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MODULE 6B
DISCRETE EVENT SIMULATION: BUILD THE MODEL (PART 2)

This module is about the process how to build model simulation using software FlexSim 2018
which is accompanied by an explanation of the tools and functions.

Define the
Collect and
Objective: Build the Validate the Conduct
Analyze
Scope and Model Model Experiment
System Data
Requirement

Figure 6 1 Step-by-Step for Discrete Event Simulation

6.1 Practicum Objective

1. Practicum participants understand the concept, function and how to use the tools of
FlexSim software.

2. Practicum participants able to build simulations based on from previous modules

using FlexSim software.

3. Practicum participants understand the application of Stat::fit software

6.2 Tools and Equipment
1. Computer
2. FlexSim Software 2018
6.3 Practicum Procedure
1. Pre-Test
2. Material Explanation
3. Build Model
4. Output Explanation
5. Post-Test
6.4 Theoritical
This section will explain about what tools are needed along with an explanation of the
functions in the process of build model simulations using FlexSim 2018.

1. Inter Arrival Time

The inter arrival time is the time between each arrival into the system and the next,
this repeats until the model is stopped. Inter arrivals require that the total number of
objects (or unlimited) to arrive is specified along with how often one object (or a
batch) arrive. Variables can be defined as either constant value such as once every 5
minutes, distributions such as Uniform Distribution or predefined variables.

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2. Process Time
This determines how long a processor spends processing a single flow item.
Processing time can be used in any combiner, separator, or processor, with or without
operator.

Use Operator(s) for process, if this box is checked the object will call for one or
more operators during its processing time. The operator(s) will be released after the
process time has expired.

Number of Operators, this will determine how many operators will use during its
process time. This property is only visible when the Use Operator(s) for Process
box is checked, and the Use the Setup Operator(s) for both Setup and Process box
is not checked.

3. Triggers
Trigger is a cause or condition that makes an activity occur. This is used when we
are going to define the activities, we want to create in the system that we are going
to model. Triggers are also referred as the behavior of an activity, how it can move
and what it has to do. Examples of triggers include OnReset, OnMessage, OnLoad,
OnResourceAvailable, and many more. Some things that triggers can do are change
the shape of the 3D input, color, location, and others.

4. Timetable
Time Tables are used to schedule state changes, such as scheduled down- time, for
specific objects in the model. Each Time Table may control many objects, and each
object may be controlled by many Time Tables. For the example a timetable will be
created to specify when an operator is on break, and another Time Table will schedule
maintenance for the processors. The timetable can be set up in different modes
allowing for nonrepeating/repeating schedules or schedules based on date and time
such as the daily repeat, weekly repeat.

5. Periodic System Shut Down

Some systems periodically stop receiving new object or items of raw material for a
given duration to catch up on the backlog of work and store in the component
warehouse. Periodic System Shutdown is the time when the system is closed or
paused. When the system stops due to breaks or due to stop working.

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6. FlexSim Feature
Here are some features at FlexSim that will be used at this module:
A. Flow Tab

Figure 6. 4 1 Flow Tab

Flow Tab is located on fixed resource. These are some properties that
are available on the Flow Tab:

Table 6. 4 1 Properties on Flow Tab

Name Function

It has a function to determine how

the object sends flow items
Output downstream. Downstream is an
object's movement to the next
process or the final process.
This picklist is to determine how the
output port or flow i t e m s
Send to port downstream behave. For example,
are First Available, By Expression,
or many more.

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B. Triggers Tab
These triggers are called when events fire or occur on the object.

Figure 6. 4 2 Triggers Tab

These are some examples of triggers:

Table 6. 4 2 Properties on Triggers

Name Function
A trigger to determine that something
On Process Finish about the flow item has been changed as
a result of going through the processor.
A trigger when we want to define an
On Exit object that sends a message to another
object in the model.
A trigger to define how the tables data
On Reset work when we reset the model and other
custom behavior.
On Entry A trigger that works when an item enters
the flow or the system.
On Message A trigger that works when a resource sent
a message.

