1. An inspector always receives 120 pcs/h.

The average inspection time is uniform, between 20 and 30

s/piece. Simulate the system in ProModel, and calculate the inspector utilization and the maximum
number of parts accumulated before the inspection process.

Inspector utilization 83.36%.

Maximum number of pieces accumulated before the inspection process 1

2. An ATM receives 30 customers/h with Poisson distribution. There are 5 possible scenarios:

Simulate the system in ProModel and calculate, for each scenario:

a) The use of the cashier.

Scenario Results
1

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 b) The average number of customers on hold.

Scenario Results
1
2

c) If in all cases the average service time is the same, to what factor are the differences (if any)
due?

They are due to the different probabilities of tardiness at the ATM, which results in different times to the
average according to the type of probability distribution.

d) What is the difference between the first and the last scenario?

The cashier is used more in the latter scenario, resulting in fewer customers waiting in line.

3. A hardware store receives 56 customers/h with Poisson distribution. The store has only two
employees, and customers must wait in line. Service time is exponential with an average of 2 min/client.
Simulate the system to steady state and calculate:

a) The use of dependents.

b) The average waiting time in line.

Carlos Alberto Medina Miguel

4. An electronics store sells 2 types of microcomputers: the E-GD and the H-GR. Inter-arrival time is
exponential with an average of 45 min/client. It is a small store, requiring only one employee to serve
customers on a "first in, first out" basis. Twenty-five percent of the customers who come in do not make
a purchase, and use the employee for exactly 15 minutes. Fifty percent of incoming customers purchase
an E-GD type computer, and the time it takes them to complete the transaction follows an even
distribution of between 31 and 36 minutes. The remaining 25% enter the store and purchase the H-GR
type computer; the time required for the sale in this case follows an exponential distribution with a
mean of 70 minutes. Simulate 8 hours and determine:

a) Use of the employee.

b) The average time a customer has to wait before being served.

5. A production system has 10 lathes. The operating time of each follows an exponential probability
distribution with a mean of 96 hours, after which a failure occurs and it has to be sent for maintenance.
The repair time is exponential with an average of 72 hours. The transfer time of the lathes between
production and maintenance is uniform, with parameters of 60 ± 15 minutes. It is desired to simulate
the system until the steady state is reached, with 1, 2, 3, 5, ..., 10 mechanics to determine in each case
the utilization of the mechanics and the average number of lathes waiting for repair.

Number of Graphic Percentage of use

mechanics
1 81.32%

2 78.34%

3 74.79%

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 4 68.55%

5 53.36%

6 43.40%

7 37.20%

8 32.55%

9 28.93%

10 26.04%

6. The company LECAR has 100 looms. The operating time of each before a breakage occurs follows an
exponential probability distribution, and the loom stops waiting for a worker to repair the breakage and
restart the operation. Repair time is 2-Erlang with an average of 5 minutes. The mean time between
breaks depends on the yarn quality, according to the following scenarios:

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Create a simulation model for each scenario, and determine the number of workers to be assigned to
breakage repair in order to keep the looms in operation 95% of the time.

Quantity per arrival Scenario Number of mechanics and results

100 per 1hr Optimistic With 10 mechanics

100 per 1hr Average With 15 mechanics

7. A library receives an average of 104 people/year with a Poisson distribution to borrow a certain book.
The person who manages to find it returns it an average of 10 days later, with exponential distribution.
People who request the book but do not receive it because it is on loan, leave and never return.
Simulate the process for one year, with 1 ,2 ,3 and 4 copies of the book, and determine in each case the
expected number of people who will be able to read the book.

Exemplary people to read the book and results

1 50 people

2 52 people

3 52 people

4 52 people

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8. To the detergent bag packing operation bags of detergent enter at a rate of 20 per minute. When the
bags enter the system, they are placed on a conveyor belt that transports them to a packing operator's
table. Conveying time on the belt is 20 s/bag. Once the bag reaches the end of the belt, it falls by gravity
to a table where it accumulates with other bags. An operator picks up the bags from the table and
places them in a box with a capacity of 30 units; the time it takes the operator to pick up a bag and place
it inside the box is 1 second/bag. Once the box is filled, the operator takes it to the box store; there he
leaves it and picks up an empty box to repeat the filling procedure. The time it takes to carry a full box
and bring an empty one follows an exponential distribution with a mean of 3 minutes. Simulate the
above system in ProModel, to obtain the graph of the number of bags on the table, the average number
of bags and the average waiting time on the table over time.

