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A Study on a Poly-Bag Manufacturing System Preliminary Analysis and

Simulation

Conference Paper · December 2009

DOI: 10.1109/ICIINFS.2009.5429802

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 A Study on a Poly-Bag Manufacturing System
Preliminary Analysis and Simulation
R. A. R.C. Gopura, T. S. S. Jayawardene
Department of Textile and Clothing Technology, University of Moratuwa, Sri Lanka
[email protected], [email protected]

Abstract- The material prices of poly bags increase with [8]. They presented the simulation tool SLX [9] and the
high degree of fluctuation and forecasters see no end to visualization tool Skopeo [10], which were both utilized to
this trend. Further, legal restrictions imposed on certain perform a prototype federation of a manufacturing plant.
types of polythene products adversely affect the demand.
In the light of the above, entrepreneurs of the poly bag In this study, initially a typical poly bag manufacturing
manufacturing face many challenges. In this study, an system is analyzed [11] to find out risks and bottlenecks of
analysis and a simulation of a poly bag manufacturing the system. In the preliminary analysis, risk and bottleneck
system were carried out to improve the productivity to analyses were carried out. A risk prioritization method was
face the underlying challenges. This paper presents also proposed in the risk analysis. The risks were prioritized
analysis, modeling and simulation methods of the system. based on their effects for the system. Then a mathematical
In addition, a risk prioritization method was proposed at model of the poly bag manufacturing system was developed
the preliminary analysis and also a simulation tool was
developed. with reasonable assumptions to obtain the optimum
throughput time of a given type of a poly bag under available
I. INTRODUCTION plant capabilities and to minimize the material wastage of the
current production setup. The system was simulated using the
The poly bag products are indispensable in day-to-day life. models described in section IV-E. The production schedule
Poly bag manufacturing industry faces major challenges since for maximum productivity was generated for the input
the material prices of poly bags increase with high degree of customer orders. For simulation, a graphical user interface
fluctuation and imposed legal restrictions on certain types of (GUI) driven simulation tool was developed using MATLAB
polythene products which result in a grave decline in demand. 7.2 software [12].
Under these circumstances, it is important to identify and
analyze the problems of the poly bag manufacturing systems, II. THE POLY BAG MANUFACTURING SYSTEM
so that solutions can be recommend for the posed challenges.
High density polyethylene (HDPE), low density In this study, we selected a typical poly bag manufacturing
polyethylene (LDPE), linear low density polyethylene system [11] of which the main process was film blowing.
(LLDPE), and polypropylene (PP) are basically used as raw Figure 1 shows a simplified schematic diagram of film
materials for the poly bag manufacturing [1]. The main blowing process [1], [2]. In film blowing, single screw
process of polybag manufacturing is film blowing [1], [2]. It extruder melts the polymer and pumps it into a tubular die
was followed by subsequent processes namely cutting, and air was blown into the center of the extruded tube causing
sealing, printing, quality checking, and packing. The majority an expansion in the radial direction. Radial and downstream
of the research in the area of poly bag manufacturing was extension stops at the freeze line (due to crystallization). Nip
focused in a single process- the film blowing process [3]-[5]. rolls collect the film and seal the top of the bubble to maintain
In the film blowing, a significant work has been carried out to pressure inside. Simplified production process flow diagram
show how polymer rheology interacts with the process [5]. of the selected system is shown in Fig. 2 [11]. The films
Relatively, little work has been done in modeling and produced in the film blowing is printed and inspected. Then
simulation of film blowing process. However, researches poly bag making was carried out by cutting and sealing of the
have been tried out the simulation of manufacturing processes films. Quality checking (QC) and inspection mark the end of
[6]-[8]. Brown et al. [6] implemented performance modeling poly bag manufacturing process. Subsequently packing
capability (simulation, capacity analysis, and cost analysis) at operation is carried out.
factories of Siemens Semiconductor for both wafer The network diagram of the selected poly bag
fabrication and back-end operations. Graul et al. [7] presented manufacturing system is shown in Fig. 3. Poly bag
a concept and a framework to capture and maintain the manufacturing system of the factory is a multi-channel multi-
multiple descriptions and its applicability in modeling and phase system with buffer storages of work in progress (WIP)
simulation of manufacturing systems. They described a at three places, namely after extrusion of film, after printing,
knowledge-based approach to support the integration of and prior to QC. Although the film extrusion process is a
multiple descriptions with collected data from legacy status continuous process, there is no online feeding mechanism in
for the use in the design and generation of valid simulation the printing machine and therefore, the film manufactured is
models. An overview of current tendencies in the accumulated on the film storage area until it is fed to printing
manufacturing area, Schumann et al. introduces a method to machines depending on the urgency of the orders and the
integrate high level architecture and existing simulation tools availability of printing machines. In case of frequently
 manufacturing and the business of the system were identified
and they were prioritized according to their effects to the
system. Then weights were given from scale of 10 according
to the priority of risks. The risk bar-chat was drawn from the
weight values of risks to indicate the effects of risk.
1. Risk Prioritization

