National University of Science and Technology

Department of Industrial and Manufacturing Engineering

MEng Manufacturing Systems and Operation Management

Manufactuing Systems TIE5215 Due 11 March 2024 Assignments:

Reporting FORMAT and Requirements

A soft copy of the model build and a soft copy of a word processed individual report for each Assignment is
expected which should take the following format:
Title page (NUST, Faculty, Department, Programme, Name, Reg No., Assignment number,)
1.0 Introduction
2.0 (Literature/Discussion on Problem/Data Collection/Model Conceptualization)
3.0 Results (graphs, tables)
4.0 Discussion on results
5.0 Conclusion
6.0 Reference/ Bibliography

Please make sure that each Figure/Table in the report is numbered and cited in the text of the report. Normally
Table are numbered at the top and Figures are numbered at the bottom. The report must have sections
numbered to guide the reader as shown in the outline example. Using Style New Times Roman, Font 12, 1.5
line spacing, A4 page.
(Each assignment is assessed 20% report documentation, 50% model running, 30% results)

Task A (50%OCW-MODSIM): Individual Assignments based on one model using Arena

DUEDATE: 11 March 2024

Assignment People in Group Number Assignment Number in Appendix People in Group

Number in will attempt A Number will
Appendix corresponding attempt
A Assignment corresponding
Assignment
1 Group 1 11 Group 11
2 Group 2 12 Group 12
3 Group 3 13 Group 13
4 Group 4 14 Group 14
5 Group 5 15 Group 15
6 Group 6 16 Group 16
7 Group 7 17 Group 17
8 Group 8 18 Group 18
9 Group 9 19 Group 19
10 Group 10 20 Group 20

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Task B (50%OCW): Groups of four Practical Assignment based on Siman & ARENA
DUEDATE: 11 March 2024 for ALL Assignments
Choose a case study problem that you do a model conceptualization with workstations and a decision
made, Data collection, Models development, Experimentation and document the whole project
Assignment People as a Group will Assignment Case People as a Group
case attempt corresponding will attempt
case corresponding case
1 Group 1 11 Group 11
2 Group 2 12 Group 12
3 Group 3 13 Group 13
4 Group 4 14 Group 14
5 Group 5 15 Group 15
6 Group 6 16 Group 16
7 Group 7 17 Group 17
8 Group 8 18 Group 18
9 Group 9 19 Group 19
10 Group 10 20 Group 20

