Evaluation of Yogurt Production Line Simulation Using Arena Software
Evaluation of Yogurt Production Line Simulation Using Arena Software
Evaluation of Yogurt Production Line Simulation Using Arena Software
Engineering
Al-Khwarizmi Engineering Journal, Vol. 15, No. 4, December, (2019) Journal
P. P. 71-78
Abstract
The main purpose of the paper is to identify the controllability of an existing production system; yogurt production
line in Abu Ghraib Dairy Factory which has several machines of food processing and packing that has been studied.
Through the starting of analysis, instability in production has been found in the factory. The analysis is built depending
on experimental observation and data collection for different processing time of the machines, and statistical analysis has
been conducted to model the production system. Arena Software is applied for simulating and analyzing the current state
of the production system, and results are expanded to improve the system production and efficiency. Research method is
applied to contribute in knowing and expecting the future running of the system to enhance the controllability of the
system production and improve the production system and machine efficiency. Moreover, build an experimental model
in Arena in order to simulate the system in term of production and process. First step is to collect the statistical data
required for analysis in terms of input and output data for analysis. Second, is to track the production problem in term of
process bottleneck in order to improve the utilization of the system. Third is to validate the model in order to overcome
the product demand of the system uncontrollability. Through the result analysis of waiting time and production rate, it is
clearly shown that system is stable with a need to resetting the capacity as a chance for the improvement, regarding to
resources utilization. Re-planning resources capacity positively enhances the production and profitability of the system.
The validation percent of the experimental results of output products and actual number of products is about 98%.
production line balance, workers and machine was optimized. Muralidaran and Sandeep [10]
performance. studied basically the analysis of an existent layout
Arena software can be used in modeling and in a pump manufacturing industry. They analyzed
simulation of flexible system for electrical the factory layout of manufacturing system, and an
machine assembly, M. Bruqi et al. [1] used Arena attempt has been made to mimic the existing
to model an electrical machine assembly and they layout of the industry by using the Arena software.
include design, analytical and optimization tasks of Stopper and Stuja [11] presented in Arena a two
complex production systems, computer different solutions for cycle time improvement
architecture, and gain good results. W. R. based on a flexible manufacturing cell for treating
Nyembaa and C. Mbohwab [2] attempted to cover parts. Marsudi and Shafeek [12] aimed to
develop an effective system for the materials flow imitate the production process of a metal stamping
of multi product furniture assembling factory industry and to estimate the utilization of the
through modelling and simulation, also provide the production line by using Arena simulation
demand at an appropriate time and a minimal cost. software.
R. Mathur et al. [3] studied the production of This work focused on evaluating an improving
utensils and the impact of the location of the in existing yogurt production line; Abu Ghraib
machines in a plant and employee's amenities on Dairy Factory in Iraq which has several machines
the efficiency of the production. also attempted to of food processing and packing. Arena Software is
improve the factory layout through using Arena applied for simulating and analyzing the current
simulation. M. S. Eryilmaza et al. [4] studied shoe state of the production system, and results are
manufacturing that was analyzed and modeled in expanded to improve the system production and
Arena and specific production policy was efficiency.
implemented and developed for the shoe making
company. R. P. Nithin et al. [5] studied a
manufacturing planning for a PVC sheets of 2. Simulation Methodology
cooling towers and aimed to raise the productivity, 2.1. Real-World System Production
the simulation study was determined by Arena
software and was designed using CAD package. The system production is a FILL SEAL 4L which is
Lopez et al. [6] conducted in the area of an automatic filling/thermo sealing machine (shown in
gynecological surgery a time study program, to Fig.1.) manufactured by means of the most modern
indicate the current level of capacity and enhance construction methods and made of high quality
the programming time so as to respond to demand materials such as stainless steel and anodized aluminum
immediately. The system was analyzed by waiting duly treated against the corrosion.
lines and used Arena simulation to estimate
suggestions for enhancing and optimizing time of
the surgeries. Neubauer and Stewart [7] aimed to
improve service quality and decreasing the costs as
they found it is difficult to make the transition
from the simple model to modeling and simulating
actual processes on the computer, suggestions
were made to others who may want to utilize
Arena software to bring the process modeling into
the Public Affairs and Administration curriculum.
