Modeling Basic Operations and Inputs

Chapter 4
Modeling Basic Operations and
Inputs

These slides were created by D. Kelton, R. Sadowski, and D. Sturrock, to accompany

their book, “Simulation with Arena,” Mc-Graw-Hill, third edition, 2003.

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 Modeling Basic Operations and Inputs

What We’ll Do ...

• Model 4-1: Electronic assembly/test system
 Modeling approaches
 New Arena modules (Decide, Record)
• Model 4-2: Enhanced electronic assembly/test
 Resource Schedules, States, and Failures
 Frequency outputs
 More on utilizations
• Model 4-3: Enhancing the animation
 Queues, Entity Pictures, Resource Pictures
 Adding Plots and Variables
• Model 4-4: Adding entity travel times
 Modify with Stations, Transfers, Routes, animation of entity movement

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 Modeling Basic Operations and Inputs

Electronic Assembly/Test System

(Model 4-1)

• Produce two different sealed elect. units (A, B)

• Arriving parts: cast metal cases machined to
accept the electronic parts
• Part A, Part B – separate prep areas
• Both go to Sealer for assembly, testing – then to
Shipping (out) if OK, or else to Rework
• Rework – Salvaged (and Shipped), or Scrapped
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 Modeling Basic Operations and Inputs

Part A
• Interarrivals: expo (5) minutes
• From arrival point, proceed immediately to Part A
Prep area
 Process = (machine + deburr+ clean) ~ tria (1,4,8) minutes
• Go immediately to Sealer
 Process = (assemble + test) ~ tria (1,3,4) min.
 91% pass, go to Shipped; Else go to Rework
• Rework: (re-process + testing) ~ expo (45)
 80% pass, go to Salvaged; Else go to Scrapped

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 Modeling Basic Operations and Inputs

Part B
• Interarrivals: batches of 4, expo (30) min.
• Upon arrival, batch separates into 4 individual
parts
• From arrival point, proceed immediately to Part B
Prep area
 Process = (machine + deburr +clean) ~ tria (3,5,10)
• Go to Sealer
 Process = (assemble + test) ~ weib (2.5, 5.3) min. ,
different from Part A, though at same station
 91% pass, go to Shipped; Else go to Rework
• Rework: (re-process + test) = expo (45) min.
 80% pass, go to Salvaged; Else go to Scrapped
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 Modeling Basic Operations and Inputs

Run Conditions, Output

• Start empty & idle, run for four 8-hour shifts
(1,920 minutes)
• Collect statistics for each work area on
 Resource utilization
 Number in queue
 Time in queue
• For each exit point (Shipped, Salvaged,
Scrapped), collect total time in system (a.k.a.
cycle time)

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 Modeling Basic Operations and Inputs

Developing a Modeling Approach

• Define pieces of model, modules, data structures,
control logic
• Appropriate level of detail – judgment call
• Often multiple ways to model, represent logic
• This model:
 Entities are the individual parts (two types)
 Separate Create modules for two part types
 Separate Process modules for each Prep area
 Process modules for Sealer and Rework, each followed by
a Decide module (2-way by Chance)
 Depart modules for Shipped, Salvaged, Scrapped
 Attribute Sealer Time assigned after Creates in Assign
modules (parts have different times at the Sealer)
 Record modules just before Departs for time in system
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 Modeling Basic Operations and Inputs

Building the Model

• New model window
• Attach Basic Process panel (if needed)
• Place modules
 Create (x 2)
Alternate strategy –
 Assign (x 2)
place one module
 Process (x 4) at a time, fill it out
 Decide (x 2) completely
 Record (x 3)
 Dispose (x 3)
• Right click — repeat last action (place module)
• Auto-Connect, or manually connect via
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 Modeling Basic Operations and Inputs

Part A Create Module

• Name: Part A Arrive
Once these entries are
• Entity Type: Part A made, they are placed on
• Time Between Arrivals the list for names of that
type (Module Name,
 Type: Random (Expo)
Entity Type, etc.) and will
– Pull-down list with options
appear on future pull-
 Value: 5 down lists for that type of
 Units: Minutes name.
– Pull-down list with options
• Default what’s not mentioned above

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 Modeling Basic Operations and Inputs