Fig. 4: Five-point Likert scale

Fig. 1: Simplified film blowing process In the risk prioritization, the qualitative effect of each risk
for the production and the business of the factory were
calculated under few criteria: productivity, performance,
output, and profit. Since the most of the data obtained were
qualitative, a five-point Likert scale was used to find
quantitative value of each criterion. The five-point Likert
Fig. 2: Simplified production process flow diagram scale is shown in Fig. 4. Then the weighted averages of the
quantitative values were calculated using equation (1).
ΣQL × 10 (1)
Weight =
QVH × N
where QL, QVH, N are quantitative value from Likert scale,
quantitative value of “Very High” in Likert scale and
numbers of criteria, respectively.

Fig. 3: Network model of the manufacturing system. PEFBM and PPFBM

indicate Poly Ethylene Film Blowing Machine and Poly Propylene Film
Blowing Machine, respectively.

changing orders of small quantities, printing process becomes

a bottleneck in the poly bag manufacturing process.

III. PRELIMINARY ANALYSIS

In the preliminary analysis, a risk analysis and a bottleneck
analysis were carried out to identify the risks faced and
bottlenecks impeding the selected poly bag manufacturing
system. The results of the analysis were used to propose Fig. 5: Risk bar-chart.
suggestions to improve the poly bag manufacturing system a- increasing material prices, b-legal restrictions, c-environmental issues,
d-price competition, e- increase of alternative products,
and to identify the characteristics of the system model to be f-customers switching to alternatives.
developed for the simulation. In the analysis, the layout of the
factory and the bag manufacturing process were visually 2. Results of the Risk Analysis
inspected and the required data (demand, production, timing, The identified risks for the system could be listed in
etc) were gathered. Few discussions were taken place with descending order of priorities: from the highest priority as a)
top management, factory manager and few experienced increasing material prices, b) legal restrictions implemented
labours. for some types of poly bags, c) environmental issues, d) price
competition, e) increase of alterative product, and f)
A. Risk Analysis customers switching to alternatives. Their estimated weight
A risk analysis method was developed to identify the risks values were 7, 5.5, 5, 4.5, 4.5 and 3.5, respectively. The
of the system. The problems that limit the manufacturing and results of risk analysis were shown in risk bar-chart of Fig. 5.
business activities of the system were the risk of the system.
If there was nothing to be done to reduce a bottleneck, the B. Bottleneck Analysis
reasons of that bottleneck also become a risk. By In the bottleneck analysis [13], all the bottlenecks of the
investigating the problems that limit the activities of the process that the system experienced were supposed to be
system and unsolvable bottlenecks, the risks of the system found. All the elements (places where actions take place) of
could be identified. In the risk analysis, the risks affecting the the process were inspected and all the tell-tail signs of
bottlenecks (poor response time, too long queue, insufficient as the storage time of bags/delay time before quality checking
resources, too slow actions, low capacity of machines etc) (Tbqc) can be made zero under optimal production with proper
were investigated. Then reasons of tell-tails signs were line balancing.
further investigated. The reasons found from the investigation
were the bottlenecks of the process. In the bottleneck B. Printing Machines
analysis, the identified bottlenecks were improper line Process time of printing machines can be modeled as below.
balancing of two production lines, lack of inventory control ⎧ Pa L p one colour
TPR = ⎨ (4)
especially in work in progress, idling of production lines, and
⎩ Pb L p two colour
improper process layout of the production lines.
where TPR, Pa, Pb are the time to print the required length of