Carlos Alberto Medina Miguel

9. A die-cutting process receives sheets according to a Poisson distribution with an average of 82
sheets/min. There are 7 die-cutting machines, each of which is capable of processing a sheet in 5
seconds. There is a large warehouse for raw material, so that all parts that cannot be die-cut
immediately can wait there. The cost of operating the machines is estimated at $10/h-punch press, and
the cost of holding a sheet in inventory is estimated at $0.500/h-sheet. Simulate the system to
determine the average sheet inventory and total cost/h.

40 hours of standard simulation.

7 die cutters $10 per hr each

Each sheet in stock per hour 0.500$.

Laminates in inventory = $95,600 per 40hr

Cost per die cutter = $280 per 40hr

10. A die-cutting process receives sheets according to a Poisson distribution with an average of 82
sheets/min. There are 7 die-cutting machines, each of which is capable of processing a sheet in 5
seconds. There is a warehouse for raw material with a capacity of 5 sheets; if a sheet arrives and cannot
enter the process or the raw material warehouse, it must be sent to another part of the plant for die
cutting. The cost of operating the machines is estimated at $10/hr-punching machine; the cost of
holding a sheet in inventory is estimated at $0.500/ sheet, and the cost of shipping the sheets to
another location is $0.800 per sheet. Simulate the system to determine the average inventory of sheets
in the warehouse before die-cutting, and the total cost/hr.

Cost per die cutter= 280$/40hrs

Laminates in inventory= 9,042$/40hrs

Failed = 139,334.4$/40hrs

Carlos Alberto Medina Miguel

11. Three different types of parts arrive at a machining center. Before arriving, they pass through a
product-in-process warehouse, with practically infinite capacity. The operating time and input rate of
the parts are as follows:

Simulate the system in ProModel for 100 hours, and determine:

a) Use of the machining center.

77.76 %

b) Total number of pieces produced.

b) Average waiting time for parts in the warehouse.

37.36 min

d) Average number of pieces in the warehouse.

12. A cleaning operator has 60 parts delivered simultaneously every hour. The cleaning time is uniform,
50 ± 10 s/piece. Simulate the above process for 500 hours to determine:

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a) Operator use.

83.14 percent

b) Average dwell time of the parts throughout the process.

25.41 min

c) Average waiting time for parts before cleaning.

24.53 min

13. A painting system has two serial processes: painting and baking. The painting time is exponential, 10
m in/piece, and the baking time is triangular (3,6,15) min/piece. For both processes there are two
painters and a kiln. The input rate is 7 pieces/h in the case of piece type 1, and 3 pieces/h in the case of
piece type 2. The time to move from one process to another is 30 seconds. Simulate the system for 5
days to determine:

a) Use of each operation.

c) Average dwell time of the parts throughout the process.

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d) Average waiting time of the parts before painting and before baking.

1,256.88 min

14. Three types of jobs come into a copy center. If a job cannot be started immediately, wait in a
common queue until one of the center's three copiers is available. The copying time and job input rate
are as follows:

After the copying process the jobs are inspected by an employee in an exponential time averaging 3, 6,
10 minutes for jobs 1, 2 and 3, respectively. Simulate the system in ProModel for 50 hours, and
determine:

a) Use of employee and copiers in the proposed situation.

b) Minimum number of employees and copiers necessary to ensure the flow of jobs.

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31 copiers and 16 inspectors

15. A type of part enters a production line. The supplier delivers exponentially with an average of 2
min/piece. The line consists of 3 operations with one machine in each operation. The process times are:

The time to move between stations is 0.0625 minutes. The animation must include a counter of the
pieces produced. Simulate in ProModel the process of 500 parts to determine:

a) Total simulation time.

b) Use of each operation.

c) Waiting time before the first operation.