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Appendix A
1. People arrive at a tyre-service centre to get new tyres fitted at the rate of one every 20 mins . Forty percent go to
the new tyre enquiry, where one worker helps them 5mins person then they proceeed to payment which taked
10mins if ecocash and 6mins if swipe. After the wait for 30mins while type is being changed. Of the 60 percent
that arrive 50% goes to tyre mend which take 20mins and the 50% goes to pressure topup for 2mins. How
many people were served with new tyres, tyre mending and pressure. What was the utilization of each station in
an 8 hour shift. Any missing information can be assumed and stated.
2. Consider a batch manufacturing process in which a machine processes jobs in batches of three units. The
process starts only when there are three or more jobs in the buffer in front of the machine. Otherwise, the
machine stays idle until the batch is completed. Assume that job interarrival times are uniformly
distributed between 2 and 8 hours, and batch service times are uniformly distributed between 5 and 15
hours. Assuming the system is initially empty, simulate the system for three batch service completions and
calculate the following statistics:
a. _ Average number of jobs in the buffer (excluding the batch being served)
b. _ Probability distribution of number of jobs in the buffer (excluding the batch being served)
c. _ Machine utilization
d. _ Average job waiting time (time in buffer)
e. _ Average job system time (total time in the system, including processing time)
f. _ System throughput (number of departing jobs per unit time)
3. A manufacturing facility has a repair shop with two repairmen who repair failed machines on a first-fail-
first-serve basis. They work together on the machine if there is one machine down (the repair still takes the
same amount of time), and otherwise, each works on a separate machine. Thus, if there are more than two
machines down, new failures simply wait for their turn to be repaired. Assume that machine failures arrive
in a combined failure stream, so that we do not need to track machine identity. More specifically, assume
that the times between machine failures are equally likely between 10 and 20 hours, and that repair times
are equally likely between 5 and 55 hours for each machine. Simulate the manufacturing facility manually
for five machine repair completions, and calculate the following statistics:
a. _ Fraction of time a machine is down
b. _ Average number of down machines waiting to be repaired
c. _ Fraction of time each repairman is busy (repairman utilization)
d. _ Fraction of time the repair facility is idle
e. _ Average time a failed machine waits until its repair starts
f. _ Throughput of the repair facility (number of repair completions per hour)
4. A two-stage manufacturing model with two processes in series. Jobs arrive at an assembly workstation
with exponentially distributed interarrival times of mean 5 hours. We assume that the assembly process has
all the raw materials necessary to carry out the operation. The assembly time is uniformly distributed
between 2 and 6 hours. After the process is completed, a quality control inspection is performed, and past
data reveal that 15% of the jobs fail any given inspection and go back to the assembly operation for rework
(jobs may end up going through multiple reworks until they pass inspection). Jobs that pass inspection go
to the next stage, which is a painting operation that takes 3 hours per job. We are interested in simulating
the system for 100,000 hours to obtain process utilizations, average number of reworks per job, average
job waiting times, and average job flow times (elapsed times experienced by job entities).
5. The emergency room of a small hospital operates around the clock. It is staffed by three receptionists at the
reception office, and two doctors on the premises, assisted by two nurses. However, one additional doctor
is on call at all times; this doctor is summoned when the patient workload up-crosses some threshold, and
is dismissed when the number of patients to be examined goes down to zero, possibly to be summoned
again later. Figure 5.20 depicts a diagram of patient sojourn in the emergency room system, from arrival to
discharge.? Patients arrive at the emergency room according to a Poisson process with mean interarrival
time of 10 minutes. An incoming patient is first checked into the emergency room by a receptionist at the
reception office. Check-in time is uniform between 6 and 12 minutes. Since critically ill patients get
treatment priority over noncritical ones, each patient first undergoes triage in the sense that a doctor
determines the criticality level of the incoming patient in FIFO order. The triage time distribution is
triangular with a minimum of 3 minutes, a maximum of 15 minutes, and a most likely value of 5 minutes.
It has been observed that 40% of incoming patients arrive in critical condition, and such patients proceed
directly to an adjacent treatment room, where they wait FIFO to be treated by a doctor. The treatment time
of critical patients is uniform between 20 and 30 minutes. In contrast, patients deemed noncritical first wait
to be called by a nurse who walks them to a treatment room some distance away. The time spent to reach

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 the treatment room is uniform between 1 and 3 minutes and the treatment time by a nurse is uniform
between 3 and 10 minutes. Once treated by a nurse, a noncritical patient waits FIFO for a doctor to
approve the treatment, which takes a uniform time between 5 to 10 minutes. Recall that the queueing
discipline of all patients awaiting doctor treatment is FIFO within their priority classes, that is, all patients
wait FIFO for an available doctor, but critical patients are given priority over noncritical ones. Following
treatment by a doctor, all patients are checked out FIFO at the reception office, which takes a uniform time
between 10 and 20 minutes, following which the patients leave the emergency room. The performance
metrics of interest in this problem are as follows:
a. _ Utilization of the emergency room staff by type (doctors, nurses, and receptionists)
b. _ Distribution of the number of doctors present in the emergency room
c. _ Average waiting time of incoming patients for triage
d. _ Average patient sojourn time in the emergency room
e. _ Average daily throughput (patients treated per day) of the emergency room
To estimate the requisite statistics, the hospital emergency room was simulated for a period of 1 year.

