Simulation Using Arena for an Automobile Assembly Plant

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SCHOOL OF TECHNOLOGICAL SCIENCES
INDUSTRIAL ENGINEERING DEPARTMENT

Simulation Project- IE532

* Table of Contents:

1. Introduction……………………………………………………………………………………………………..2

2. Approach………………………………………………………………………………………………………….3

3. Input Analyzer………………………………………………………………………………………………….9

4. Animation……………………………………………………………………………………………………….10

5. Results…………………………………………………………………………………………………………….11

4. Discussion……………………………………………………………………………………………………….15

5. Conclusion………………………………………………………………………………………………………16

* Introduction:

In this project a model was built to simulate processes of an automobile assembly plant, which is divided into three main departments:

1) The body shop: it is the first department of the plant, where the assembly process starts. In this department, two raw materials are received: a) The body side panels (BSP) b) The floor pan (FP).

Starting with the ‘BSPs’, these are fastened at the very beginning of the process by three sequential ‘toy tabbing’ workstations, then they are sent to a ‘Robogate line’ consisting of four parallel welding robots, in order to be welded. Each BSP is sent to the robot with the least number waiting in the queue. After that, BSPs are sent to ‘re-spot line’, which contains three sequential work cells; the first cell has two machines. Each BSP selects any of the 2 machines in a random order. The second cell also has the same 2 machines, but each BSP is sent to one of them according to a cyclical order. The third cell has only one machine. Finally BSPs are sent to manual assembly station.

Floor pans (FPs) are directly sent to the same manual assembly station, then one welded BSP is assembled with one FP to form the ‘car’s body’.

2) The paint shop: this is the second department, where the car body is to be painted. The first step is to pass the assembled ‘car’s body’ through a dipping tank in phosphate workstation. Then, it passes through prime tank in prime workstation. After that, the painted body is left for drying on an overhead conveyor. At the end of this department there is an inspection point, where 80% of the painted bodies go directly to the next department, and 20% go into a repair loop to be fixed. The repair loop has a maximum capacity for 10 cars, so when the line is full the cars should wait in a buffer.

3) Trim-chassis: this is the third and the last department, where the motor, transmission, steering, seats and wheels will be added to the painted car body.

* Approach:
We started our model working on the first department.
First of all, we started creating the BSPs using the ‘Create’ module. The creation time of each BSP is recorded using an attribute using ‘Assign’ module. Then, using a submodel, the three sequential toy tabbing processes are represented by 3 sequential ‘Process’ modules, each preceded by a buffer station. The entity is transferred from one process to the next buffer station using the arrow as the transfer time is considered to be zero. Entities are now routed using the ‘Route’ module to the next robogate line station, each in 2 minutes. A new submodel is used, where ‘Pickstation’ module is used to reflect the entity pick of the robot that has the minimum number waiting in a queue. After a robot is picked, entity is transferred to the robot’s buffer station and then to the robot itself, where it is processed.

After that, entities are transferred to the respot line station using the ‘Route’ module, each in 2 minutes. As before, a new submodel for this workstation is used, where three sequential cells are displayed using ‘Process’ modules, the first two with a set of resources defined in the ‘Set’ spreadsheet showing machines 1 and 2 used in this workstation, and a third cell represented by a ‘Process’ module with one machine used as a resource. Each cell is preceded by a buffer station and the transfer time within the workstation, between cells is considered...
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