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 d) Percentage of time the part was blocked.

16. Parts arrive at a punching process from 8:00 a.m. onwards. The interarrival time is exponential, with
an average of 30 s/piece. Drilling can be performed on any of the 3 existing machines; however, due to
the size of the power transformer, the machines cannot work at the same time. It has been decided that
production will be carried out on machine 1 for the first 3 hours of the shift, on machine 2 for the next 3
hours, and on machine 3 for the last 2 hours. Due to scheduling reasons, machine 1 always starts at 8:15
a.m. The drilling times for each machine are shown below:

Make a model in ProModel to simulate 30 days of 8 hours each, and obtain:

a) Production at the end of each day.

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 b) Probability distribution of daily production.

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Poisson distribution of 956 pcs.

17. An office receives 2 types of clients. The arrival rate of type I clients follows a uniform distribution
(100-150) m in/client; the rate of the second type follows a constant distribution with a mean of 120 m
in/client. There is only one server that has to serve both types of customers on a first-in, first-out basis.
The time it takes to serve type I clients follows an exponential distribution with a mean of 25 min/client,
while the service time of the second type of clients follows a 2-Erlang distribution with a mean of 35 m
in/client. Simulate until 500 type II clients have been served and determine:

a) Total simulation time

1000 hrs

b) Number of type I clients served.

c) Average time spent in the office for each type of customer.

d) Maximum number of clients in the office.

It would be a maximum of 5 customers

18. In a bank there are 2 cash registers, each with its own row of infinite size: register 1 for "fast"
customers with a time of 2 minutes, and register 2 for "slow" customers with a time of 16.4 minutes, in
both cases with exponential distribution. Slow" and "fast" customers arrive according to an exponential

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function, averaging 8 and 20 m in/customer, respectively. On some days, in particular, only 1 cashier
comes to work and has to serve both lines according to the following cyclical sequence: 5 "fast"
customers and 2 "slow" customers. The time to move between boxes is 0.33 minutes. Simulate in
ProModel the process for 80 hours, and determine:

a) Average number of customers waiting in each queue.

fast row 96.75

slow row 5.49

b) Optimal sequence of attention to minimize the average waiting time, considering both types of
customers.

19. Heat exchangers enter a cleaning system exponentially, averaging 5 h/piece. The process consists of
3 operations with one machine and in each operation. The process times are:

A forklift is available for all movements between stations. The transfer time between stations is 3-Erlang
with an average of 30 min/exchange. The animation must include a counter of the pieces produced. I.
Simulate in ProModel the process of 500 exchangers to determine:

a) Total simulation time.

2821 hrs

b) Use of each operation.

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 c) Waiting time before the first operation.

40526.22 min

d) Percentage of time the part was blocked.

e) Would you recommend having another forklift? Justify your answer.

Yes, because this way there would be less blockage and reduce the time in the system.

II. Simulate the model with a scenario where the forklift fails exponentially every 15 working hours and
is repaired with a normal distribution with mean 30 minutes and standard deviation 5 minutes. In this
case, would it be appropriate to have two or more forklifts? Justify your answer.

It would be appropriate to have more than two forklifts, because the time in the system increases and
so does the blockage.

20. An average of 10 persons/h with Poisson distribution try to enter a hotel hot tub. On average, each
person stays 20 minutes with exponential distribution. In the jacuzzi there are only 6 spaces, so if a
person arrives and all the places are occupied, he/she leaves in a huff and does not return. Simulate the
process for 100 hours.

a) What is the use of the Jacuzzi?

53.31%.

b) On average, how many people are in the hot tub?

3.20 people

c) On average, how many people per hour can use the hot tub?

0.13 people

d) How many places should the jacuzzi have to ensure that 95% of the people who arrive can enter?

21. Determine through ProModel the number of machines a system requires to process parts, with a
constraint of maintaining a utilization between 60 and 80%. Pieces arrive according to a Poisson

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distribution, with an average of 1.5 customers per minute. When a part enters and all machines are
busy, it remains in a single row common to all machines. The processing time follows an exponential
distribution with a mean of 3 minutes. Include in the results the values of utilization, average waiting
time and average number of waiting pieces.

