Analysis and Management
of Production System
Lesson 14: Discrete event simulation
Prof. Giulia Bruno
Department of Management and
Production Engineering
giulia.bruno@polito.it
Definition of simulation
“The process of designing a model of a real system
and conducting experiments with this model for the
purpose either of understanding the behavior of the
system or of evaluating various strategies (within
the limits imposed by a criterion or set of criteria) for
the operation of the system.”
Shannon, R. E. 1975
Systems Simulation – The Art and Science, Prentice-
Hall.
in other words…
Create a tool to do many test
Definition of simulation
● Simulation is the imitation of a system
Based on knowledge or assumptions about the operation of
the system
Used to monitor or predict the behavior of the system
● Simulation is performed using a model
An abstraction of the real system
Contains all the assumptions needed to solve a problem
• Algorithmic (sequence of steps)
• Mathematical (equations)
• Logical (conditions)
The model can be “run” to observe the system
Application areas
Steps of a simulation
● Verification ● Validation
Writing a correct Creating a correct
program model
Classification of Simulation types
Model
Deterministic Stochastic
Static Dynamic Static Dynamic
Continuous Discrete Continuous Discrete
Classification of Simulation types
Deterministic Stochastic
Simulation models that contain no random A stochastic simulation model has one or more
variables are classified as deterministic. random variables as inputs. Random inputs lead to
Deterministic models have a known set of random outputs. In a stochastic simulation, the
inputs which will result in an unique set of output measures must be treated as statistical
outputs. estimates of the true characteristics of the system.
Input Input
… parameters … parameters are
are real stochastic
numbers 1 variables
1 2 2
… … … …
… = … … ≠ …
Classification of Simulation types
Static Dynamic
A static simulation model, Dynamic simulation models
sometimes called a Monte Carlo represent systems as they
simulation, represents a system change over time.
at a particular point in time.
Classification of Simulation types
Discrete Continuous
A discrete model is one in A continuous model is one in
which the state variable(s) which the state variable(s)
change only at a discrete set change continuously over time.
of points in time.
Number of costumer waiting
Temperature of the machine
in line
Discrete event simulation (DES)
● Used to model systems that change state at
discrete points in time as a result of specific events
● Example of events
Order/part arrival
Product movements
Process start/finish
Machine breakdowns/repairs
● Example of states
Machines: processing, idle, setup, blocked, down
Queues: empty, full
Operators: utilized, idle
Transports: travelling, loading, unloading
PROS-CONS of SIMULATION
• Flexibility • Study problems with less
• Manipulate time danger and lower costs
• Improve understanding of • Study new designs without
system interrupting real system
• Answer “what-if” questions • Study new designs without
• Model large and complex needing extra resources
systems
• More expensive than analytical model
• Time consuming
• Each model refers to a single family of
problems
• The result is not an optimal solution
FlexSim simulation software
12
● Discrete Event Simulation tool
● Developed by FlexSim Software Products Inc.
● Pogramming environment that can reproduce any
process or production environment and analyze all
aspects of management
FlexSim simulation software
13
● Easy modeling
● 3D graphic vision
● High object customization
● Possibility to set the path and the activities that the various
entities must follow and execute
● Possibility to create an interface that makes the insertion
possible from input of the variables characterizing the objects
and displaying all the output statistics requested by the user
Download: current version
Go to FlexSim Click on “Create a After Completing the Open the
website and Registration the Download Link Downloaded File.
new FlexSim
Click on Account” and Start will appear. Select Accept and
“FREE the Registration. Click on “Install”.