R. Mathur et al. [8] obtained arrangement, order of
the facilities and the efficient locations. The
industry of utensils was a typical example of a
work-flow shop that based production system.
Also they pursued to explore and improve the
current factory layout by making an attempt to
imitate the current and the proposed factory Fig. 1. FILL SEAL 4L Production machine.
layouts by using Arena software. Faisal et al. [9]
aimed to understand the attitude of a system or
estimating strategies for the operation of the The machine consists of the following:
system, Arena was used to comprehend the 1. Basement: The base represents the machine
standing layout and the utilization of each station body and all parts are installed on it such
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Kawthar A. Mohammed Al-Khwarizmi Engineering Journal, Vol. 15, No. 4, P.P. 71- 78 (2019)
pneumatic and electric members. To access the on a good preservation of product. The sealing
base, it is necessary to remove the side covers by station thermo seals the lids on the containers.
means of the endowed keys. 5. Ejection Station: It is the last station of the
2. Cups Denester: The cup denester is the first normal packaging cycle and makes the ejection of
operative station. Its function is to denest and to container from the machine. This station is usually
transfer the cups from the store into the cup holder. formed by 3 main parts: the elevator, the pusher,
Two forks with double section. being driven by a and the carrying ejection conveyor with
pneumatic cylinder, make the separation of a continuous operation.
container from the pile. 6. Control Panel: The control panel is the interface
3. Dosing Station: After being destacked, the cups that allows the operator to set the parameters of the
are filled by means of a volumetric doser endowed machine and check for proper operation. the
with a dosing regulator. On the doser there is a control panel consist of start button, stop button,
hopper for containing the product. The doser is emergency button, reset button and touch screen
entirely made of AISI 316 stainless steel and it is panel.
formed of a cylinder inside which there is a special
sucking-pumping piston and of pneumatic 2.2. Real-World System Modelling
dispenser which keep in sucking phase the product
is brought from the hopper to the suction chamber. The time has been calculated manually of each
4. Sealing Station: The sealing station performs the process (in seconds) 30 times. After calculating the
most important task of the packaging cycle. In data, the real-world process is simulated and
fact, the sealing efficiency depends on the correct modeled in Arena software. Figure (2) represent
working of this station (on the quality of the the model for all the processes in Arena.
employed materials and on the compatibility of the
cup with the thermo sealing lid too) and vouches
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Kawthar A. Mohammed Al-Khwarizmi Engineering Journal, Vol. 15, No. 4, P.P. 71- 78 (2019)
Table 1,
Designed plan of the system.
# Characteristic Value
1 Number of Processes 5
2 Number of Buffers 4
3 Number of shifts 1
4 Designed Production 5118 Products Fig. 9. Observation data for filling process.
5 Production Rate 4.22 sec.
6 Run per Shift 6 hr.
7 Run Length 21600 sec.
1. Processes Inputs
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Kawthar A. Mohammed Al-Khwarizmi Engineering Journal, Vol. 15, No. 4, P.P. 71- 78 (2019)
Fig. 11. Observation data for sealing process. Fig. 13. Input data for buffering time of filling
process.
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Kawthar A. Mohammed Al-Khwarizmi Engineering Journal, Vol. 15, No. 4, P.P. 71- 78 (2019)
Table 2,
Characteristic results analysis. In general, below % 80 of the resources
Filling Covering Sealing Exiting utilization is completely secured the system
Process Process Process Process running for a long production term as well as
proving a reasonable chance for increase the
Waiting 0.0 0.0 0.0 0.0
Time
demand responsiveness of the system that makes
Waiting 0.0 0.0 0.0 1.0 the improvements are possible. % 0.7215 is
Number observed at the covering process that criticizes the
Utilization 0.6557 0.7215 0.5500 0.7000 improvements but on the other hand makes the
system planner is able to analyze the capability
Number 4,566 Number 4,563 Total 12.5 limits of the system for future investments.