Part B Create Module

• Name: Part B Arrive
• Entity Type: Part B
• Time Between Arrivals
 Type: Random (Expo)
– Pull-down list with options
 Value: 30
 Units: Minutes
– Pull-down list with options
• Entities per Arrival: 4

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 Modeling Basic Operations and Inputs

Part A Attributes Assign Module

• Name: Assign Part A Sealer and Arrive Time
• Add button:
 Type: Attribute
 Attribute Name: Sealer Time
 New Value: TRIA(1, 3, 4)
• Add button:
 Type: Attribute
 Attribute Name: Arrive Time
 New Value: TNOW (to compute time in system on exit)
TNOW is the internal Arena variable name for the simulation clock; see
Help > Arena Help > Contents >
Variables, Functions, and Distributions > Date and Time Variables

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 Modeling Basic Operations and Inputs

Part B Attributes Assign Module

• Name: Assign Part B Sealer and Arrive Time
• Add button:
 Type: Attribute
 Attribute Name: Sealer Time
 New Value: WEIB(2.5, 5.3)
• Add button:
 Type: Attribute
 Attribute Name: Arrive Time
 New Value: TNOW
Names for things in Arena
– Default names usually suggested
– Names placed on appropriate pull-down lists for future reference
– All names in a model must be unique (even across different kinds of objects)
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 Modeling Basic Operations and Inputs

Process Module Actions

• Delay
Entity just sits here for the specified time; no Resource
involved, so multiple entities could be undergoing this Delay
simultaneously
• Seize Delay
Entity must first Seize the specified number of units of a
Resource (possibility for Queueing if they’re not available),
then undergoes the Delay … assume that the entity will
Release the Resource units at another downstream module
• Seize Delay Release
Like Seize Delay, but entity releases Resource units after
Delay (what we want in this model)
• Delay Release
Assumes entity had already Seized Resource units at another
upstream module, now Delays and Releases Resource units
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 Modeling Basic Operations and Inputs

Prep A Process Module

• Name: Prep A Process
• Action: Seize Delay Release
• Resources subdialog (Add button):
 Type: Resource (a pull-down option) If several Resources
 Resource Name: Prep A were named (Add
button), entity would have
 Quantity: 1 (default) to Seize them all before
• Delay Type: Triangular the Delay could start.

• Units: Minutes
• Minimum: 1
• Value (Most Likely): 4
• Maximum: 8

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 Modeling Basic Operations and Inputs

Prep B Process Module

• Name: Prep B Process
• Action: Seize Delay Release
• Resources subdialog (Add button):
 Type: Resource (a pull-down option)
 Resource Name: Prep B
 Quantity: 1 (default)
• Delay Type: Triangular
• Units: Minutes
• Minimum: 3
• Value (Most Likely): 5
• Maximum: 10

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 Modeling Basic Operations and Inputs

Sealer Process Module

• Name: Sealer Process
• Action: Seize Delay Release
• Resources subdialog (Add button):
 Type: Resource (a pull-down option)
 Resource Name: Sealer
 Quantity: 1 (default)
• Delay Type: Expression
• Units: Minutes
• Expression: Sealer Time Recall – Sealer Time attribute
was defined upstream for both
Parts A and B … now its value is
being used … allows for different
distributions for A and B.

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 Modeling Basic Operations and Inputs

Sealer Inspection-Result Decide Module

• Decide module provides branch points
 By Condition (entity Attributes, global Variables)
 By Chance (multi-sided, possibly-biased hypercoin flip)
• Name: Failed Sealer Inspection
• Type: 2-way by Chance (default)
• Percent True: 9
• Different exit points for True, False results –
connect appropriately downstream
− Note it’s percent true, not probability of true … so “9” means probability of 0.09
− We arbitrarily decided “true” meant part failed inspection … could have reversed
(but would change numerical results ... why? ... does this upset you? ... why?)
− This is a rich, deep, versatile module … explore its Help button

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 Modeling Basic Operations and Inputs

Rework Process Module

• Name: Rework Process
• Action: Seize Delay Release
• Resources subdialog (Add button):
 Type: Resource (a pull-down option)
 Resource Name: Rework
 Quantity: 1 (default)
• Delay Type: Expression
• Units: Minutes
• Expression: EXPO(45) Had to use the general Expression
choice for Delay Type since what we
want (EXPO) is not directly on the
Delay Type pull-down list.

