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 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpartof thematerialisconcerned,specificallytherightsoftranslation,reprinting,reuseofillustrations,recitation, broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,andtransmissionorinformation storageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilarmethodology nowknownorhereafterdeveloped.Exemptedfromthislegalreservationarebriefexcerptsinconnection 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. 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Printedonacid-freepaper SpringerispartofSpringerScience+BusinessMedia(www.springer.com) 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
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