Technology Forge Version 1.0 Arena Tutorial 3 Electronic Assembly Process - Part 1 2009 Mark Polczynski All rights reserved Arena Tutorial 3 - Electronic Assembly Process - 1 1
Tutorial Objectives: Create a basic model of an electronic assembly process. Use an Assign module to assign different delay times for different assemblies. Use Record modules to create new measures of system performance. Review the properties of the often-used Weibull probability distribution. Arena Tutorial 3 - Electronic Assembly Process - 1 2
Electronic Assembly Example Metal case comes in 2 versions: Part A and Part B Top and bottom case pieces are identical. Metal case Circuit board Sealant Arena Tutorial 3 - Electronic Assembly Process - 1 3
Store Room Part A Case Supplier Part A Case Sealant Good assembly Ship Circuit Board Supplier Circuit board Electronic Assembly Salvaged assembly Salvage Part B Case Supplier Part B Case Scrap assembly Scrap Process we will be simulating Context Diagram for this Example Arena Tutorial 3 - Electronic Assembly Process - 1 4
Simulation goals are to collect statistics on: Resource utilization for each resource What percent of the available work time is each resource in the process busy? Number of units in queue at each operation How many units are waiting to be worked on at each operation? Time in queue at each operation How long does each unit wait to get worked on? Arena Tutorial 3 - Electronic Assembly Process - 1 5
Do not include circuit boards and sealant in this model Arena Tutorial 3 - Electronic Assembly Process - 1 6
Desired statistics for each process module: - Resource utilization - Units in queue - Time in queue Basic Model Arena Tutorial 3 - Electronic Assembly Process - 1 7
Arena Tutorial 3 - Electronic Assembly Process - 1 8
Do these next Configure Create Modules Arena Tutorial 3 - Electronic Assembly Process - 1 9
Configure Finish Part A Surfaces Arena Tutorial 3 - Electronic Assembly Process - 1 10
Configure Finish Part B Surfaces Next Arena Tutorial 3 - Electronic Assembly Process - 1 11
Start configuring the Seal Assembly module We will return to this module later to specify Delay Type Arena Tutorial 3 - Electronic Assembly Process - 1 12
Do this next Configure decision modules Arena Tutorial 3 - Electronic Assembly Process - 1 13
Configure Rework Seal module Arena Tutorial 3 - Electronic Assembly Process - 1 14
Tutorial Objectives: Create a basic model of an electronic assembly process. Use an Assign module to assign different delay times for different assemblies. Use Record modules to create new measures of system performance. Review the properties of the often-used Weibull probability distribution. Arena Tutorial 3 - Electronic Assembly Process - 1 15
Finish configuring the Seal Assembly module Part A and Part B have different delay times Arena Tutorial 3 - Electronic Assembly Process - 1 16
Start configuring the Assign module for Part A Arena Tutorial 3 - Electronic Assembly Process - 1 17
Finish configuring the Assign module for Part A Arena Tutorial 3 - Electronic Assembly Process - 1 18
Start configuring the Assign module for Part B Arena Tutorial 3 - Electronic Assembly Process - 1 19
Finish configuring the Assign module for Part B Arena Tutorial 3 - Electronic Assembly Process - 1 20
f ( x) x 1 x/ e Weibull distribution of Sealer Times α = 2.5 β = 5.3 0.25 0.2 Probability 0.15 0.1 0.05 Time between arrivals Probability of next part arriving x minutes after previous part 0 0 2 4 6 8 10 12 Sealer Time (minutes) Arena Tutorial 3 - Electronic Assembly Process - 1 21 x
Finish configuring the Seal Assembly module Arena Tutorial 3 - Electronic Assembly Process - 1 22
Run simulation! Desired statistics for each process module: - Resource utilization - Units in queue - Time in queue Arena Tutorial 3 - Electronic Assembly Process - 1 23
Desired statistics for each process module: - Resource utilization - Units in queue - Time in queue Review results Arena Tutorial 3 - Electronic Assembly Process - 1 24
Review results Desired statistics for each process module: - Resource utilization - Units in queue - Time in queue Arena Tutorial 3 - Electronic Assembly Process - 1 25
