of the Month Syndrome Objective Problem Statement Modeling and Simulation Concepts Software Selected for the Project Work Study of the Process to Be Modeled Process Mapping Data Collection Machine Wise Data Collection CYCLE TIME (Seconds) Dispatch Plan for the Yamaha Line (GSF-Gear Shifter Fork) Delay Timings in the Processing Line Building a Virtual Model and Achieving AS IS Condition Report - As Is Condition Reports and Analysis Results Conclusion Authors Biography, Contact Creating a Model for Virtual Commissioning of a Line Head Control Using Discrete Event Simulation Steffen Bangsow, Uwe Günther 7.1 Introduction and Motivation Definitions Software in the Loop and Hardware in the Loop Approaches OPC Virtual Commissioning of Line Controls Task and Challenge Virtual Commissioning and Discrete Event Simulation Use Case Virtual Commissioning Simulation Methodology Virtual Commissioning Tests Problems during Virtual Commissioning Effects of Virtual Commissioning

8 X Contents 7.4 Outlook Summary Company Profile and Contact References Optimizing a Highly Flexible Shoe Production Plant Using Simulation F.A. Voorhorst, A. Avai, C.R. Boër 8.1 Introduction Problem Description System Description Modelling Issue Simulation Architecture and Input Data Analysis Simulation of Shoes Flow Production Batches Composition Simulation of Dynamic Labor Reallocation Labor Allocation Modeling Simulation Results and Performances Evaluation Use-Case One for Assembly Area: Producing Only One Family of Shoes Use-Case Two: Producing Two Shoes Families Use-Case Three for Assembly Area: Producing Three Shoes Families Finishing Area Overall Performances Production Plant Overall Performances Conclusion Authors Biographies References Simulation and Highly Variable Environments: A Case Study in a Natural Roofing Slates Manufacturing Plant D. Crespo Pereira, D. del Rio Vilas, N. Rego Monteil, R. Rios Prado 9.1 Introduction Sources of Variability in Manufacturing: A PPR Approach Statistical Modelling of Variability Case Study: The Roofing Slates Manufacturing Process Process Description The PPR Approach to Variability The Model Conceptual Model Statistical Analysis Model Implementation and Validation Process Improvement New Layout Description New Layout Simulation

9 Contents XI 9.5 Discussion and Conclusions Integrated Group for Engineering Research - Authors References Validating the Existing Solar Cell Manufacturing Plant Layout and Pro-posing an Alternative Layout Using Simulation Sanjay V. Kulkarni, Laxmisha Gowda 10.1 Introduction Problem Statement Purpose Scope Objective Methodology System Background Plant Layout Details Description of Process Model Building and Simulation Assumptions of the Model Simulation Model Model Verification Model Validation Simulation Model Results and Analysis Simulation Experiment Analysis and Discussion Performance Measures Cost Analysis Summaries of Simulation Experiments Conclusions Future Scope Authors Biography, Contact References APPENDIX End-to-End Modeling and Simulation of High-Performance Computing Systems Cyriel Minkenberg, Wolfgang Denzel, German Rodriguez, Robert Birke 11.1 Introduction Design of HPC Systems The Age of Ubiquitous Parallelism End-to-End Modeling Approach Traditional Approach Taking the Application View Model Components Tools: Omnest Computer Networks Network Topologies

10 XII Contents Indirect Networks: Fat Trees Meshes and Tori Dragonflies Deadlock Case Study 1: PERCS Simulator PERCS Project PERCS Compute Node Model and Interconnect Plug-In Concept Sample Results Case Study 2: Venus Tool Chain Workload Models Network Models Sample Results Scalability Parallel Discrete Event Simulation Parallel Simulation Support in Omnest Venus Conclusion Authors Biography, Contact References Working with the Modular Library Automotive Ji í Hloska 12.1 Creating and Managing User-Defined Libraries in Plant Simulation Modular Libraries in Plant Simulation German Association of the Automotive Industry and the Modular Library Automotive Structure of the Modular Library Automotive General Principles of the Functionality Structure of Objects of the Modular Library Automotive Examples of Simple Models Using Point-Oriented Objects from the Modular Library Automotive Model of a Kanban System Model of Body Shop Production Line Conclusion Authors Biography, Contact References Using Simulation to Assess the Opportunities of Dynamic Waste Collection Martijn Mes 13.1 Introduction Related Work

11 Contents XIII 13.3 Case Description Company Description The Underground Container Project Current Planning Methodology Data Analysis Problem Description Planning Methodologies Static Planning Methodology Dynamic Planning Methodology Simulation Model and Experimental Design Structure Settings Experimental Factors Performance Indicators Replication/Deletion Approach Model Verification and Validation Results Sensitivity Analysis Analysis of Network Growth Benchmarking Conclusions and Recommendations Authors Biography, Contact References Applications of Discrete-Event Simulation in the Chemical Industry Sven Spieckermann, Mario Stobbe 14.1 Introduction Specific Challenges in the Chemical Industry State-of-the-Art and Solution Approaches Examples Study of a Global Supply Net Support of New Site Design Capacity Analysis of Selected Tanks Summary and Conclusions Authors Biography, Contact References Production Planning and Resource Scheduling of a Brewery with Plant Simulation Diego Fernando Zuluaga Monroy, Cristhian Camilo Ruiz Vallejo 15.1 Introduction Case of Study Structure of the Brewing Process Related to the Digital Factory Production Planning and Execution

12 XIV Contents 15.3 The Scheduling Tool Architecture of the Scheduling Tool User Interaction Benefits of Digital Factory as a Scheduling Tool Authors Biography, Contact Use of Optimisers for the Solution of Multi-objective Problems Andreas Krauß, János Jósvai, Egon Müller 16.1 Strategies and Tendencies of Factory Planning and Factory Operation Basics of Methods for Simulation and Optimization Simulation and Costs Simulation and Optimization Case Studies Case Study 1: Dimensioning of Plants with the Aid of Optimizers (by Andreas Krauß) Case Study 2: Order Controlling in Engine Assembly with the Aid of Optimisers (by János Jósvai) Authors Biography, Contact References Author Index Subject Index