6. Press operation. The press department of an automobile manufacturing facility runs two main operations,
each with its own press machine: front-plate press operation and rear-plate press operation. These
operations can be performed in any order, but both have to be performed for each arriving plate. Plates
(jobs) arrive randomly and their interarrival times are exponentially distributed with mean 5 minutes. The
service time in the front-plate press operation is distributed iid Unif(1, 5) minutes, and in the rear-plate
press operation it is distributed iid Unif(2, 6) minutes. A plate joins the queue of the press operation with
the least number of plates waiting at that time (since there is no sequencing requirement), and on
completion joins the queue of the other press operation after which it departs from the system. Finally, the
press department is a three-shift facility running 24 hours a day.
a. Develop an Arena model of the press department, and simulate it for one year.
b. Estimate the following statistics:
_ Average time arriving plates spend in the press department
_ Utilization of the press machine in each operation
_ Average queue delay at each operation
_ Average time in the press department of those arriving plates that join first the rear-plate press
operation, and then proceed to the front-plate press operation
7. Electrolytic forming process. An expensive custom-built product goes through two stages of operation.
The first stage is an electrolytic forming process, served by two independently operating forming
machines, where the product is built in a chemical operation that must conform to precise specifications.
The second stage is a plating operation in which the product is silver plated. Customer orders arrive with
interarrival times distributed Tria (3, 7, 14) hours, and join a queue in front of the forming process. The
electrolytic forming processing time is distributed Unif (8, 12) hours. The silver-plating process also has a
queue in front of it. Plating time is distributed Unif (4, 8) hours. The variability in the processing times is
due to design variations of the incoming orders. The two processes do not perform perfectly. In fact, 15%
of the jobs that emerge from the forming process and 12% of the jobs that emerge from the plating process
are defective and have to be reworked. All defective jobs are sent to a single rework facility, where design
modifications and corrections are performed manually. However, plating reworks have a lower priority
than forming modifications. Plating rework times are distributed Unif (15, 24) hours, while forming
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 reworks are distributed Unif (10, 20) hours. Jobs departing from the rework facility go back to the process
they came from to redo the operation found defective. Jobs that successfully complete the plating process
leave the facility. Note that a job may go back and forth between a process and the rework operation any
number of times.
a. Develop an Arena model of the electrolytic forming process, and simulate it for 1 year (24
hours of continuous operation).
b. How busy are each of the two operations and the rework facility?
c. What are the expected delays in process queues and the rework facility?
d. What is the expected job flow time throughout the entire facility?
e. Suggest a change in the system to reduce (even slightly) the expected job flow time. Run the
modified model and compare the job flow statistics.
8. Supermarket cashier management. A supermarket is open 24/7 and operates in 3 shifts: first shift from8:00
A.M. to 4:00 P.M., second shift from4:00 P.M. to 12:00 A.M., and third shift from 12:00 A.M. to 8:00
A.M. Customers arrive according to a Poisson process with shift-dependent arrival rates, and their
shopping times (excluding checkout) are Shown in Table 8 but shift dependent. Consequently, the
supermarket management assigns variable numbers of cashiers per shift. The arrival, shopping, and cashier
parameters are displayed in the following Table 8. After shopping, customers queue up in a single line for
checkout. Checkout times of customers are shown in Table 8, but shopping-time dependent as follows: a
customer's checkout time is 2 minutes plus a random fraction of its shopping time, where the fraction is
triangular between 20% and 30%, with a most likely value of 25%. Finally, a customer is assigned to the
shift during which it departs from the supermarket (note that a customer may arrive during one shift and
depart during a subsequent one).
a. Develop an Arena model of the supermarket, and simulate it for 30 days.
b. Compute the average, variance, and squared coefficient of variation of customer waiting times
for a cashier (excluding checkout processing times).
c. What is the per-shift average sojourn time of customers in the supermarket?
d. What are the overall instant and scheduled cashier utilizations?
Table 8
Shift Number Arrival Rate Shopping Time Number of Cashiers
Distribution
(customers per minute) (minutes)
1 16.8 Unif (5, 15) 2
2 24.0 Unif (15, 40) 4
3 0.7 Unif (1, 5) 1

9. Consider a pair of faculty generating grant proposals that take 10 days of work on average but whose
completion times are highly variable. Half the proposals require both faculty members and the other half
require only one of them. Assume that faculty cannot work on more than two proposals at a time and wait
doing other activities if necessary. Use simulation to estimate how many proposals the faculty pair can
expect to generate in a year.