79.83% utilization

Average waiting time: 1.87 minutes.

Average number of pieces in queue: 1.47 pieces.

22. The diagram shows the process and routing of parts within a manufacturing cell. All parts must enter
and exit the cell through the AS/RS. The numbers on the arrows in the diagram represent the
percentage of flow that is sent to other equipment; for example, 10% of what goes into cutting is sent to
the AS/RS, 85% to squaring, and 5% to reprocessing. An automatic control system always maintains 10
parts within the system (see diagram below).

Simulate in ProModel and determine for each operation:

a) Utilization.

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 b) Maximum number of pieces.

c) Average number of pieces.

23. In the closed system shown in the diagram, 20 parts are always kept in process. Each one enters
from a main belt through a transfer robot, and must visit the 2 grinding stations before returning to the
transfer robot to be sent back to the main line. The parts move through conveyor belts (see diagram
below).

Simulate for 200 hours and determine:

a) Hourly production.

Production per hour is 5.3≈ 5 pieces

b) Use of the stations.

Carlos Alberto Medina Miguel

c) Average in-process inventory at each station.

d) Average dwell time of parts in closed system

24. Five trucks are used to transport concrete from one place to another. There is only one loading
hopper, and the time to do so follows an exponential distribution with an average of 20 minutes. The
time to transport concrete and return for more material follows an exponential distribution with a mean
of 180 minutes. Simulate the movement of the trucks to answer:

a) On average, how long does a truck wait in the hopper line?

b) What fraction of the time is the hopper not used?

c) If 500 trips are scheduled, how long will it take to make them?

1462 hrs

25. A production system of the EHYPSA company receives type 1 parts every 5 ± 3 minutes, and type 2
parts every 3 ± 2 minutes. Type 1 parts go through cleaning in a time of 8 ± 3 minutes; when leaving,

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25% must be cleaned again, and the remaining 75% leave the system for sale. Type 2 parts first undergo
verification in a time of 9 ± 3 minutes, and then cleaning in a time of 3 ± 1 minutes. When leaving
cleaning, 5% must be cleaned again, and the remaining 95% leaves the system for sale. Simulate the
system one m es and determine the minimum number of check and cleaning operators to maximize
hourly production. Indicate number of pieces of each type produced during the month.

Original

Enhanced

26. At HELEED hospital, patients enter the emergency rooms at a Poisson rate averaging 4 person/hour.
Eighty percent of patients enter directly into one of the 5 wards; the remaining 20% are taken to a
secretary for a registration process. The time in registration is 5 ± 0.5 min/patient, then, they go to the
emergency rooms. Two physicians are on call in the emergency rooms, and they take 3-Erlang time to
check patients with an average of 30 m in/patient. After this time the patient is transferred to other
areas of the hospital, according to his condition. Run a model in ProModel to simulate 3 48-hour
replications of the above situation and determine, with a confidence interval of 95%:

a) Average waiting time for patients in the registration process.

The average recording time is 9.93 minutes.

b) Maximum number of clients who were in the entire hospital.

152 patients were discharged, but 3 remained in the hospital system.

(c) Use of physicians, emergency rooms and secretary.

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27. A certain part requires 2 operations: welding in 6 minutes, and grinding in 6.4 minutes. The arrival of
pieces is uniform between 10 and 15 min/piece. Stores of infinite size exist before each operation. There
is only one operator to do both operations, according to the following cyclic sequence: 5 pieces in
welding and 5 pieces in grinding. The time to move between machines is 1 minute. Simulate in
ProModel the process 480 hours, and determine the average waiting time for parts in the warehouses
before each operation.

28. A packaging machine is fed by two conveyor belts. Sweets enter through the first one at a constant
rate of 2000 sweets/h. For the second one, bags enter. The machine packs 50 candies per bag and
places the packed product on a third belt for transportation to the finished product warehouse. Total
packing time is 20 seconds. The speed of the belts is 150 feet per minute. Every 3 hours the baler stops
for adjustment and cleaning; the time to carry out these operations is exponential with an average of 10
minutes. While the baler is being adjusted, bags and candy continue to enter the system. Develop a
model in ProModel and determine the average bag entry rate.