IV. DEVELOPMENT OF MATHEMATICAL MODEL given type of bag, the printing time per length on one colour
Simulation of the system was carried out to study the machine and two colours machine, respectively. Printing time
system and further to identify the problem of the system. For per unit length varies depending on the nature of the print,
the simulation, a mathematical model of the system was number of colours, and the roller size of which perimeter
developed through a careful study of the manufacturing equals to the printing length. Lp is the print length of a given
process in the system. The objectives of modeling and bag.
simulation were the optimization of time to produce a given C. Bag Making
type of a poly bag under available capabilities of the plant Bag making process consists of two operations namely the
and minimization of the material wastage under the current sealing and cutting. The printed film was fed continuously to
production setup. In a multi-phase production system, the bag making machine which is momentarily stopped it at the
total time to produce a given item is the summation of the correct position as sensed by optical sensors for simultaneous
time required at individual phase and the time duration sealing and cutting operations. The bag making time can be
required in switching between the phases if applicable. In the calculated as follows:
poly bag manufacturing system, total time to produce a given TBM = Fbm Lb + TS &C (5)
type of a poly bag was the summation of times of film
extrusion, film storage, printing, WIP storage, bag making, where TBM is time taken to make the bag in the bag making
quality checking, and setup at each operation. Since the set up section for a given product. Fbm, Lb, TS&C are the average
time was for the production of a large number of bags, per feeding rate of the machine including acceleration and
bag set up time can be neglected as compared to the time deceleration sessions, length or width of the bag which is
concedes for other operations. Sub-model of each event of subjected to feeding, and cutting and sealing time of the
manufacturing is given in next sub-sections. In the final sub- machine respectively. Cutting and sealing time is almost a
section F an optimal production schedule was detailed. constant for a particular gauge of a film. Only at setting up of
bag making machine few bags are subjected to quality
A. Film Extrusion Machines checking for sealing strength and this operation stops once
Sub- model of film extrusion machines can be given as; the bag making machine was set to the required strength.
Only few bags were wasted in this setting up process of a
⎧ K (1 + Wa ) Le if the material is PE large volume of production and time taken for this setting up
TFE = ⎨ a (2)
⎩ K b (1 + Wb ) Le if the material is PP process can be neglected.
where TFE, Ka, Kb are the time to extrude the required length D. Quality Checking
of a given type of bag, the film extrusion time per length of With a time study it was revealed that the quality checking
type A machine and type B machine, respectively. Le, Wa, Wb time of the bag is proportional to the area. Additionally extra
are the film length of a given bag, the parameters representing time was required when a defective bag was to be removed
the percentage wastes due to power failures and setting up of from the bundle. It was also proportional to the area of the
the film extrusion for a given product on type A machine and bag since the difficulty in handling increases as the size of the
type B machine, respectively. These figures may vary with bag increases. The average time for QC can be stated as;
the frequency of power failure (until generator is switched TQC = Z e B + Z d Bα (6)
on), and the frequency of style variations. However, typical
average values for medium volume production have been where TQC is the time for quality checking of a given product.
used for simulation. Type A machine uses the polyethylene Ze, Zd, B, α are the time needed to check a unit area of bag for
whereas type B machines uses the polypropylene for film quality, additional time required to carry out the removing