10. A factory is considering investing in a higher quality robotic device to make its product and comparing
that possibility with simply purchasing a second device and running two parallel lines. Currently, 25% of
its robot’s produce typically needs reworking. Right now, the factory needs to ship only 325 units per 12-h
shift but demand is pushing that to 425. The managers want you to help them understand their quality-
versus-productivity tradeoff.
a. Suppose that you time 12 inter-arrivals of parts at the robot. The results are: 90, 95, 90, 90, 98,
92, 93, 94, 91, 88, 89, 91, 92, 87, and 90. Also, suppose that rework is ‘‘very random’’
typically requiring 10 min ‘‘plus or minus 10 min’’ after which the item is re-run through the
robot. Also, suppose that the factory managers tell you to assume that the robot operations take
a time that is TRIA(80, 85, 90) in seconds based on a past study.
b. Perform input analysis to estimate what you need for simulation and show your results in a
flow chart.
c. Perform simulation with a sufficient number of replications to estimate the number of
expected units shipped. Provide an estimate for the half width. Also, display the expected
numbers shipped for at least 3 values of the fraction of units needing rework.

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 d. Provide decision-support for the company declaring conclusions and characterizing your own
uncertainties appropriately.

11. An office that dispenses automotive license plates has divided its customers into categories to level the
office workload. Customers arrive and enter one of three lines based on their residence location. Model
this arrival activity as three independent arrival streams using an exponential interarrival distribution with
mean 10 min for each stream, and an arrival at time 0 for each stream. Each customer type is assigned a
single, separate clerk to process the application forms and accept payment, with a separate queue for each.
The service time is UNIF(8, 10) min for all customer types. After completion of this step, all customers are
sent to a single, second clerk who checks the forms and issues the plates (this clerk serves all three
customer types, who merge into a single first-come, first-served queue for this clerk). The service time for
this activity is UNIF(2.66, 3.33) min for all customer types. Develop a model of this system and run it for
5,000 min. Provide a confidence interval for the average and maximum time in system for all customer
types combined.

12. Customers arrive at an order counter with exponential interarrivals with a mean of 10 min; the first
customer arrives at time 0. A single clerk accepts and checks their orders and processes payments, taking
UNIF(8, 10) min. Upon completion of this activity, orders are randomly assigned to one of two available
stock persons (each stock person has a 50% chance of getting any individual assignment) who retrieve the
orders for the customers, taking UNIF(16, 20) min. These stock persons only retrieve orders for customers
who have been assigned specifically to them. Upon receiving their orders, the customers depart the system.
Develop a model of this system and run the simulation for 5,000 min, observing the average and maximum
customer time in system.

13. Stacks of paper arrive at a trimming process with interarrival times of EXPO(10); all times are in minutes.
There are two trimmers, a primary and a secondary. All arrivals are sent to the primary trimmer. If the
queue in front of the primary trimmer is shorter than five, the stack of paper enters that queue to wait to be
trimmed by the primary trimmer, an operation of duration TRIA(9, 12, 15). If there are already five stacks
in the primary queue, the stack is balked to the secondary trimmer (which has an infinite queue capacity)
for trimming, of duration TRIA(17, 19, 21). After the primary trimmer has trimmed 25 stacks, it must be
shut down for cleaning, which lasts EXPO(30). During this time, the stacks in the queue for the primary
trimmer wait for it to become available. Animate and run your simulation for 5,000 min. Collect statistics,
by trimmer, for resource utilization, number in queue, and time in queue.

