Ex_3.pdf

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EXERCISE 3 – Adding a QC Operation –
Alternative Routing
Please enlarge the previous simulation model (production of 100 parts of Gear 1) with a
Quality control station (QC) and optimize the arrival parameters assuming a batch size of 5.
Part number
13
Part name
Gear 1
Material
40H
Operation #
Work station
run time
setup time
[h]
[h]
10
Saw
0.03
0.15
20
Lathe
0.15
0.45
30
Hobbing
machine
0.48
0.6
40
Drill
Press
0.2
0.23
50
Broaching
machine
0.2
0.25
60
Hardening
station
2
0.5
70
QC
0.1
0.25
80
Modelling Instructions:
1. Create a QC station under Location, and assign an Interface for it
2. Create a Variable (global) named
counter
3. At the Output Buffer from the Hardening station, define an instruction for choosing
alternative paths. Route 1 leading to the QC and Route 2 leading to the Output, such
that every 10
th
component will reach the QC.
Process
Station
Hardening
Station
Output Buffer
Entity
Entity Y
Entity Y
Operation
Blk
1
-
Output
Entity Y
-
Routing
Destination
Rule
Buffer B
-
FIRST 1
-
Move Logic
MOVE WITH
resource name
THEN
FREE
-
WAIT
run time
UNGROUP
counter = counter + 1
IF counter >= 10
THEN
BEGIN
route 1
counter = 0
END
ELSE
BEGIN
route 2
END
1
Entity X
QC
FIRST 1
MOVE WITH
resource name
THEN
FREE
Entity X
Output Buffer
2
Entity X
OUTPUT
FIRST 1
MOVE WITH
resource name
THEN
FREE
Process continuation …
…
…
…
…
…
Review of Grouping and Alternative Routing
Please update the model from Exercise 1 with a Hardening and Quality Control station in a
similar manner as performed in Exercise 2 and Exercise 3. The technological operations are
defined below. Optimize the arrival parameters (batch size: 5).
Part number
1
Part name
Shaft 1
Material
40H
Operation #
Work station
run time
setup time
[h]
[h]
10
Saw
0.015
0.15
20
Lathe
0.25
0.52
30
Keyway
cutter
0.083
0.3
40
Horizontal
Milling
Machine
0.47
0.5
50
Hardening
Station
2
0.5
60
Cylindrical
Grinder
0.176
0.32
70
Splines
Grinder
0.37
0.4
80
Lathe
0.015
0.52
90
QC
0.1
0.25
1. Create a QC station under Location, and assign an Interface for it
2. Remember about an additional Input Buffer and an Output Buffer (at the Hardening
station) with a capacity of 5 using the Rule First In, First Out (FIFO)
3. You should have two entities:
shaft_1
and
group_shaft_1
4. Use two workers; one for processing operations and one responsible for transport
operations only (update the processing accordingly)
5. At the hardening operation use the logic order
WAIT
(for technological operations not
using a resource)
6. At the other machining Locations:
USE
resource name
FOR
time value
7. At the Input and Output Buffer use the logic order
GROUP
and
UNGROUP
respectively as indicated below. (Group 5 shafts together)
8. Create a Variable (global) named
counter1
9. At the second Lathe operation, define an instruction for choosing alternative paths.
Route 1 leading to the QC and Route 2 leading to the Output, such that every 10
th
component will reach the QC.

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