extrusion. The time delay before printing is imperative since operation for a defective item of unit area, the area of a given
manufactured film was accumulated on the machine until the bag, and the rejection ratio. The bags survived at quality
roll meets the required weight and it can be given by; checking subsequently undergo packing operation. The
values of Ze and Zd were found from a time study.
Tm = [( N − 1) / 2]TFE (3)
where N is the number of bag lengths accumulated on a roller. E. Handling and Packing Time
Further, a delay at film store (Tbp) which can be set to zero in Actual handling time of a poly bag in packing operation
minimum time production was also included in the model. has a non-linear relationship with the area of the bag and it
However, delay time just before making bags (Tbbm) as well depends on some other factors such as the static charges,
material, and the thickness of bag. Since Sri Lanka is a investigation has normally of 5-6 days lead time and number
tropical country with high humidity level, the effect of static of machines used for production is below 15, the optimum
charges can be neglected. Further, for a particular type of a production scheduling of interest can be considered as a small
poly bag, material and thickness of the poly bag are almost scale Job Shopping Scheduling problem. In addition, it
constant. For simplicity, counting time in handling and receives few orders per day. Rather than satisfying with a
packing time are assumed to be proportional to the area of the good solution, it is prudent to go for an optimum scheduling
bag. Packing and unpacking time (TH) included in handling under prevailing circumstances. Therefore, mixed integer
time which are constants. Further recording of quality on the programming solution method was applied. Here, it is
given sheets also needs a constant time (TR). assumed that there are N jobs and M machines, and each job
⎧C a Ba n + T H + T R follows a predetermined route. The operation (i, j) is
T H & PK = ⎨ (7)
processing of job j on machine i, with processing time Pi,j.
⎩C b Bb n + T H + T R Also it is assumed that jobs do not re-circulate. Suppose ti,j is
where TH&PK is the handling and packing time for a given start time of job j on machine i, i =1, 2, …, m and j =1, 2, …,
product. Ca, Cb, and n are the constants of proportionality in n. Ultimate aim is to minimize mixed space Cmax (shop finish
handling and packing times of polythene and polypropylene time) using the mixed integer programming formulation.
bags, and number of bags per pack respectively. TH, TR C max ≥ t x, y + Px, y (11)
handling time and report time per bag respectively.
In case of considering the minimum time to manufacture a C max ≥ t 7 , y + P7, y (12)
poly bag, storage times in between two operations should be C max ≥ t 8, y + P8, y (13)
equal to zero.
where y is the last job received and 7, 8 are the cutting
Tmin . manufacturing = TFE + TPR + TBM + Tm (8) machines which ends the process.
When manufacturing 100 poly bags, α numbers of bags t i , j + Pi , j ≤ t i +1, j i, j for all existing job (14)
were found to be defective in average. Therefore, in order to t i , j + Pi , j ≤ t i , j +1 + m(1 − xi , j , j + i ) (15)
survive 100 poly bags after quality checking, it was required (16)
t i , j +1 + Pi , j +1 ≤ t i , j + mxi , j , j +i
to manufacture10,000/(100-α) poly bags. Since effective bags
after QC are packed and therefore handling and packing time ti,j ≥ 0, xijk € {0,1}
was only applicable to effective items. Further delay time in
the process do not get affected by the number of items in V. SIMULATION OF THE SYSTEM
short run since it was a multi-phase feeding system. The simulation of the system can be basically divided into
Therefore, effective throughput time requirement to pack an two categories namely system simulation and Monte Carlo
effective item can be given as; simulation. System simulation was employed in deterministic
Tthroughputt = [(TFE + TPR + TBM + Tm + TQC ) /(1 − α / 100)] processes and the performance of the system depends on