14. E-commerce and supply chains. Consider BlueSky Books, a marketing and publishing company of a
popular book (only one copy per customer order). The marketing activity centers on the website
BlueSky.com operating 24 hours a day, which receives orders from customers and passes them on to the
publisher. The publisher prints and maintains a small inventory of the book, and uses it to fulfil customer
orders. Book requests are generated at a client host, and arrive with exponential interarrival times of rate
10,000 units per day. The CPU time per book order at the client node is exactly 1 second, and the size of
each request message is precisely 2048 bytes. Book requests are sent to the server host through a
communications (transmission) network with BWC of 2250 bytes/second and MTE of only 60%. The
server host has a single server process that receives all book requests and processes them. The elapsed time
per request is 4 seconds and includes charging the customer’s credit card, transferring the proceeds to a
bank account, and updating a local database with order information. On completion of processing, the
server sends two messages of size 1024 bytes each over the transmission network—an acknowledgment
message to the client and an order message to the publisher. The BlueSky publishing division has one
press on its shop floor, and is guaranteed to have sufficient supplies of ink and paper on hand. The press
can operate 24 hours a day and never experiences failures. The time it takes to print a batch of 3000 books
is iid Tria(2.5, 4, 6) hours. As soon as the publishing division receives an order from the website, it ships
the order to the customer (and records an inventory reduction of one unit). The publishing division
maintains a maximal inventory of 15,000 books, but when it drops down to 3000 books, the press is
activated to replenish the inventory to 15,000 books, at which point the press is idled again. The shipping
time for a book delivery is iid Unif(1, 3) days. Unsatisfied book orders are backordered. If there are
outstanding backorders, they are satisfied first as soon as a new production batch is completed. The
remaining books, if any, are added to the on-hand inventory.
a. Develop an Arena model for the BlueSky operation and simulate it for 15 days, starting with
an initial inventory of 1000 books on hand.
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 b. Estimate the following statistics:
i. _ Average acknowledgment response time (the time a customer waits for an
acknowledgment starting at the moment the order is submitted)
ii. _ Average total response time (the time it takes the book to arrive at the customer’s
address from the moment of order submission), but only for customers whose demand
was satisfied immediately, without a need for backordering
iii. _ Average inventory level of books at the publishing division
iv. _ Average backorder level
Hint: If you use a Delay module for the Unif(1, 3) days to delivery, then the student version of Arena might be
inadequate, due to too many transaction entities in the model. Instead, include this (random) time in an
expression of the total response time to be tallied (the expression should be entered into the Tally module for
parsimony).

15. Traffic light at road intersection. Montgomery Township is considering installing a traffic light at the
three-way intersection of Don’t Drink and Drive Ave. and Buckle Up Ave., where accidents occur
frequently. Assume that each direction of every avenue consists of 2 lanes. The layout of the intersection is
shown in the next illustration.

Vehicles approach the intersection with the following iid interarrival time distributions and destinations:
_ From the north: Interarrival times are Unif (2, 14) seconds. Twenty-five percent of the cars turn east, and
75% proceed south.
_ From the south: Interarrival times are Unif (2, 15) seconds. Forty percent of the cars turn east, and 60%
proceed north.
_ From the east: Interarrival times are Unif (12, 18) seconds. Fifty percent of the cars turn north, and 50% turn
south.

It takes 5 seconds to go through the intersection in any direction (provided the light is green, of course). The
traffic light works in cycles in the following manner:
_ First, the light for the north–south direction turns green, and the following scenario unfolds. During the first
45 seconds, non-turning traffic from the north and from the south can proceed, as well as right turns from the
east and from the south. However, left turns from either the north or from the east are not allowed. During the
next 25 seconds, the light remains green for southbound cars but becomes red for northbound cars. During this
time, left turns from the north are allowed, as well as right turns from the south and the east.
_ Second, the light turns red in the north–south direction and then turns green in the easterly direction for 25
seconds. During this period, all traffic from the east and right turns from the south are allowed to proceed.
However, note that left turns from the north are not allowed to proceed.
a. Assuming time-homogenous (stationary) arrival rates (i.e., rates do not change over time), simulate the light-
controlled behavior of the intersection for 5 days.
b. For each car stream (lane), what is the average waiting time at the intersection? c. Keeping in mind that the
Schedule module cannot be used with uniforminterarrival times, describe how to model a system with a 20%
increase in the arrival rates of all cars during the rush hours of 7 A.M.–9 A.M. in the morning and 5 P.M.–7
P.M. in the evening. Note that the Arena student version
may not accommodate the modified system.
Hint: You may model the passage of cars through the intersection using a Process module for each stream. The
traffic light may be modeled as a single entity seizing these Process modules cyclically to stop the traffic.