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 Modeling Basic Operations and Inputs
Rework Inspection-Result Decide
Module
• Name: Failed Rework Inspection
• Type: 2-way by Chance (default)
• Percent True: 20
We arbitrarily decided “true”
meant part failed inspection

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 Modeling Basic Operations and Inputs

Record Modules
• Arena collects and reports many output statistics
by default, but sometimes not all you want
• We want time in system (average, max) of parts
sorted out by their exit point (Shipped, Salvaged,
Scrapped)
 It’s this sorting that Arena doesn’t do by default ... it would
automatically sort by Entity Type if we had Entities checked
in Run > Setup > Project Parameters (which we don’t)
• Record module can be placed in the flowchart to
collect and report various kinds of statistics from
within the model run as entities pass through it
• For Tally-type output performance measures (see
Chapter 3)
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 Modeling Basic Operations and Inputs

Shipped Parts Record Module

• Name: Record Shipped Parts
• Type: Time Interval
 This option records the length of time that elapsed up to
now (TNOW) from when an entity attribute was marked with
a time “stamp” upstream ... Attribute Name is below ...
 There are several other options for Type … explore via
Record module’s Help button!
• Attribute Name: Arrive Time
 Was defined upstream as the clock value in the Assign
modules instantly after each entity was Created
• Tally Name: Record Shipped Parts
 Determines the label in the reports Other two Record modules –
just like this except for Name
and Tally Name.
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 Modeling Basic Operations and Inputs

Dispose Modules
• Three separate exit points for three separate part
disposition (Shipped, Salvaged, Scrapped)
• Could have directed all three exit types to a
single Dispose module
 But having separate ones produces animation counts of the
three dispositions
• Also, having separate Dispose modules allows
for differentially checking the boxes to Record
Entity Statistics
 Produces flow statistics separated by entity type (if Entities
Statistics Collection is checked in Run > Setup > Project
Parameters), not by final disposition of part … so we did
need our Record modules and Arrive Time attribute
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 Modeling Basic Operations and Inputs

Run > Setup for Run Control

• Without this, model would run forever – no
defaults for termination rule
 That’s part of modeling, and generally affects results!
• Project Parameters tab:
 Fill in Project Title, Analyst Name
 Defaults for Statistics Collection, but we cleared the check
box for Entities – not needed for what we want (we installed
our own Record modules), and would slow execution
• Replication Parameters tab:
 Replication length: 32, accept Hours default for Time Units
 Base Time Units: Minutes for inputs without Time Units
option, internal arithmetic, and units on output reports
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 Modeling Basic Operations and Inputs

Different Part A, B Entity Pictures

• Entity data module (just single-click on it in
Project Bar, edit via spreadsheet only)
• Row for each Entity Type (Part A, Part B)
• Pull down Initial Picture pull-down menu, select
different pictures for each Entity Type
 Edit > Entity Pictures to see, change the list of pictures
that’s presented here … more later

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 Modeling Basic Operations and Inputs

Running the Model

• Check (if desired)
 Find button to help find errors
• Go (will automatically pre-Check if needed)
 Some graphics don’t show during run … will return when
you End your run … control via View > Layers
 Status Bar shows run progress – replication number,
simulation time, simulation status
• Animation speed – increase (>), decrease (<)
• Pause ( ) or Esc key; to resume
• Run > Step ( ) to debug
• Run > Fast-Forward ( ) to turn off animation
 Run > Run Control > Batch Run (No Animation) is fastest
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 Modeling Basic Operations and Inputs

Viewing the Results

• Counters during animation for modules
 Create, Dispose, Decide – incremented when entity leaves
 Process – number of entities currently in the module
• Asked at end if you want to see reports
 What you get depends on Run > Setup > Project Parameters
– Looks like the Rework area is a bottleneck ... more later
 Navigate through report with browsing arrows, tree at left
 Tally, Time-Persistent, and Counter statistics
 Avg, Min, Max, and 95% Confidence Interval half-widths
– Confidence intervals are for steady-state expectations … more later
– May not be produced if run is not long enough for reliable stats
• Generally difficult/unreliable to draw conclusions
from just one run … more later
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 Modeling Basic Operations and Inputs
Model 4-2: The Enhanced Electronic
Assembly and Test System
• A Story
 Original model shown to production manager
 Pointed out that this is only the first shift of a two-shift day
— on second shift there are two operators at Rework (the
bottleneck station) … 16-hour days
 Pointed out that the Sealer fails sometimes
– Uptimes ~ exponential, mean 2 hours
– Repair times ~ exponential, mean 4 minutes
 Wants to buy racks to hold rework queue
– A rack holds 10 parts
– How many racks should be bought?
 Run for 10 days
• Need: Resource Schedules, Resource States,
Resource Failures
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 Modeling Basic Operations and Inputs