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 On Setup Finish A trigger that works when a resource
(machines) finishes its setup time

C. Separator Tab

Figure 6. 4 3 Separator Tab

Separator Tab is used to separate object. These are some properties are
available:

Table 6. 4 3 Properties on Separator Tab

Name Function
Flowitems inside of flowitem entering
Unpack through port will be removed. At the real
case when the input comes as package
form, the separator object will unpack the
package.
Split The separator machine will duplicate
copies of the entering flow item.

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D. Combiner Tab

Figure 6. 4 4 Combiner Tab

Combiner Tab is used to combine object. These are some properties

are available:

Table 6. 4 4 Properties on Combiner Tab

Name Function
To determine which mode that will be
Combine Mode used on combiner object. There are pack,
join, and batch.
Only available when Join mode is
selected. In Join mode, the objects that
come in through ports greater than 1 are
destroyed after the combiner is finished
Recycle To
processing. Rather than destroying the
extra flow items, you can use this option
to recycle them to a specific flow item
recycling bin.

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6.5 Study Case
SIMBI Corporation is an assembly company that sell a stirling machine. The company
do the assembly process of the components separately, then after several processes it
will turned out to be a stirling machine as the finish product. SIMBI Corporation has 25
factories in Indonesia. The product is consisting of four main components that are lower
platform, main machine, piston tube, and upper platform. As a product variation,
SIMBI Corporation produce two color variation in the stirling machine, and the
variation are 60% green stirling machine and 40% yellow stirling machine.

After running for some time SIMBI Corporation found that the demand forecasting for
the 13th month is 80.526. Therefore, with the 23 working days in a month, one factory
should produce at least 140 stirlings/day.

With the existing system, the company will have a loss profit around Rp 5.100.000,00/
day. In order to fulfill the demand forecasting, SIMBI Corporation need your help as an
industry analyst to find and give a solution that will be used to decide what will be done
to face the problems that occur in the company with hard Operation Research
methodology, and also you need to do a production system simulation with a
consideration of working shift or amount of machine.

The following figure is stirling machine that SIMBI Corporation produced.

Figure 6. 5 1 Striling Machine

Every arrival of lower platform package consists with 70 unit components. After its
arrival, The Lower Platform Package then enters the separator machine with
distribution time U (204, 215) minutes.

Every arrival of Piston Tube Package consists of 65 unit components. After its

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arrival, Piston Tube Package then enters the separator machine with distribution time
U (185, 216) minutes. After processed by separator machine with distribution time
N (1.02, 0.268), piston tube unit and lower platform unit are being processed by
installation machine with distribution time N (1.62, 0.405) to be half-finished stirling
machine through the queue lower platform package and the queue of piston tube
package.

Every arrival of the Upper Platform Package consists of 75-unit components. Upper
platform is divided by two color, that are green and yellow with the percentage of
production is respectively 60% and 40%. After its arrival, upper platform unit enters
the separation machine with distribution time U (225, 246) minutes.

Every arrival of Main Machine Package consists of 75-unit components, with

distribution time N (249, 26.8) minutes to enters the separator machine. After its
processed by separator machine, the half-finished product, upper platform unit and
main machine unit are being processed again in assembly machine with distribution
time N (3.28, 0.888) to be Finished Stirling Machine in green color and yellow color.
Then the finished product of green stirling machine and yellow stirling machine will
be brought to the inspection area.

In the Inspection Area, Finished Stirling Machine in Green and yellow color will be
inspected by one operator of quality control with distribution time N (2.21, 0.457). The
operator of quality control will get salary Rp 20.000,00/hour. Inspected Stirling
Machine in Green and Yellow color then moved to the warehouse area through the
queue conveyor for Green stirling machine and Yellow stirling machine.