(9)
+ TH & PK + Tbp + Tbbm + Tbqc
parameters of the systems and the operational algorithms
used. Selection of best operational strategy and optimal
In case of considering minimum throughput time, storage tuning of system parameters can be done by means of system
times in between two operations should be equal to zero. simulation. If the system operation mimics stochastic nature
such as arrival of customer orders that were beyond the
Tmin .time = [(TFE + TPR + TBM + Tm + TQC ) /(1 − α / 100)] + TH & PK (10)
control of the system, such system outputs can be obtained
Assumptions in the modeling are rate of film extrusion, with Monte Carlo simulation. Randomness in the process was
printing, and bag making which are to be constant for a given achieved in simulation by the generation of random numbers
product on a particular type of machine, no idling time for and random observations were generated through inverse
printing and bag making machines since WIP is adequately transformation method with an appropriate probability
available in stocks, initial storage of bags can entirely fulfill distribution. In generation of corresponding probability
the demand of QC section in all time, QC is carried out by the distribution, Monte Carlo sampling process was used. The
skilled labours and has an almost constant rejection ratio for production system under investigation was a hybrid system of
the production, and impact of absenteeism can be neglected. deterministic nature and stochastic nature. Therefore, both
F. Production Schedule simulation techniques were jointly used in obtaining the
Each job is characterized by a fixed order of operations, simulation results. All the time durations at each production
each of which is to be processed on a specific machine for a stage, QC, packing, and delay time of film blowing on the
specified duration. Each machine can process at most one job machine can be calculated based on the real factory data.
at a time and once a job initiates processing on a given However, Tbp, Tbbm, and Tbqc depend on the urgency of the
machine, it must complete processing uninterrupted. The order, production quantity, similar productions in processing,
objective of scheduling is to achieve maximum productivity. and the operational decisions were taken by the management.
In other words, it is required to find a schedule that minimizes Therefore, it mimics uncertainty and hence Monte Carlo
the make-span of the jobs with reasonable assumptions. sampling process can be devised in stochastic simulation
Therefore, the optimum production schedule becomes the model. The real data obtained for time before printing, time
problem of Job Shop Scheduling. Since the system under before bag making, and time before QC are used to calculate
 TABLE I TABLE IV
DELAY TIME BEFORE PRINTING (Tbp) PRODUCT SPECIFICATIONS
Random Bag Bag
Delay time No. of Gauge of
Probability P(x) Cumulative F(x) variable range Product Material width length
classes (days) colours bag
(r1) (cm) (cm)
0 0.31 0.31 00-30 A PE 1 15 52 150
1 0.24 0.55 31-54 B PE 1 18 25 150
2 0.22 0.77 55-76 C PP 2 15 16 120
3 0.14 0.91 77-90 D PE 2 15 24 120
4 0.09 1.00 91-99
TABLE V
TABLE II DETAILS OF CUSTOMER ORDERS
DELAY TIME BEFORE QUALITY CHECKING (Tbqc) Quantity Date of
Order Product
Random (bags) received
Delay time
Probability P(x) Cumulative F(x) variable range 1 A 2000 13-10-2008
classes(days)
(r2) 2 B 1200 13-10-2008
0 0.24 0.24 00-23 3 C 750 13-10-2008
1 0.32 0.56 24-55 4 D 1500 15-10-2008
2 0.21 0.77 56-76
3 0.11 0.88 77-87 TABLE VI
4 0.08 0.96 88-95 MONTE CARLO SIMULATION OUTPUTS
5 0.04 1.00 96-99 Product Tbp Tbbm Tqc Tmin.time Tthroughput
1 1440 4320 1440 49.28 7249.28
TABLE III 2 1440 7200 0 45.40 8685.40
DELAY TIME BEFORE BAG MAKING (Tbbm) 3 0 4320 4320 57.30 8697.30
Random 4 0 1440 2880 81.80 4401.80
Delay time
Probability P(x) Cumulative F(x) variable range
classes (days)
(r3)
0 0.04 0.04 00-03
1 0.16 0.20 04-19
2 0.25 0.45 20-44
3 0.20 0.65 45-64
4 0.14 0.79 65-78
5 0.11 0.90 79-89
6 0.06 0.96 90-95
7 0.04 1.00 96-99