Change Run Conditions

• Redefine a “day” to be 16 hours – Run > Setup >
Replication Parameters
• Change Replication Length to 10 (of these) days

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 Modeling Basic Operations and Inputs

Schedules
• Vary Capacity (number of units) of a resource
over time
• In Resource Data module (spreadsheet view)
 For Rework Resource, change Type from Fixed
Capacity to Based on Schedule
 Two new columns – Schedule Name and Schedule Rule
 Type in a schedule name (Rework Schedule)
 Select a Schedule Rule – details of capacity decrease if the
Resource is allocated to an entity
– Ignore – Capacity goes down immediately for stat collection, but
work goes on until finished … “break” could be shorter or gone
– Wait – Capacity decrease waits until entity releases Resource, and
“break” will be full but maybe start/end late
– Preempt – Processing is interrupted, resumed at end of “break”
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 Modeling Basic Operations and Inputs

Schedules (cont’d.)
• Define the actual Schedule the Resource will
follow – Schedule data module (spreadsheet)
 Row already there since we defined Rework Schedule
 Format Type is Duration for entries based on time past
simulation beginning
 Type is Capacity, for Resource schedule (more later on
Arrival Type)
 Click in Durations column, get Graphical Schedule Editor
– X-axis is time, Y-axis is Resource Capacity
– Click and drag to define the graph
– Options button to control axis scaling, time slots in editor, whether
schedule loops or stays at a final level forever
– Can use Graphical Schedule Editor only if time durations are
integers, and there are no Variables or Expressions involved

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 Modeling Basic Operations and Inputs

Schedules (cont’d.)
 Alternatively, right-click in the row, select Edit via Dialog
– Enter schedule Name
– Enter pairs for Capacity, Duration … as many pairs as needed
If all durations are specified, schedule repeats forever
If any duration is empty, it defaults to infinity
– Can involve Variables, Expressions
 Another alternative – right-click in the row, select Edit via
Spreadsheet
– Enter capacity Value, Duration pairs

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 Modeling Basic Operations and Inputs

Resource Failures
• Usually used to model unplanned, random
downtimes
• Can start definition in Resource or Failure module
(Advanced Process panel) … we’ll start in Failure
• Attach Advanced Process panel if needed, single-
click on Failure, get spreadsheet view
• To create new Failure, double-click – add new row
• Name the Failure
• Type – Time-based, Count-based (we’ll do Time)
• Specify Up, Down Time, with Units

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 Modeling Basic Operations and Inputs

Resource Failures (cont’d.)

• Attach this Failure to the correct Resource
 Resource module, Failures column, Sealer row – click
 Get pop-up Failures window, pick Failure Name Sealer
Failure from pull-down list
 Choose Failure Rule from Wait, Ignore, Preempt (as in
Schedules)
• Can have multiple Failures (separate names)
• Can re-use defined Failures for multiple
Resources (operate independently)

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 Modeling Basic Operations and Inputs

Frequencies
• Record time-persistent occurrence frequency of
variable, expression, or resource state
 Use here to record % of time rework queue is of length 0,
(0, 10], (10, 20], … to give info on number of racks needed
• Statistic data module (Advanced Process panel)
 Five Types of statistics, of which Frequencies is one
 Specify Name (Rework Queue Stats), Frequency Type
(Value)
 Specify Expression to track and categorize
– Right-click in field to get to Expression Builder
 Report Label (Rework Queue Stats)
 Pop-up secondary spreadsheet for Categories (browse file)
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 Modeling Basic Operations and Inputs