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16. Bulk port operations. Port Lasfar is an iron ore exporting port that operates 24 hours a day and 365 days a
year. The annual export plan calls for nominal deterministic ship arrivals at the rate of one ship every 20
hours. However, ships usually do not arrive on time due to weather conditions, rough seas, or other
reasons, and consequently, each ship is given a 7-day lay period. Assume that ships arrive iid uniformly in
their lay periods. Ships vary in tonnage according to the following distribution:

Arriving ships queue up FIFO (if necessary) at an offshore anchorage location, from where they are towed
into port by a single tug boat as soon as the berth becomes available. The tug boat is stationed at a tug
station located at a distance of 30 minutes away from the offshore anchorage. Travel between the offshore
anchorage and the berthing area takes 1 hour.
There are two berths and two loaders at the port. An uninterrupted iron ore supply arrives at the port from a
nearby mine. Whenever there is only one ship at the berths (only one berth is busy), both loaders load the
ship together in half the time. However, as soon as another ship arrives at the empty berth, one of the
loaders starts working on the new ship. In this case, the current ship continues its loading with only one
loader. The loaders are identical and their rate of loading is 2000 tons per hour. Hence, the loading rate
becomes 4000 tons per hour when both loaders work on the same ship. Assume no time is involved in
shifting loaders. Once a ship is loaded at a berth, it relinquishes that berth (and the loader), and then
requests tug boat service and waits until the tug boat arrives. Since there is only one tug boat, it does not
matter whether it waits at the berth and then relinquishes the berth after the tug boat arrives or it releases it
first and waits in a different area. The tug boat tows it away to the offshore anchorage, from where the boat
departs with its iron ore for its destination. Higher priority is given to departing vessels in seizing the tug
boat. Port Lasfar does not experience tidal activity or storms or any other stoppages.
a. Develop an Arena model for Port Lasfar, and simulate it for 1 year (8760 hours).
b. Estimate the following statistics:
_ Berth and ship loader utilization
_ Average ship port time
_ Average number of ships at the anchorage
_ Average ship delay at the anchorage
Hint: Since a loader may have to be separated from a ship in the middle of loading, you may approximate
the loading time as consisting of increments of, say, 10 minutes, and load as much as you can in a 10-
minute period and then check the status of the other berth. If you need to separate a loader, do it
immediately; otherwise, continue for another 10 minutes of loading. Loading will continue until the entire
ship is loaded. During this time, the model may experience periods with one loader working on the ship,
and other periods with two loaders working on the ship.

17. Job shop operations. The production of various metal kitchen pots and utensils calls for sheet metal
processing. KitchenWare Inc. (KWI) is a company that produces a number of metal kitchen products.
KWIs shop floor has three major sheet metal processing areas. These are shearing, press brake forming,
and deep drawing. Shearing is a process where roughly sized sheet metal pieces are cut from rolls of sheet
metal. The company uses various sizes of sheet metal rolls. Press brake forming is a type of bending and
forming operation. Also, deep drawing is an operation that makes a suitably deep sheet metal piece to
make pots, pans, and food and beverage containers. The shop floor houses one shear press machine, two
press forming machines, and one deep-drawing machine.
KWIs products are categorized as pots or pitchers. These two categories of product arrive in equal
proportions in a combined stream with uniform interarrival times between 15 and 25 seconds. Product
types have individual process plans and processing times as follows:

8
 The distances between locations (in feet) are given in the following diagram (distances are the same in each
direction).