29. Clients arrive at the SRE office to receive their passports at a Poisson rate with an average of 18
clients per hour. Upon entering, they take a token that allows them to be served on a first-come, first-

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served basis. Ninety percent of customers enter the waiting room directly, and the rest fill out a few
forms first in an even time (6 ± 2) minutes. There are 2 servers to serve customers in the waiting room;
the average service time is exponential with an average of 6 minutes. The waiting room has 40 chairs. If
a customer arrives and all the chairs are occupied, he/she stands and sits down when one of them is
vacated. Each time 10 passports are issued, the server stops serving the line and leads the served
customers to the back, after which he continues to serve the line; the time to and from follows an
exponential function with an average of 5 minutes. Make a model in ProModel to simulate for 8 hours
the current situation, so that, at the end of the simulation, the following results are displayed on the
screen:

a) Average waiting time in line.

Standby time is 30.77 min.

b) Average number of persons seated.

11 People.

c) Average number of people standing.

None

d) Maximum number of persons in the waiting room.

30 people.

e) Use of servers.

Server 1: 87.20 %.
Server 2: 84.80 %.

30. At PESYPINSA, parts enter a painting process at a Poisson rate averaging 1.0 min/part. Before
painting, the parts should be weighed on either of the two existing scales: the time on the scale is
uniform, (2 ± 0.5) minutes. There is one person who performs the painting operation in 12 minutes per

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part, with exponential distribution. There is also a standby painter, who enters the process whenever
the number of parts in the work-in-process warehouse enters the scales and the paint exceeds 10, and
remains working for one hour, after which he stops painting and returns to his standby position. Make a
model in ProModel to simulate for 8 hours the current situation, so that, at the end of the simulation, it
is indicated on the screen:

a) Average waiting time in the paint warehouse.

Standby of 191.69 in standby.

b) Maximum number of pieces that accumulated in the whole system.

290 pieces.

c) Use of the scale and painters.

Scale 1 is: 81.46 %.

Scale 2 is: 71.98 %.
Painter: 99.60 %.
Reserve painter: 61.83 %.

31. The MOLGADE Co. manufactures molds and wants to simulate a part of its process in ProModel. The
molds are initially stored in the raw material warehouse, in sufficient quantity so as not to stop
production due to lack of material. The first operation is a sandblasting, which lasts 4 minutes. Next, one

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of six inspectors checks the dimension of the molds; each inspector takes 3-Erlang with an average of 18
minutes to check. The molds are then transported to a kiln in batches of 5, using a traveling crane. The
transport time is 6 minutes, and the company has two cranes for this movement. Four batches are
loaded into the furnace to start the heating process; this time is one hour. After leaving the oven, the
molds are cooled in the open air in 3 ± 1 hour. Once the process is finished, they are packed in boxes of
25 molds. The packing time is triangular (2,3,6) m in/box, and the molds are transported in containers of
8 boxes each to the finished product area in an AGV. The time required for this movement is 10 minutes.
Three shifts of eight hours each are worked. Model the operation for one m es for:

a) Determine equipment utilization, average in-process inventory and dwell time of a mold in the
system.

Cleaning: 100
Inspection: 46.18 %.
Oven: 74.78 %.
Packaging: 8.48 %.
The average in-process inventory is 32,476 molds.
The average time the mold remains in the system is 16,436.67 min.

b) Detect problems and propose increases or decreases in resources.

Increasing the cleanliness results in a better mold flow, which results in more output molds in
the system. They result in fewer molds in the system and remain in the system for a shorter
time. Increased to 5 cleaning units.

c) Determine, for the proposed solution, the equipment utilization, the average in-process inventory,
and the dwell time of a mold in the system.

Cleaning: 100
Inspection: 99.36 %.
Oven: 99.9 %.
Packaging: 8.69 %.
The average in-process inventory is 28,901 molds.
The average time the mold remains in the system is 14,585.44 minutes.

Carlos Alberto Medina Miguel

Carlos Alberto Medina Miguel