Frequencies (cont’d.)
• Add another Frequency (in Statistic module) to
give a finer description of the Sealer states
 Will produce statistics on proportion of time Sealer is in
each of its three possible states – Busy, Idle, and Failed
• Frequencies are not part of default Category
Overview report – open Frequencies report from
Project Bar (get a separate window for them)

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 Modeling Basic Operations and Inputs

Results of Model 4-2

• Differ from those of Model 4-1 since this is a
longer run, modeling assumptions are different
 All of which causes underlying random-number stream to
be used differently (Chapter 12)
• Prep A/B didn’t change (other than run length and
random variation) … need statistical analysis of
simulation output (Chapters 6, 7, 12)
• Sealer is more congested (it now fails)
• Rework is less congested (50% higher staffing)
• Frequencies report suggests one rack suffices
about 95% of the time, two racks all the time
 See text for discussion of Standard, Restricted Percents

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 Modeling Basic Operations and Inputs

Utilizations – Some Fine Points

• Two utilizations reported for each Resource
 Instantaneous Utilization is the time-average of the ratio of
the number of units that are busy to the number of units
that are scheduled
– By definition, counts periods when zero units are scheduled as
zero-utilization periods
 Scheduled Utilization is the average number busy divided
by the average number available
– No division-by-zero problem, assuming there were ever any units of
the Resource scheduled at all (if not, it shouldn’t be in the model)
• Identical for fixed-capacity Resource
• Can differ for Resources on a variable Schedule
 If Resource capacity varies among several different positive
values, it’s better to use Scheduled Utilization
 See text for discussion of issues and even finer points

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 Modeling Basic Operations and Inputs

Model 4-3: Enhancing the Animation

• Get “Spartan” generic default animation for some
things (queues, connector-animation movement)
 Usually sufficient for verification, validation
• Often want to customize, enhance it a bit
 More realism, impact
• Can pull animation away from model logic in
model window
 Useful for big models, complex animation
 Set up Named Views for model logic, animation, or close-
ups of parts of animation
• Animation objects are connected to model logic
 Identifiers, physical location (Shift-drag to decouple)

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 Modeling Basic Operations and Inputs

Changing Animation Queues

• Lengthen (click, drag, maybe hold shift) to “hold”
more entities
 Simulation logic, results still OK even if animated queue
overflows
• Rotate to re-orient for realism
• Change the “form” of the queue from Line (the
default) to Point — fixed places for entities
 Double-click on the queue
 Select Type to be Point
 Click Points… button
 Successively click Add for points, then OK
 Drag them around on screen
 Check Rotate box to show entities turning
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 Modeling Basic Operations and Inputs

Changing the Entity Pictures

• Earlier – used Entity data module to assign
different Initial Pictures to different Entity Types
• Now – customize the list, or alter the pictures in it
 Edit > Entity Pictures
 Left column – names, pictures currently on the list
 Right column –picture libraries (.plb filename extension)
 Add a hand-drawn picture – Add button on left, name it in
Value field at top, double-click on blank depressed button,
then artwork (or paste in a copied graphics image)
– New name won’t appear in Entity data module until you type it there
 Edit an existing picture – double-click, artwork
 Copy a picture over from picture library
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 Modeling Basic Operations and Inputs

Adding Resource Pictures

• Animate a Resource – Resource button in
animate toolbar – get Resource Picture
Placement window
• Left column – default pictures for different
Resource states
 Attach logically to a Resource by Identifier pull-down list
 Double-click to edit the artwork by hand, or paste in
previously copied graphics images
 Seize area – where seizing entity will “reside”
 Multiple seize areas for multi-capacity Resources
• Right column – picture libraries (.plb files) – can
copy over to selected (depressed) state pictures
• Accept window, cross hairs, click to place
 Resize, reposition later
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 Modeling Basic Operations and Inputs

Adding Variables and Plots

• Variable animation – just show a value of
something as a number, watch it change
 Variable object from Animate toolbar
 Double-click, specify Expression to be shown (Expression
Builder), and cosmetics
 Resize, reposition later
• Dynamic animated plots – discussed in Chapter 3
• Other animation objects from Animate toolbar
 Clock (TNOW), variety of formats
 Level (thermometer) animation
 Others discussed later

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 Modeling Basic Operations and Inputs