the probabilities from random observations using inverse

transformation method. Since delay time is a continuous
Fig. 6: Menu hierarchy of developed GUI
variable, data are divided into several classes in applying
inverse transformation method in the above three cases.
Probabilistic tables obtained for various delay times are given
in Table I, Table II, and Table III.

VI. SIMULATION RESULTS

Computer simulation was carried out using MATLAB
software package. Table IV shows the specifications of poly
bags. In Table IV, PE and PP are polyethylene and
polypropylene. In addition to these specifications, required
quantities, date of receive, and the deadlines for the
(a) (b)
production are also noted on the customer orders (Table V). Fig. 7: Snap shots of GUI. (a) Main window. (b) Developer details window
These details were used as the input for simulation trials.
Table VI tabulates results of Monte Carlo simulation for the
products A, B, C, and D in Table V. The time requirement at
each process and total time were calculated for the seven
products and listed in Table VII. All the simulation times
except bag making time (TBM) in Table VII were in minutes.
Bag making time (TBM) in Table VII was in seconds. The
generated production schedule of customer orders of Table V
was given in Table VIII. The menu hierarchy of the
developed GUI was shown in Fig. 6. The GUI can be used to
input/edit all the necessary data for the simulation. It could
give the simulation output numerically and graphically. In
addition, it can display the production schedule. It includes Fig. 8: Snap shot of ‘Load Parameter’ window
 TABLE VII
SIMULATED PROCESSING TIMES AND MINIMUM MANUFACTURING TIME (IN MINUTES)
Product TFE TPR TBM (s ) TQC TH&PK Tm Tmin manufacturing
A 0.08495 0.41600 0.90400 3.04621 0.40382 45.31 45.82602
B 0.03905 0.20000 0.8500 1.51328 0.31759 43.31 43.56322
C 0.02997 0.20000 0.75000 1.51328 0.26271 55.28 55.52248
D 0.03750 0.59259 0.73200 0.95700 0.29407 79.91 80.55229

TABLE VIII
PRODUCTION SCHEDULE (ALL TIMES ARE IN MINUTES)
Production Film blowing Printing Bag making QC and Throughput Bags print in machine
Order
start time time time time handling time time one colour two colour
1 0 84.96 416.00 15.07 460.00 976.03 1000 1000
2 977.00 23.43 120.00 8.50 146.47 298.40 600 600
3 1276.00 11.24 150.00 4.69 88.80 254.73 0 750
4 1531.00 28.13 888.89 9.15 125.11 1051.27 0 1500

four menu items in the menu bar: input, output, simulation, allocation in accordance with the product type causes to
and help. In the input menu four sub-menus are available: increase the manufacturing productivity. QC conceded a
load parameter, edit parameter, customer order, and exit. considerably large production time. Therefore, a work study
Load parameter and edit parameter sub-menus are for loading should be carried out in QC process and a suitable training
and updating the input parameter of the simulation. Customer program should be carried out for the staff of the QC division
orders can be checked and updated from the customer orders accordingly. The following points will be interesting topics
sub-menu. Few snap shots of developed GUI are shown in for future study in this area: incorporating a pricing system
Fig. 7 and Fig. 8. and optimizing the profit of the company rather than the
production times, develop a material price forecasting system
CONCLUSION
and generating the optimum inventory schedule for a given
This paper presented an analysis, a modeling and time horizon, adaptation of wastage recycling into the
simulation of a poly bag manufacturing system. A graphical simulation tool.
user interface driven simulation tool was also developed for
ACKNOWLEDGMENT
the simulation. In the simulation, system simulation and
Monte Carlo simulation were performed to calculate the The authors would like to extend their sincere gratitude to
optimum throughput time of a given type of a poly bag under Thermo Plastic (Pvt) Ltd, Sri Lanka, Hemantha Munasinghe,
available capabilities of the plant and to minimize the Asiri Amarasena, and Dr. (Mrs.) Nirosha Agalawatta.
material wastage under the current production setup. In
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