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Manufacturing simulation
1. Subject Name
Unit Manufacturing Process Simulation Solution Customization
Faculty Name : Prof. Sameer Agrawal
M.Tech. (Automobile Engineering)
2. Simulation in Manufacturing Systems
Simulation in manufacturing systems is the use of software to make computer
models of manufacturing systems.
This is done to analyze them and thereby obtain important information.
Its use has been limited due to the complexity of some software packages, and to
the lack of preparation some users have in the fields of probability and statistics.
5. Objectives of Manufacturing Systems
The most important objective of simulation in manufacturing is the understanding of the
change to the whole system because of some local changes.
It is easy to understand the difference made by changes in the local system but it is very
difficult or impossible to assess the impact of this change in the overall system. Simulation
gives us some measure of this impact.
6. Objectives of Manufacturing Systems
Measures which can be obtained by a simulation analysis are:
Parts produced per unit time
Time spent in system by parts
Time spent by parts in queue
Time spent during transportation from one place to another
In time deliveries made
Build up of the inventory
Inventory in process
Percent utilization of machines and workers.
Calculation of optimal resources required
Validation of the proposed operation logic for controlling the system.
Data collected during modelling that may be used elsewhere
7. Example
150 Parts in
10 Hrs.
100 Parts
in 10 Hrs.
Another
Machine for
completing the
task
Next
machine
Incoming
Next
machine
with 150
parts
8. Use of Manufacturing Systems
Simulation is used to address some issues in manufacturing as follows:
In workshop to see the ability of system to meet the requirement.
To have optimal inventory to cover for machine failures.
9. Methods of Manufacturing Systems
In the past, Manufacturing simulation tools were classified as languages or
simulators.
Discrete event simulation.
Continuous simulation approach.
In the movement of liquids in oil refineries or chemical plants.
Hybrid simulation
10. Framework to evaluate Manufacturing
simulation
Definition of usability:
“The extent to which a product can be used by specified users to achieve specified
goals with effectiveness, efficiency, and satisfaction in a specified context of use.”
11. Framework to evaluate Manufacturing
simulation
Definition of usability:
Performance criterion Usability attributes
Effectiveness
Accuracy: Extend to which the quality of the output corresponds to the
goal
Efficiency
Time: How long users take to complete tasks with the product
Mental effort: Mental resources users need to spend on interaction with
the product
User Satisfaction
Ease of use: General attitudes towards the product
Specific attitudes: Specific attitudes towards or perception of the
interaction with the tool
12. Just in Time Production
It is a methodology aimed primarily at reducing times within the production system
as well as response times from suppliers and to customers.
Its origin and development was mainly in Japan, largely in the 1960s and 1970s and
particularly at Toyota.
Alternative terms for JIT manufacturing have been used.
Motorola's choice was short-cycle manufacturing (SCM).
IBM's was continuous-flow manufacturing (CFM),
Demand-flow manufacturing (DFM),
Toyota Production System (TPS)
13. Bottlenecks in implementing JIT in an
Industry
JIT improvement won`t do any good.
Its sounds like a good thing but we still don’t want to do it
Look good on paper but…..
Costs are already as low as that can possibly get
But we already been doing things that way
We can`t lower costs any more without lowering quality
Everything is going just fine now ,Why change it?
That`s a lousy idea! We already tried that 20 years ago
Look we understand this stuff better than anybody(so don’t tell us what to do)
14. Just in Time
The focus of JIT is to improve the system of production by eliminating all forms of waste.
15. Just in Time Functions
Zero inventory
Zero lead time
Zero failure
Eliminates waste .
Achieves streamlined production .
Eliminate disruptions in production … caused by poor quality, schedule changes, late
deliveries.
Makes the manufacturing delivery system flexible by allowing it to handle a variety of
products and changes in the level of output.
Reduces setup and delivery times .
19. OOTB Software Solution
(out-of-the-box feature)
IT is a feature or functionality of a product that works immediately after or even without any
special installation without any configuration or modification.
It also means that it is available for all users by default, and are not required to pay
additionally to use those features, or needs to be configured.
20. OOBE
(Out-of-box experience)
It is the experience an end-user has when taking a product out of the box and preparing to
first use.
It, as opposed to the point-of-sale experience or the interaction experience of an expert
user.
This includes the initial configuration of a piece of hardware or software on a computer.
For hardware products, a positive OOBE can be created with logical easy-to-follow
instructions and good quality of manufacturing.
21. OBF / OOBF
(Out-of-box failure)
It refers to the perceived failure of a product that occurs immediately upon first usage.
In relations to computing, an out-of-box failure can refer to the immediate failure mode
when installing or performing initial configuration on a piece of computer hardware or
software.
Causes for out-of-box failures include poor quality control, wrong configuration of the
product, and bugs/glitches if the failure is software-related.
It can be highly detrimental to the value of the brand, retailer, or OEM, especially when
customer expectations for the product are high.
23. OOTB Software Solution
(out-of-the-box feature)
An OOTB solution is simply readily made and catered for your business. It works
immediately and should require minimal efforts to install it.
An OOTB solution is usually meant for businesses with a standard operation process and it
does not require much customization.
24. OOTB Software Solution
(out-of-the-box feature)
Benefits of Out of the Box Software : When you need a solution for your standard business
process, an OOTB solution might just be perfect for you.
Minimal effort to set up
High availability
FAQs
Minor customization
Economical
25. OOTB Software Solution
(out-of-the-box feature)
Cons of Out of the Box Software: this solution may be the ideal one for your business, you
might not find certain features that you really need.
Migration
Lack of customization
Overcrowding features
27. Custom Software Solution
A custom software solution is designed and developed specially for businesses with special
needs.
The software developed by the software developer should be unique and fit the needs of
the business.
It should also be customizable whenever the customer requires it.
28. Custom Software Solution
Benefits of Custom Software : If you need much more than a standard software to match
your business’ needs, this solution may just be your lifesaver.
Competitive edge
Customization
API integration
Agile software development
29. Custom Software Solution
Cons of Custom Software : While a custom software may sound ideal for your business, there
are some limitations that you might face.
Costly
Deployment time
30. Which One Should I Choose?
While there are pros and cons to both the solutions, the ideal solution ultimately depends
on your business’ requirement.
Make a checklist to compare both solutions by asking some questions by yourself.
Do I need a high level of customization for my solution?
Can either of the software integrate my current APIs?
Which solution fits my budget?
Which solutions are my competitors using and how can I outperform them?
How can I find a good software developer?
31. How to Find a Good Software Developer
If you’re going for the OOTB solution, it’s no feat to find the more popular ones. You will find
them usually having a large and active community on the web. The real nutcracker here is
finding a good software developer for your custom software.
One of the recommended ways is to hire an in-house software engineer as you will be
required to follow up closely with him/her on the project. It’s imperative to read through a
software engineer resume as their skills may differ. Ensure that you hire the software
engineer with the correct skill sets for your project.
“If you have a killer business idea and wondering who can help you to plan, architect and
develop that Mobile App or Web App, you should look for a Custom Software Development
Company.”
