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MFG Simulation System LR

The lab report details an experiment focused on enhancing productivity through manufacturing system simulation using Flex Sim software. Key objectives included optimizing workflows, reducing bottlenecks, and improving resource utilization, with findings demonstrating effective queue management and demand-driven dispatching. The report also emphasizes safety protocols necessary in an industrial setup to prevent accidents and ensure worker well-being.

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21 views3 pages

MFG Simulation System LR

The lab report details an experiment focused on enhancing productivity through manufacturing system simulation using Flex Sim software. Key objectives included optimizing workflows, reducing bottlenecks, and improving resource utilization, with findings demonstrating effective queue management and demand-driven dispatching. The report also emphasizes safety protocols necessary in an industrial setup to prevent accidents and ensure worker well-being.

Uploaded by

kannaiah0208
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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LAB REPORT

ME308 MANUFACTURING LABORATORY-II

Date of submission: 16/02/2025 Name: A. KANNAIAH GUPTHA


Group (Sub-group): Monday(C) Entry No: 2022MEB1292

Experiment No. 05: Manufacturing system simulation:


● Experiment title: To enhance overall productivity by optimizing workflows, reducing bottlenecks, and improving
resource utilization. This ensures smoother operations, higher efficiency, and minimal process delays.

● Objectives:
• Identifying and eliminating waste along with non-value-added activities to streamline operations and
improve workflow efficiency.
• Enhancing the effective utilization of available resources, including manpower, machinery, and
materials, to maximize output while minimizing costs.
• To improve overall productivity by optimizing processes and eliminating inefficiencies.
● Material and apparatus used:
• Computer system with Windows or macOS
• Flex Sim simulation software
• Experiment setup document
● Experimental procedure:
• Create the Flexsim objects of the model. The user selects and drags the Flexsim objects into the model
view window of the model.
• Connect the ports for the routing of flow items and define process flow. To connect an object’s output
ports to the input ports of another object, the user has to press and hold the A-key on the keyboard, then
click and hold the left mouse button on the first object, drag the mouse to the next object, and release the
mouse button.
• Add data to the model parameters. The user adds actual data (e.g., processing times, resource demands,
others) to the model. This is done by double-clicking on the Flexsim objects and adding data for the
various parameters. Examples of these parameters are: the processor’s operation time, the capacity of the
queue, arrival rate, the routing logic, and so on.
• Reset the model.
• Perform a simulation run of the model. The user runs the simulation and examines the results.
• Analyze the simulation results
• Modify and enhance the model according to the user needs.
● Results and discussion:
• The model effectively adjusted processing power by enabling or disabling additional processors based
on queue length and demand fluctuations. This ensured an optimized balance between machine
utilization and cost-effectiveness, preventing unnecessary idle time or overloading.
• By refining queue management and transport scheduling, the system reduced overall lead time. The
synchronization between production and transportation allowed seamless movement of goods,
eliminating unnecessary delays in workflow.
• The truck transport model showcased the benefits of demand-driven dispatching. Instead of running
empty or making frequent small trips, the transporter waited until a predefined quantity was reached,
ensuring fuel efficiency and reduced operational costs.
• By implementing multiple processors in parallel, the workload was evenly distributed, reducing waiting
times at critical points. This approach prevented bottlenecks and improved overall system efficiency
without excessive capital investment.
• The simulation demonstrated how minor adjustments in process parameters (e.g., setup time, processing
time, queue thresholds) could significantly impact system performance. This flexibility makes the model
scalable for future modifications, aligning with evolving production demands.
● Learning from the experiments:
• Adjusting processing and setup times directly affected queue lengths and overall throughput,
demonstrating the importance of time optimization in a production system.
• Implementing a condition-based transportation system (e.g., truck dispatch based on queue size)
provided insights into how real-time decision-making can minimize waiting time and transportation
costs.
• Introducing parallel processors helped distribute the workload efficiently, showing how multi-resource
utilization can increase system efficiency while managing inventory costs.
• Experimenting with different queue configurations illustrated the significance of buffer zones and
priority scheduling in preventing bottlenecks and ensuring a smooth workflow.
• The experiment highlighted the power of simulation in testing different manufacturing and logistics
scenarios, helping in predictive analysis, decision-making, and future process improvements.
● Safety concern in an Actual Industry Setup:
• Follow machine safety protocols to prevent accidental startups and operator injuries.
• Ensure ergonomic workstations to reduce worker fatigue and health risks.
• Store materials properly to prevent overloading, spills, and workplace hazards.
• Enforce transport safety rules to prevent forklift or vehicle collisions in the factory.
• Implement emergency response plans for fire, chemical spills, and equipment failures.

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