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Workers and Machine Performance Modeling in Manufacturing System Using

Arena Simulation

Technical Report · September 2014

DOI: 10.13140/2.1.3829.3282

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Workers and Machine Performance Modeling in Manufacturing System
Using Arena Simulation

Kassu Jilcha, Hannan Sherif, Eshetie Berhan

Addis Ababa University, Addis Ababa Institute of Technology, Addis Ababa, Ethiopia
hannyshe@gmail.com

ABSTRACT
Discrete event simulation involves the modeling of the system as it improves through time and is
particularly useful for modeling queuing systems. This paper focuses the development and analysis of a
simulation model of an existing production line. An ARENA simulation model was developed,
verified, and validated to determine the daily production and potential problem areas for the various
request levels. The results show that throughput from the existing system is low because of occurrence
of bottlenecks, and waiting time identified. The study aim is to raise awareness of the importance of
considering human and machine performance variation in such simulation models; and to present some
conceptual ideas for developing a worker manager for representing worker and machine performance in
manufacturing systems simulation models.

Keywords: PVC pipe product, Arena simulation, waiting time, throughputs, capacity utilization

1. Introduction

Industry Performance improvements arising from increased manufacturing integration continues to be

one of the primary competitive issues in current days. Recent research in to manufacturing systems
integration has identified the need for effective positioning of business objectives down through the
organization and the subsequent measurement of performance in critical areas as key elements of
sustainable competitive advantage[7].

Highly industries rely on workers and machine performance since productivity depends on workers and
machine availability. A company will not be able to participate and will not survive in a long-term
perspective if employees do not attribute a high significance to such organization goals. However, poor
workers and machine and machine performance can be recognized some of the factors are of high load
of work, financial stress, and illness. Therefore, workers and machine performance, as this function is
essential required for huge value to the organization in maintaining and strengthening its business and
revenue growth.

The objective of this paper is to provide industry with a complete set of tools, techniques and
procedures to allow examining of existing workers and machine performance systems applying
consequently simulation system model which could be used as a before an existing system is altered or
a new system built, to reduce the chances of failure to meet specifications, to eliminate unforeseen
bottlenecks, to prevent under or over-utilization of resources, and to optimize system performance.
Simulation can be either discrete event or continuous simulation. In continuous model, the state of the
system can change continuously over time. In discrete model, though changes can occur only at
separated points in time [6]. In this paper, discrete event simulation is used to model workers and
machine performance in Ethiopia Plastics Industry.

2. Material and Methods

The study was conducted considering different materials and methods to achieve the goal of this study.
The literature reviews and software applications discussed under were utilized to come up with good
solution. Simulation, in particular discrete event simulation, has still not gain industries wide
acceptance as decision support tool for performance evaluation. The researchers has provide the
example of the application of discrete event simulation in evaluating performance of a production
line. The data was collected from an electronic manufacturing company’s production line and the
simulation model is built using proModel simulation software [2]. Discrete-event simulation can
provide information on how a line will function before, during, and after the line is in operation. A
simulation model can also provide a visual animation of the line to see how product will flow through
the line. An ARENA® simulation model was developed, verified, and validated to determine the daily
production and potential problem areas for the various demand levels. At the highest demand level, the
simulation results suggest that the line is not capable of meeting demand. Additional analysis indicates
that multiple workstations could prove problematic with minor fluctuations in demand. Problematic
workstations were identified for each assembly area and for the line as a whole. Performance evaluation
is an important phase in the design of assembly lines in a mixed model production environment.
Simulation models helped us to identify production line bottlenecks and evaluate some number of
suggested solutions [5].Any type of manufacturing system can be modeled and its performance can be
analyzed.Thus, simulation arena is the best tool to support collaborative workthrough the study.

3. Discussion and Results

3.1 Production Process Flow

In general, there are 5 main workshops in Ethiopia plastic industry. Raw materials in the form of
garden hose and master batch are supplied by foreign countries like Asia and in domestic likeElsewady
Cables Ethiopia and directed to raw material store for storing & quality checking. They will be sent to
two operating process continuous and injection section and turn on heat treatment and take the melted
plastic the screw thread then forced into mold. The bundle will be prepared by hauloof. After the
product is finished it will be inspected and then packaging will be done. Finally; the product will be
kept in finishing storage.