DOWNLOAD”. Click “Download” under
Download FlexSim Express.
https://www.flexsim.com/flexsim/
Example 1
● Items arrive every 25 seconds on average
The statistical probability distribution that best represents
the inter-arrival pattern is an exponential distribution with
mean 25
● The processing time at the workstation is
exponentially distributed with an average value of
20 seconds
● Build a model in FlexSim to simulate the process
Modelling steps
● Start a new model
● Drag and drop objects from the library to create a
layout
● Connect ports
● Edit object properties (double click on object)
Source properties
21
Queue properties
22
Processor properties
23
Example 2
25
● Add a dashboard to the first model to report
Utilization of the processor
Average staytime in the processor and in the queue
Average WIP in the processor and in the queue
Example 3
27
● Add a second processor in the previous model
40% of items go to Processor1
60% of items go to Processor2
● Add the corresponding elements to the dashboard
Let’s Flex-Simulate
Example flow variability
• SCENARIO 1
• Constant process time = 10 min
• Constant arrival rate
• Cases:
• A) 1/30 pz/min
• B) 1/20 pz/min
• C) 1/10 pz/min
• D) <1/10 pz/min
Example flow variability
CONSIDERATIONS
• If Inter-arrival time = Process time, Then Q = 0, Utilization = 100%
• If Inter-arrival time > Process time, Then Q = 0, Utilization <100%
• If Inter-arrival time < Process time, Then Q > 0, Utilization = 100%
Example flow variability
• SCENARIO 2
• Constant process time = 10 min
• Variable arrival rate
Penny Fab line
The fourth cleans
A punch press Press that stamps Lincoln’s face on one side away any burrs.
that cuts penny and the Memorial on the back. The third
blanks. places a rim
on the penny.
Penny Fab One consists of a simple production line that makes
giant one-cent pieces used exclusively in Fourth of July
The raw material
parades. The line consists of 4 machines in sequence that use
is a zinc sheet. well-known, stable processes.
The end item is
the penny.
Assumptions
• Each machine takes exactly 2 hours to perform its operation
• After each penny is processed, it is moved immediately to the
next machine
• The line is available 24h per day (ideal machines)
• The market for giant pennies can be assumed to be unlimited,
so there are always arrivals for the line (continuous arrivals)
Flexsim model
S Q1 P1 Q2 P2
P4 Q4 P3 Q3
Analysis of the line
Dashboard
Drag it to the
Dashboard Use these names
to select items in
the library
Throughput per
each processor
Utilization per Number items
each processor per each
queue during
time
Simulation run
Simulation run
The duration of the
simulation was not
enough to allow the
system to pass the
transient state.
Transient and steady state
Transient and steady state
Experiment
IT
PT1 PT2 PT3 PT4 U1 U2 U3 U4 Q1 Q2 Q3 Q4 TH
source
120 120 120 120 120 100% 100% 100% 100% 0 0 0 0 0.5
120 120 120 120 100 100% 100% 100% 83.3% 0 0 0 0 0.5
120 120 120 140 100 100% 100% 100% 71.7% 0 0 >0 0 0.43
120 140 120 140 100 100% 86.1% 100% 71.7% >0 0 0 0 0.43
140 140 120 140 100 100% 86.1% 100% 71.7% 0 0 >0 0 0.43
150 120 120 120 120 80.5% 80.6% 81.2% 81.9% 0 0 0 0 0.4
150 140 130 120 110 93.5% 87.5% 80.6% 74.5% 0 0 0 0 0.4
110 120 130 140 150 100% 100% 100% 100% >0 >0 >0 >0 0.39
100 100 100 100 120 100% 100% 100% 100% 0 0 0 >0 0.5
Bottleneck
Penny Fab TWO
Station 1 Station 4
Station 2
Station 3
Penny Fab TWO
Process time of Station capacity
Station number Number of machines
machines (minute) (jobs/hour)
1 1 120 0.5
2 2 300 0.4
3 6 600 0.6
4 1 120 0.5
Bottleneck
Penny Fab TWO
Penny Fab TWO
Penny Fab TWO
Process time of Expected station
Number of
Station number machines CV capacity
machines
(minute) (jobs/hour)
Source - Exp(0.00833) - -
1 1 N(120, 36²) 0.3 LV 0.5
2 2 N(300, 150²) 0.5 LV 0.4
3 6 N(600, 150²) 0.25 LV 0.6
4 1 N(120, 120²) 1 MV 0.5
Bottleneck
Penny Fab TWO