In Out Time
4. Conclusion
Results analysis of the waiting time and
number as zeros approves the non-need to model According to the results, a simulation method
the buffering for each process as automated help researcher to build a software model which is
system. The production rate is closely similar to mimics the real system. Conducting experiments
the designed production that stated in previous on the model allows the researchers to analyze the
table (2), observed difference in the production as real system and predicates future behaviors. Arena
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Kawthar A. Mohammed Al-Khwarizmi Engineering Journal, Vol. 15, No. 4, P.P. 71- 78 (2019)
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ﻣﺠﻠﺔ ﺍﻟﺨﻮﺍﺭﺯﻣﻲ ﺍﻟﻬﻨﺪﺳﻴﺔ ﺍﻟﻤﺠﻠﺪ ،15ﺍﻟﻌﺪﺩ ،4ﺻﻔﺤﺔ (2019) 78 -71 ﻛﻮﺛﺮ ﻋﺒﺪ ﺍﻟﺤﻤﻴﺪ ﻣﺤﻤﺪ
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* ** ،ﻗﺴﻢ ﻫﻨﺪﺳﺔ ﺍﻟﺘﺼﻨﻴﻊ ﺍﻟﻤﺆﺗﻤﺖ /ﻛﻠﻴﺔ ﺍﻟﻬﻨﺪﺳﺔ ﺍﻟﺨﻮﺍﺭﺯﻣﻲ /ﺟﺎﻣﻌﺔ ﺑﻐﺪﺍﺩ /ﺍﻟﻌﺮﺍﻕ
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*ﺍﻟﺒﺮﻳﺪ ﺍﻻﻟﻜﺘﺮﻭﻧﻲ[email protected] :
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ﺍﻟﻐﺮﺽ ﺍﻟﺮﺋﻴﺲ ﻣﻦ ﺍﻟﺒﺤﺚ ﻫﻮ ﺗﺤﺪﻳﺪ ﻗﺎﺑﻠﻴﺔ ﺍﻟﺘﺤﻜﻢ ﻓﻲ ﻧﻈﺎﻡ ﺍﻧﺘﺎﺟﻲ ﺣﺎﻟﻲ؛ ﺧﻂ ﺇﻧﺘﺎﺝ ﺍﻟﺰﺑﺎﺩﻱ ﻓﻲ ﻣﺼﻨﻊ ﺃﺑﻮ ﻏﺮﻳﺐ ﻟﻸﻟﺒﺎﻥ ﻭﺍﻟﺬﻱ ﻳﺤﺘﻮﻱ ﻋﻠﻰ ﺍﻟﻌﺪﻳﺪ ﻣﻦ
ﺁﻻﺕ ﺗﺼﻨﻴﻊ ﻭﺗﻐﻠﻴﻒ ﺍﻟﻤﻮﺍﺩ ﺍﻟﻐﺬﺍﺋﻴﺔ ﺍﻟﺘﻲ ﺗﻤﺖ ﺩﺭﺍﺳﺘﻬﺎ .ﻣﻦ ﺧﻼﻝ ﺑﺪء ﺍﻟﺘﺤﻠﻴﻞ ،ﺗﻢ ﺍﻟﻌﺜﻮﺭ ﻋﻠﻰ ﻋﺪﻡ ﺍﺳﺘﻘﺮﺍﺭﻳﺔ ﻓﻲ ﺍﻹﻧﺘﺎﺝ ﻓﻲ ﺍﻟﻤﺼﻨﻊ ﻛﻤﺎ ﺗﻢ ﺗﺼﻤﻴﻢ ﺍﻟﺘﺤﻠﻴﻞ ﺑﻨﺎ ًء
ﻋﻠﻰ ﺍﻟﻤﻼﺣﻈﺔ ﺍﻟﺘﺠﺮﻳﺒﻴﺔ ﻭﺟﻤﻊ ﺍﻟﺒﻴﺎﻧﺎﺕ ﻟﻤﺪﺓ ﺯﻣﻨﻴﺔ ﻣﺨﺘﻠﻔﺔ ﻣﻦ ﻣﻌﺎﻟﺠﺔ ﺍﻟﻤﺎﻛﻴﻨﺎﺕ ،ﻭﻗﺪ ﺗﻢ ﺇﺟﺮﺍء ﺍﻟﺘﺤﻠﻴﻞ ﺍﻹﺣﺼﺎﺋﻲ ﻟﻨﻤﺬﺟﺔ ﻧﻈﺎﻡ ﺍﻹﻧﺘﺎﺝ .ﻳﺘﻢ ﺗﻄﺒﻴﻖ ﺑﺮﻧﺎﻣﺞ ﺃﺭﻳﻨﺎ
Arenaﻟﻤﺤﺎﻛﺎﺓ ﺍﻟﺤﺎﻟﺔ ﺍﻟﺮﺍﻫﻨﺔ ﻟﻨﻈﺎﻡ ﺍﻹﻧﺘﺎﺝ ﻭﺗﺤﻠﻴﻠﻬﺎ ،ﻭﻳﺘﻢ ﺗﻔﺼﻴﻞ ﺍﻟﻨﺘﺎﺋﺞ ﻟﺘﺤﺴﻴﻦ ﺇﻧﺘﺎﺝ ﺍﻟﻨﻈﺎﻡ ﻭﻛﻔﺎءﺗﻪ .ﺗﻢ ﺗﻄﺒﻴﻖ ﻁﺮﻳﻘﺔ ﺍﻟﺒﺤﺚ ﻟﻠﻤﺴﺎﻫﻤﺔ ﻓﻲ ﻣﻌﺮﻓﺔ ﻭﺗﻮﻗﻊ