Change pictures for Part A and Part B Arena Tutorial 3 - Electronic Assembly Process - 1 26
Animate resources Arena Tutorial 3 - Electronic Assembly Process - 1 27
Animated model Arena Tutorial 3 - Electronic Assembly Process - 1 28
Tutorial Objectives: Create a basic model of an electronic assembly process. Use an Assign module to assign different delay times for different assemblies. Use Record modules to create new measures of system performance. Review the properties of the often-used Weibull probability distribution. Arena Tutorial 3 - Electronic Assembly Process - 1 29
Simulation goals are to collect statistics on: Resource utilization for each resource What percent of the available work time is each resource in the process busy? Number of units in queue at each operation How many units are waiting to be worked on at each operation? Time in queue at each operation How long does each unit wait to get worked on? Cycle time How long does each part take to get through the entire system? Good assembly cycle time, Salvaged assembly cycle time, Scrap assembly cycle time. Add cycle time statistics Arena Tutorial 3 - Electronic Assembly Process - 1 30
Cycle time: How long does each part take to get through the entire system? Good assembly cycle time, Salvaged assembly cycle time, Scrap assembly cycle time. How does this split out? Arena Tutorial 3 - Electronic Assembly Process - 1 31
Add cycle time recorders Arena Tutorial 3 - Electronic Assembly Process - 1 32
From a few slides ago Configure the Record modules The other Record modules are configured similarly Arena Tutorial 3 - Electronic Assembly Process - 1 33
Cycle times for assemblies Arena Tutorial 3 - Electronic Assembly Process - 1 34
Tutorial Objectives: Create a basic model of an electronic assembly process. Use an Assign module to assign different delay times for different assemblies. Use Record modules to create new measures of system performance. Review the properties of the often-used Weibull probability distribution. Arena Tutorial 3 - Electronic Assembly Process - 1 35
The Weibull distribution can take on many shapes, depending on the values of the shape parameters: a ~= 1 a ~= 4 a t ( a 1) e ( t / b) a b a 1 < a < 4 Review of Weibull distribution Arena Tutorial 3 - Electronic Assembly Process - 1 36
For a = 1, Weibull reduces to Exponential a t ( a 1) e ( t / b) a b a 1 t (1 1) e ( t / b) 1 b 1 1 1 (0) ( t / b) ( t / b) b t e b e 1/ b e ( t) Arena Tutorial 3 - Electronic Assembly Process - 1 37
0.1000000 0.0900000 0.0800000 0.0700000 0.0600000 0.0500000 0.0400000 f(t):for Weibull Plot 1 Plot 2 Plot 3 Exponential λ = 0.1 Weibull a = 1 0.8 1.2 b = 10 12.98 8.05 f ( t) a b a t ( a 1) e ( t / b) a Effect of varying a for Wiebull Weibull: a=1 Weibull: a=.8 Weibull: a=1.2 0.0300000 0.0200000 0.0100000 0.0000000 0 10 20 30 40 50 60 Arena Tutorial 3 - Electronic Assembly Process - 1 38
For a ~4, Weibull mimics Normal Distribution 0.03 Weibull vs Normal Plot 1 Plot 2 Plot 3 Wiebull a 4 3 5 b 55 43 68 Normal a 50 b 14.5 0.025 0.02 0.015 Normal Wiebull: a=4 Wiebull: a=3 Wiebull: a=5 0.01 0.005 0 0 10 20 30 40 50 60 70 80 90 100 Arena Tutorial 3 - Electronic Assembly Process - 1 39
Wiebull for: 1 < a < 4 f(t) for Weibull Disctibution 0.02 0.018 0.016 Plot 1 Plot 2 Plot 3 a = 1.2 2 2.5 b= 42 48 56 0.014 0.012 0.01 a=1.2 a=2 a=2.5 0.008 0.006 0.004 0.002 0 0 20 40 60 80 100 120 140 Arena Tutorial 3 - Electronic Assembly Process - 1 40
The Arena Input Analyzer can help us to use the best time distribution models: Arena Tutorial 3 - Electronic Assembly Process - 1 41
Tutorial Objectives: Create a basic model of an electronic assembly process. Use an Assign module to assign different delay times for different assemblies. Use Record modules to create new measures of system performance. Review the properties of the often-used Weibull probability distribution. Arena Tutorial 3 - Electronic Assembly Process - 1 42
Contact the Author: Mark Polczynski, PhD The Technology Forge mhp.techforge@gmail.com Arena Tutorial 3 - Electronic Assembly Process - 1 43