Based on the calculation from 3rd module, this following below is table of arrival time
distribution for every package:

Table 6. 5 1 Arrival Time Distribution

Total Unit in Arrival Time

No Component
a Package Distribution (Time)
1 The Lower Platform Package 70 pcs U (204, 215)
2 The Piston Tube Package 65 pcs U (185, 216)
3 The Upper Platform Package 75 pcs U (225, 246)
4 Main Machine Package 75 pcs N (249, 26.8)

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 Table 6. 5 2 Proccess Time Distribution

Process Time Distribution

No Workstation
(Time)
1 All Separator Machine N (1.02, 0.268) minutes
2 Assembly Machine N (3.28, 0.888) minutes
3 Installation Machine N (1.62, 0.405) minutes
4 Inspection Area N (2.21, 0.457) minutes.
The operation process chart of stirling machine shown in the figure below

Figure 6. 5 2 Operation Process Chart

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The working hours of the company last for 9 hours, starting from 08.00 AM–5.00 PM
for 5 working days (Monday – Friday) with one hour for rest time between 12.00 PM–
01.00 PM. Throughout the production processes that has been carried out by the
operators, sales manager of SIMBI Corporation records the unfulfilled order which is
as many as 6 striling on average.

The following bellow is Triggers information:

Table 6. 5 3 Triggers Information

No Location Trigger Split

1 Arrival of Lower Platform -
Package
2 Arrival of Piston Tube On Creation: -
Package Set Object Color: Teal

3 Arrival of Main Machine -

4 Arrival of Upper Platform On Creation: -
Package Set Item by Percentage:
(60= Type 1) (40 = Type 2)
Set Color by Case:
(Type1= Green) (Type 2 =
Yellow)
5 Separator of Lower Platform On Process Finish: Change 3D 70 pcs
Package Shape (BOX)
6 Separator of Piston Tube 65 pcs
7 Separator of Main 75 pcs
Machine
8 Separator of Upper Platform 75 pcs
Package
9 Installation Machine -
10 Assembly Machine On Process Finish: -
Change 3D Shape= (BOX)
Set Item by Percentage:
(60= Type 1) (40 = Type 2)
Set Color by Case:
(Type1= Green) (Type 2 =
Yellow)
11 Inspection Area -

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6.6 Entity Flow Diagram

Figure 6.6.1 Entity Flow Diagram

6.7 Labwork
The following below is about the guidelines for lab work 6B Module Build the model
which is a continuation of the previous module.

6.7.1 Creating Time Table

A. Defining Working Shift / Time Table

1. Click menu bar View-> Toolbox-> Click icon-> Time Table
2. The Time Table Parameters Window, to define the Factory Working Hour
according to the scenario, change the name of the Time Table to Factory
Working Hours.

3. Click the Members tab, click on icon and then click as shown in the image
below, after match to the image below, click select. The locations that work on
this Time Table are all queue locations, all machines (combiner, separator and
processor, operator, conveyor and racks Finished Product Warehouse).

Figure 6. 7 1 Select the Object Time Table Parameter Windows of Finished Product Warehouse

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4. Click the Table tab, then change the mode to weekly repeat as shown in the
image below.

Figure 6. 7 2 Change the Model

Define the hours of factory working hours according to the scenario, which is
from Monday to Friday, at 08.00AM - 05.00PM, by blocking the table on
Monday-Friday at 08.00AM - 05.00PM and click Make Operational Time, as
shown below. Don’t forget to click apply and ok.

Figure 6. 7 3 Table of Time Blocked

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 5. Define the break time on factory working hours’ time according to the scenario,
which is every Monday to Friday, at 12:00AM to 01:00PM, by blocking the
table on Monday-Friday at 12:00PM to 01:00PM and click Make Down Time,
as shown below, then click apply.

Figure 6. 7 4 Break Time

B. Define Periodic System Shutdown

1. Click menu bar View -> Toolbox -> Click icon -> Time Table

2. In the Time Table Parameters window, change the name of the Time
Table to Periodic System Shutdown to define Periodic System Shutdown
according to the scenario

3. Click Members tab, click icon and then click the location of
Component Warehouse, because in the scenario it is known that during
breaks and non-work, the entire arrival of the component will go into
component Warehouse, then the location that only works on these hours is
the location of component Warehouse.