ﺍﻟﺘﺸﻐﻴﻞ ﺍﻟﻤﺴﺘﻘﺒﻠﻲ ﻟﻠﻨﻈﺎﻡ ﻟﺘﻌﺰﻳﺰ ﻗﺎﺑﻠﻴﺔ ﺍﻟﺘﺤﻜﻢ ﻓﻲ ﺇﻧﺘﺎﺝ ﺍﻟﻨﻈﺎﻡ ﻭﺗﺤﺴﻴﻦ ﻧﻈﺎﻡ ﺍﻹﻧﺘﺎﺝ ﻭﻛﻔﺎءﺓ ﺍﻟﻤﺎﻛﻴﻨﺔ .ﻓﻈﻼ ﻋﻦ ﺫﻟﻚ ،ﻳﺘﻢ ﺑﻨﺎء ﻧﻤﻮﺫﺝ ﺣﻘﻴﻘﻲ ﻟﻠﺘﺠﺮﺑﺔ ﻓﻲ ﺑﺮﻧﺎﻣﺞ
ﺃﺭﻳﻨﺎ Arenaﻣﻦ ﺃﺟﻞ ﺍﻟﺘﺤﻜﻢ ﻓﻲ ﺍﻟﻨﻈﺎﻡ ﻣﻦ ﺣﻴﺚ ﺍﻹﻧﺘﺎﺝ ﻭﺍﻟﻌﻤﻠﻴﺔ .ﺍﻟﺨﻄﻮﺓ ﺍﻷﻭﻟﻰ ﻫﻲ ﺟﻤﻊ ﺍﻟﺒﻴﺎﻧﺎﺕ ﺍﻹﺣﺼﺎﺋﻴﺔ ﺍﻟﻤﻄﻠﻮﺑﺔ ﻟﻠﺘﺤﻠﻴﻞ ﻣﻦ ﺣﻴﺚ ﺑﻴﺎﻧﺎﺕ ﺍﻟﻤﺪﺧﻼﺕ
ﻭﺍﻟﻤﺨﺮﺟﺎﺕ ﻟﻠﺘﺤﻠﻴﻞ .ﺍﻟﺨﻄﻮﺓ ﺍﻟﺜﺎﻧﻴﺔ ،ﻫﻲ ﺗﺘﺒﻊ ﻣﺸﻜﻠﺔ ﺍﻹﻧﺘﺎﺝ ﻭﻋﻮﺍﺋﻖ ﺍﻟﻌﻤﻠﻴﺔ ﺍﻟﺘﻲ ﺗﺤﺪﺙ ﻣﻦ ﺃﺟﻞ ﺗﺤﺴﻴﻦ ﺍﻹﻓﺎﺩﺓ ﻣﻦ ﺍﻟﻨﻈﺎﻡ .ﺍﻟﺨﻄﻮﺓ ﺍﻟﺜﺎﻟﺜﺔ ﻫﻮ ﺍﻟﺘﺤﻘﻖ ﻣﻦ ﺻﺤﺔ
ﺍﻟﻨﻤﻮﺫﺝ ﻣﻦ ﺃﺟﻞ ﺍﻟﺘﻐﻠﺐ ﻋﻠﻰ ﺍﻟﻄﻠﺐ ﻋﻠﻰ ﺍﻟﻤﻨﺘﺞ ﻋﻨﺪ ﻋﺪﻡ ﺇﻣﻜﺎﻧﻴﺔ ﺍﻟﺘﺤﻜﻢ ﻓﻲ ﺍﻟﻨﻈﺎﻡ .ﻣﻦ ﺧﻼﻝ ﺗﺤﻠﻴﻞ ﻧﺘﺎﺋﺞ ﻭﻗﺖ ﺍﻻﻧﺘﻈﺎﺭ ﻭﻣﻌﺪﻝ ﺍﻹﻧﺘﺎﺝ ،ﻳﺘﻀﺢ ﺑﻮﺿﻮﺡ ﺃﻥ
ﺍﻟﻨﻈﺎﻡ ﻣﺴﺘﻘﺮ ﻣﻊ ﺍﻟﺤﺎﺟﺔ ﺇﻟﻰ ﺇﻋﺎﺩﺓ ﺗﻌﻴﻴﻦ ﺍﻟﻘﺪﺭﺓ ﺑﻮﺻﻔﻬﺎ ﻓﺮﺻﺔً ﻟﻠﺘﺤﺴﻴﻦ ،ﻓﻴﻤﺎ ﻳﺘﻌﻠﻖ ﺑﺎﺳﺘﺨﺪﺍﻡ ﺍﻟﻤﻮﺍﺭﺩ ﺇﻥ ﺇﻋﺎﺩﺓ ﺗﺨﻄﻴﻂ ﻗﺪﺭﺓ ﺍﻟﻤﻮﺍﺭﺩ ﺗﻌﺰﺯ ﺑﺸﻜﻞ ﺇﻳﺠﺎﺑﻲ ﺇﻧﺘﺎﺝ
ﺍﻟﻨﻈﺎﻡ ﻭﺭﺑﺤﻴﺘﻪ .ﺗﺒﻠﻎ ﻧﺴﺒﺔ ﺍﻟﺘﺤﻘﻖ ﻣﻦ ﺻﺤﺔ ﺍﻟﻨﺘﺎﺋﺞ ﺍﻟﺘﺠﺮﻳﺒﻴﺔ ﻟﻠﻤﻨﺘﺠﺎﺕ ﺍﻟﻤﺨﺮﺟﺎﺕ ﻭﺍﻟﻌﺪﺩ ﺍﻟﻔﻌﻠﻲ ﻟﻠﻤﻨﺘﺠﺎﺕ ﺣﻮﺍﻟﻲ .٪٩٨
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