Part transportation among workstations is handled by three fork trucks, which run at a speed of 50
feet/second. Each truck can carry a batch of five items. When a job is completed at the shear-press or press-
forming workstations, it is placed into an output buffer. As soon as five units of the same type accumulate
in the output buffer, they are batched, and a request is made for a fork truck. Once a batch is taken to the
press-forming workstation, it is split into its original items, and each item is placed into an input buffer. In
contrast, in the deep-drawing workstation, batches are not split into individual units, but rather are
processed in batches of five units at a time. After their last operation (press forming or deep drawing),
batches of five items are taken to the shop exit from where they leave the shop floor in batches.
The press-forming process is subject to random failures at any point in time, with Tria (400, 600, 1200)
seconds of uptime and Unif (1, 2) minutes of downtime.
a. Develop an Arena model of the shop floor of KWI and simulate it for a period of 30 days of continual
operation.
b. Estimate the following statistics at each workstation:
_ Job flow times per type through the workstation
_ Machine utilization and average downtimes
_ Job delays in the queue of each process
_ Average time to batch five units at the shear-press workstation and each press forming workstation
_ Average WIP levels at each workstation

18. Three-stage production line. Consider the filling and inspection system consisting of three stages in series
shown in the next illustration. Bottles arrive with exponentially distributed interarrival times with a mean
of 2 minutes. They enter a filling operation with an infinite buffer in front of it to accommodate arriving
bottles. The filler fills a batch of five bottles at a time. Filling times are uniformly distributed between 3
and 5 minutes. The entire batch of 5 bottles then attempts to join the sealer queue (of 10-bottle capacity) as
individual bottles. However, if the sealer queue cannot accommodate the entire batch, the filler becomes
blocked until space becomes available in the sealer queue. The filler is subject to failures with exponential
times to failure with a mean of 50 minutes, and with triangularly distributed downtimes with parameters
(2, 5, 10) minutes. Failures may occur at any point in time. The sealing operation is performed on a batch
of three bottles at a time. It takes precisely 3 minutes to seal all three bottles. The inspection queue has a
finite capacity of 10 bottles. Inspection takes precisely 1.45 minutes per bottle. Experience shows that 80%
of bottles pass inspection and depart from the system, while the rest are routed to a rework station to
modify the fill volume. The rework station has an infinite-capacity queue and a single server. Rework
times are uniform between 1 and 4 minutes. After rework, bottles are routed back to the inspection queue
for another inspection. However, rework bottles have a higher priority than nonrework bottles. Note that a
bottle may go through rework more than once.

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 a. Develop an Arena model for the production line, and simulate it for 1 year, assuming 365 days of work
per year and 8 hours of work per day.
b. Estimate the following statistics:
_ Average WIP contents in each buffer
_ Server utilization for each workstation
_ Average flow time through the system
_ Distribution (histogram) of flow times with five intervals
_ State probabilities (busy, idle, down, blocked) of every resource in the system
_ Probability that the filling, sealing, and rework workstations are simultaneously
blocked by the inspection station

19 NUST has one computer for student use. Students arrive at the computer norm (15, 10) mins to use the
computer for norm (12, 6) mins. If the computer is busy 60% will come back in 10mins to use the computer. If
still busy 50% of the 60% will return in 15mins, How many students fail to use the computer to 500 that
actually finish? Demand and service occur 24 hours a day.

20 Jiffy Car Wash is a five stage operation that takes norm (2,1) mins for each stage. There is room for 6 cars
to wait to begin wash. The car wash facility holds 5 cars which move through the system in order, one car not
being able to move until the car ahead of it moves. Cars arrive every Norm (2.5, 2) mins for a wash. If the car
cannot get into the system it drives across the street to Speedy Car Wash. Estimate the balking rate per hour,
this the number of cars that drive off per hour and the number of cars that go through to be washed and the
utilization of the servers for on 12 hour day.

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