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 Figure 6. 7 5 Select the Object Time Table Parameter Windows of Component Warehouse

4. Click Table tab, then change the mode to weekly repeat as the previous
step.

5. Define the Periodic System Shutdown time according to the scenario,

which is from Monday-Sunday, except when the factory is in operation,
then click Make Operational Time, as shown below, then click Apply.

Figure 6. 7 6 Periodic System Shutdown

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6.7.2 Define Inter-Arrival Time
1. Double click on the arrival icon in FlexSim layout, for example is the arrival
location of the Lower Platform Package until the window appears as below,
make sure Arrival Style is used InterArrival Time, adjust FlowItem Class with
Study Case, and make sure to unchecklist box Arrival at time 0.

Figure 6. 7 7 Uncheck Box List Arrival at Time

2. Click on icon in the source tab, until the options appear like the image
below, then click the Statistical Distribution option, and select the distribution
type to use.

Figure 6. 7 8 Select the Distribution Type

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3. After selecting the distribution type to use, enter the arrival time according to
the scenario, for example, the arrival time of lower platform assembly based on
the scenario is U (204, 215) distribution, then click apply and ok.

Figure 6. 7 9 Inter Arrival Time Defined

4. Take these steps for all arrivals according to the scenario study case. To make
sure, check table 6.5.1 Table Arrival Time Distribution.

Figure 6. 7 10 Display the Result of Inter Arrival Time

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6.7.3 Defining Processing Time
1. Double click on the machine icon in FlexSim layout, for example is the
location of the Separator, until the window appears as below, and make sure
unchecklist box Use Operator (s) for Setup and box Use Operator (s) for
Process.

Figure 6. 7 11 Unchecklist Box Use operator(s)

2. Click on icon on the ProcessTimes tab at the Process Time box, until the
options appear like the image below, then click the Statistical Distribution
option, and select the distribution type to use.

Figure 6. 7 12 Select the Distribution Type

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 Figure 6. 7 13 Select the Distribution Type

3. After selecting the distribution type to be used, enter the arrival time according
to the scenario, for example, the time in the Separator machine according to the
scenario is N (1.02, 0.268) distribution, then click apply and ok.

Figure 6. 7 14 Process Time Defined

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 Figure 6. 7 15 Process Time Defined

4. Perform these steps for all Machines, with the exception of the Inspection
Area. To make sure, check table 6.5.2 Process Time Distribution.

Figure 6. 7 16 Process Time Defined

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6.7.4 Defining Processor Time
1. Double click on the Inspection Area icon in the FlexSim layout, until the
window appears as below, and make sure unchecklist box Use Operator (s)
for Setup and Checklist box Use Operator (s) for Process.

Figure 6. 7 17 The Window Processor Time

2. Click on icon on the Processor tab of the Time Process box, until the
options appear like the image below, then click the Statistical Distribution
option, and select the distribution type to use.

Figure 6. 7 18 Define Distribution Type

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 3. After selecting the distribution type to be used, enter the Inspection Area
time according to the scenario, the time in the Inspection Area according to
the scenario is N (2.21, 0.457) distribution, then click apply and ok.

Figure 6. 7 19 The Result Time in Inspection Area

6.7.5 Defining Separator

1. Click two times at Separator Lower Platform icon on FlexSim layout
2. Click the Separator tab in the Separator Properties and click on the Split
option. Checklist box Convey Items Across Separator Length, change Split /
Unpack Quantity to 70, and change Recycle from to Box as shown below, then
click apply and ok.