Figure 1. Injection process flow

Figure 2. Continuous (extrusion) process flow

3.2 Data analysis

The collected data through the means of interviews, direct observation and using documents are
analyzed. Fitting Input Distribution through the Input analyzer is used to identify fitted statistical
distribution. It is used to evaluate the distribution’s parameter and calculates a number of measures of
the data. To select which type of distribution to use, the author has compared the square error of each
distribution. The larger the square error value, the further away the fitted distribution is from the actual
data.

3.3 Problem Formulation of the Study

The problem observed in this paper is the lack of experts and variation on processing the PVC pipe in
adjusting the heat treatment and low capacity utilization of the workshop which causes variation to the
specified product during this the number of recycle products are higher per days. The industry can fail
to achieve the goal for efficient and economical production. Capacity includes all resources such as
machineries, workers etc. of the factory. The overall objective of the study is to model the production
line of the factory and analyze its performance using simulation. Then finally, a proposed model is
prepared with an improved performance.

3.4Model assumption

In Ethiopia Plastics Industry, there are three shifts per day. Workers distribution through the specified
time per shifts can be delayed by different kind of incidents. The actual working time for whole system
is 8.00 hours per day. Since it is not expected that a person will work without some interruptions, the
operators may take time out for their personal needs. Assumptions are taken for modeling the variation
of workers performance at time to rest, machine failure, and power gone. The model for one shifts are
modeled and analyzed. In the study only PVC pipe line is selected. Raw material is assumed as a
constant, no interruption is occurred in continuous and random for injection. The manufacturer working
time is 8.00 hours per day.

Table 1. PVC pipe process time distribution in injection

Table 2. Workers Distribution in continuous (extrusion)

Table 3. PVC pipe process time distribution in continuous (extrusion)

3.5 Model Formulation

In modeling design the type of analysis is performed on workers and machine performance. The
products that are selected are the one that is most often produced and are considered as one of the main
products of Ethiopia Plastic Industry. The working period in Ethiopia Plastic Industry is five days and a
half and eight hours.

Figure 2 Workers distribution model

 Figure 3. Continuous Extrusion Model

Figure 4. Injection model

3.6 Model Verification

Verification assesses the correctness of the formal representation of the intended model, by inspecting
computer code and test runs, and performing consistency checks on their statistics [13].
More specifically, verification consists in the main of the following activities:
1. Inspecting simulation program logic.
2. Performing simulation test runs and inspecting sample path trajectories. In particular, in a visual
simulation environment (like Arena), the analyst inspects both code printout s as well as graphics to
verify (as best one can) that the underlying program logic is correct.
3. Performing simple consistency checks, including sanity checks as well as more sophisticated checks
of theoretical relations hips among predicted statistics.
In simulation modeling, each part of model run with different set of inputs and the obtained outputs
were compared by using throughputs and little’s formula with real outputs.
3.7 Model validation
Validation activities are critical to the construction of credible models. The standard approach to model
validation is to collect data (parameter values, performance metrics, etc.) from the system under study,
and compare them to their model counter parts.
Number of Replication Estimation
A good design of simulation replications allows the analyst to obtain the most statistical information
from simulation runs for the least computational cost. In particular, minimizing the number of
replications and their length is necessary to obtain reliable statistics. To decide on the number of
replication the model must run some initial set of replication so that sample average, standard
deviation and confidence interval are computed.
Table 4 .Number of replication
For PVC pipe continuous extrusion production line the initial replication (no) is 6 and the initial half
width (ho) is 21.40. Assuming the h= 0.25, taking 95% Confidence Level;

.
n≅ 6 − 1,1 − 0.05/2 .
. .
n ≅ 0.025,5 ≅(2.571)2* = 1,666
. .
By considering equation (6) the number of replications is 1,666

4. Conclusion
In this study worker and machine performance in manufacturing system using simulation has been used. The
simulation is done by using Arena software. The performance measure used is throughput and it is directly
related to waiting time; work in process, resource or capacity utilization. Simulation models were built for
the continuous(extrusion) and injection workshops separately and finally amodel is prepared for the purpose
of conducting the computer based simulation. The problems identified are the throughput from the existing
system is low because of occurrence of bottlenecks, and waiting time identified. Workers agent should be
assigned on the machinery and workers performance to focus on each operating system due that the number of
recycle products can be reduced. Otherwise, the company continues like this for a long time, it will be difficult
for them to compete in today’s market. Therefore, to improve the existing performance of the company should
improve resource utilization.

5. Reference
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8. Martínez, F. E. (2002). Application of SIMAN ARENA Discrete Event Simulation Tool in the .
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