ISE 403: Homework Lab #3, Spring 2012
Due: Wednesday- February 29, 2012 at 11:59pm
Embellishments to Problem 3, Lab #2, Receiving
incoming Mechanical and Electronic parts. These embellishments are incremental,
i.e. each embellishment expands the model further.
Make a copy of LAB3.doe located in the course website.
Embellishment 2: Suppose the Stockroom
supervisor wants to clear the area from the "bulky" Mechanicals.
For this reason, he is placing a higher priority to store Mechanical parts.
Revise your model to study the impact of this change on the cycle time. Review
the output report and answer the following questions for before and after
this operational policy change:
- Embellishment 1: Expand the model
to include the stockroom operations. To detrash the containers and store parts,
assume it takes a stockroom operator UNIF(10,15) minutes and UNIF(15,20) minutes
for Mechanical parts and Electronic parts, respectively. Determine the number
of stockroom operators you need to keep their utilization within a 85 to 95%
range. Run your revised model with your recommended number of stockroom operators
for 10 replications, each for five days, each day consists of three 8-hour
shifts. Review the output report and answer the following questions:
- What are the expected utilization of the operators (Mechanical Receivers,
Electronic Receivers, Electronic Inspectors, and Stockroom Operators)?
- What is the average WIP in the entire process?
- What is the overall average cycle time for combined lots?
- What percentage of time do lots spend waiting?
- What is the oaverage cycle time for the Electronic lots sent to the
- What the average cycle time for the Mechanical Lots?
- How many lots can be received per shift?
- What is the average cycle time for the Electronic lots in the stockroom?
- What is the average cycle time for the Mechanical lots in the stockroom?
- Embellishment 3: Suppose the supervisor
of Receiving would like to consolidate the two receiving processes. Revise
the model to determine the impact of consolidating the two areas, i.e., is
it possible to remove one operator and maintain the same performance level?
To monitor the behavior of the receiver queue, use a dynamic plot and set
the Expression Synchronization feature.
- Embellishment 4:
To keep the aisles clean, only a sample of components from the Electronics
lots that are tagged for inspection are sent for inspection. The original
lots are sent to the stockroom (as before, these lots remain in quarantine-
"soft quarantined" by the inventory control system). After inspection,
if a sample passes the inspection, the sample is sent to the stockroom to
be added to the original lot (the quarantine flag is now removed); if it fails
the inspection, as before, it is sent to the Material Review Board for further
investigation (the original lot remains in the "soft quarantined"
state). Detrashing and storing the original lots takes the same amount of
time, UNIF(15,20). Storing samples though takes much less time, UNIF(3,5)
minutes. Storing the samples has a higher priority over the original because
this triggers the removal of the original lot from quarantine state and make
them accessible to manufacturing. Revise your model to reflect this operation
policy change. Determine if this change significantly reduces the WIP for
Electronic lots ( do not include samples in your WIP as they are negligible).
Use your output statistics from running your two models each for 10 replications
to justify your conclusion. Hint: You need to use SEPARATE module in the BASIC
PROCESS panel to duplicate entities. Also note that in the Category Overview
Report WIP is reported by entity type.
In addition to any possible MS Word/Excel/PowerPoint files that answer
the questions, called HWLAB3, turn in following ARENA files:
Q1. Turn in the model file (.doe) and call it "yournameHWLAB3p1.doe".
Q2. Turn in the model file (.doe) and call it "yournameHWLAB3p2.doe".
Q3. Turn in the model file (.doe) and call it "yournameHWLAB3p3.doe".
Q4. Turn in the model file (.doe) and call it "yournameHWLAB3p4.doe".