Model 4-4: The Electronic Assembly and

Test System with Part Transfers
• Generalize Model 4-3
• All part transfers now take 2 minutes (not instant)
… want to model and animate
 Includes:
– Arriving parts to prep areas
– Departing parts to appropriate exit
– All internal part transfers
 Regardless of distance ... will fix this (unrealistic)
assumption in Chapter 8

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 Modeling Basic Operations and Inputs

New Arena Constructs

• Station – location where some process occurs
 Arrivals, manufacturing cells, departures
 Each Station given a unique name
 Can serve as an entry point for a section of model logic
 Station marker represents a logical station in the
flowchart/animation
• Station Transfer – entities move between Stations
without direct connection
 Several different types – we’ll use Routes here, which allow
for positive transfer time, but no other delays like “room” on
the transitway or transporters
 Route paths represent Routes in the flowchart/animation
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 Modeling Basic Operations and Inputs

Adding the Route Logic – From Arrival

• Stations and Station Transfers affect both the
model logic and the animation
• Start with Model 4-3 … change to Model 4-4
• For incoming parts (A and B) delete connection
from Assign modules to “Prep” Process modules
 Replace with Station/Route module pairs
– Station module (Advanced Transfer panel) – define entity’s current
location
Module Name vs. Station Name
– Route module (Advanced Transfer panel) – send entity out
Route Time, Destination Station
 No direct connections exiting from the Route modules –
Route module’s Destination Station Name defines that

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 Modeling Basic Operations and Inputs

Adding the Remaining Route Logic

• Add Station modules for entry to each Prep area
 Station names are Prep A Station, Prep B Station,
and are the destination stations for Routes after arrivals
• Process modules for Prep A, Prep B unchanged
• After prep, entities connected to Route module to
send to next station (sealer)
 Don’t need a separate Station module for outgoing side
• Similar changes for rest of model
 Station modules for incoming parts into sealer, rework,
each of three Record modules (entity exit points)
 Route modules for outgoing parts out of sealer inspection,
rework inspection (two for each Decide module – pass/fail)
• Could run model now, get correct results … but
no animation of transfers …
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 Modeling Basic Operations and Inputs

Why Not Just Add Delays?

• Simpler approach than the above to getting the
two-minute transfer times:
 Insert a Process module with Action = Delay for 2 minutes
on each relevant connection
 Alternatively, use Delay module from Advanced Process
panel
• Actually this would work fine from modeling,
numerical-output viewpoints
• But it would not allow animation of part transfers,
so we’ll proceed with the Stations and Routes

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 Altering the Animation – Station
Modeling Basic Operations and Inputs

Markers, Routes
• Add animation for Stations and Routes
• Station button , Animate Transfer toolbar
 Attach Identifier to it from pull-down list of station names
 Get cross hairs, place (click) marker in animation
 Can place several station markers for the same logical
station (to represent incoming, outgoing sides)
 Can drag station markers around later
• Route button from Animate Transfer toolbar
 Options for appearance of entities as they travel the route
 Get cross hairs; click in origin, destination Station Markers
– Intermediate clicks for corners along the route
 Can drag around endpoints, corners later
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 Modeling Basic Operations and Inputs

Altering the Animation – Entity Pictures

• Part B arrivals are in batches of four parts/batch
 But constant travel time to Prep B implies they travel “on
top of each other” so it looks like just one part B
 Try – change Route time from 2 to EXPO(2), see
separation along the route
• Create illusion to animate the batch
 Assign module just after Part B Arrive
 Add assignment of Entity Picture to Picture.Batch B
 Edit > Entity Pictures to draw the new picture
– Copy Picture.Part B and rename it Picture.Batch B
– Double-click on picture, use Picture Editor to get four circles
 When batch arrives to Prep B, change to single circle
– Add Assign module after Prep B Arrival Station
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 Modeling Basic Operations and Inputs

What We’ll Do ...

• Model 4-1: Electronic assembly/test system
 Modeling approaches
 New Arena modules (Decide, Record)
• Model 4-2: Enhanced electronic assembly/test
 Resource Schedules, States, and Failures
 Frequency outputs
 More on utilizations
• Model 4-3: Enhancing the animation
 Queues, Entity Pictures, Resource Pictures
 Adding Plots and Variables
• Model 4-4: Adding entity travel times
 Modify with Stations, Transfers, Routes, animation of entity movement

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