Figure 6. 7 20 Change Split/Unpack Quantity

3. Do the step for all Separator Machine based on the study case. To make

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 sure, check Table 6.5 Arrival Time Distribution

6.7.6 Define the Combiner

1. Click two times at Installation Machine icon on FlexSim layout.
2. Click the Combiner tab in the Installation Machine Properties. Change
Combine Mode to Join, change Recycle To to Do Not Recycle Items, and in
the Components List table, change Target Quantity to 1, as shown below,
then click apply and ok.

Figure 6. 7 21 Result of Installation Machine Properties

3. Click two times at Assembly Machine icon on FlexSim layout

4. Click the Combiner tab in the Assembly Machine
5. On Installation Machine Properties, select Combiner Tab then Change
Combine Mode to Join, change Recycle To to Do Not Recycle Items, and in
the Components List table, change Target Quantity to 1, as shown below,
then click apply and ok.

Figure 6. 7 22 Combiner properties for Assembly Machine

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6.7.7 Defining Trigger
1. Click two times at Separator Lower Platform icon on FlexSim layout.
2. Click Triggers tab on Separator Properties window
3. Click icon at OnProcessFinish box ->Click Visual->Click Change
3D Shape

4. Change the shape to Box, as shown in the picture below to visualize the
transformation from platform package to box. Then click apply and ok.

Figure 6. 7 23 Triggers Setting for Separator Lower Platform

5. Double clik at Arrival upper platform icon on FlexSim layout.

6. Click Triggers on Arrival upper platform Properties window.

7. Click icon on OnCreation box ->Click Data->Click Set Item Type by

Percentage->click (Add Case) icon

8. Change the Percent to 60 on Type 1, and Percent to 40 on Type 2, as shown

in the picture below, because the green color has a percentage of 60% and
the yellow color has a percentage of 40%

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 Figure 6. 7 24 Triggers Setting for Arrival Upper Platform Package

9. Click (Added a new operation to the trigger) icon-> Click Visual->

Click Set Color by Case-> Click icon two times
10. Change the color of Type 1 to Green and Type 2 to Yellow, as shown in the
picture below.

Figure 6. 7 25 The result Trigger for Arrival Upper Lower platform

11. Click two times at Arrival Piston Tube icon on FlexSim layout

12. Click Triggers tab on Arrival Piston Tube Properties window.

13. Click icon at OnCreation box-> Click Visual-> Click Set Object Color

14. Change the color to teal as shown in the picture below to differentiate
with others component.

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 Figure 6. 7 26 Triggers Setting for Fuel Container Package

15. Double click at Assembly Machine icon on FlexSim layout.

16. At OnProcessFinish box, choose Data, add Set Item Type by Percentage
and Set Color by Case according to the scenario like the previous steps.

Figure 6. 7 27 Triggers Setting for Assembly Machine

6.7.8 Defining Flow

1. Click two times at Assembly Machine icon on FlexSim layout
2. Click Flow tab at Assembly Machine Properties window-> Checklist box
Use Transport

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 Figure 6. 7 28 The Flow for Assembly Machine

3. Click two times at Inspection Area icon on FlexSim layout.

4. Click Flow tab at Inspection Area Properties window-> Change Send to
Port to By Expression, as shown in the picture below.

Figure 6. 7 29 The Flow for Inspection

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6.7.9 Run Model
1. Click icon-> Click Date and Time-> Click Warmup Time-> Change
the time to 07.00 AM-> Click Stop Time-> Change the time to 06.00 PM

2. Make sure Warmup Time and Stop Time match the image below (Date can
adjust according to your scenario)

Figure 6. 7 30 Setting Run Time

3. Click icon-> Click icon

4. And the result will be like this:

Figure 6. 7 31 Final Result

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 Reference
Manufacturing Process Laboratory Industrial Engineering Telkom University. (2020).
Manufacturing Process Article 2020.

Flexsim. Timetable. Accessed on 9 April 2020 in

https://docs.flexsim.com/en/19.1/Reference/Tools/TimeTables/

Bowden, Harrel Ghosh. (2004). Simulation Using ProModel, Second Edition.

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