DEPARTMENT OF INDUSTRIAL ENGINEERING AND MANAGEMENT

R.V. COLLEGE OF ENGINEERING, BANGALORE – 59.

III YEAR / VI SEMESTER PLANNER FOR ACADEMIC YEAR 2005

Document No.: Evensem 2005/IEM/LP/IEM 32
Version No.: 01
LESSON PLAN
SIMULATION LABORATORY
Introduction to the subject: Lab Incharge – K.N. Subramanya

Simulation is one of the most powerful tools available to decision-makers responsible for the design and
operation of complex processes and systems. It makes possible the study, analysis and evaluation of
situations that would not be otherwise possible. In an increasingly competitive world, simulation has
become an indispensable problem solving methodology for engineers, designers and managers.
Simulation provides cheap insurance and a cost effective decision making tool for managers. It allows us
to minimize risks by letting us discover the right decisions before we make the wrong ones.
Simulation is the imitation of the operation of a real-world process or system over time. Simulation
involves the generation of an artificial history of the system, and the observation of that artificial history
to draw inferences concerning the operating characteristics of the real system that is represented.
Simulation is an indispensable problem-solving methodology for the solution of many real-world
problems. Simulation is used to describe and analyze the behavior of a system, ask "what if" questions
about the real system, and aid in decision making.

Objective of the Laboratory:

1. To expose students to object oriented simulation packages on ARENA and PROMODEL
2. To build exercises of manufacturing and service operations.
3. To analyse the outputs using output analyser

Laboratory course outline

Class: Laboratory Course : Lab Code: Period of the semester:

VI Sem Simulation Lab IML68 March – June 2005
Day Tuesday Thursday Saturday Free Day Wednesday Friday
Lab
Time 1.00 – 4.00 1.00 – 4.00 10.45 – 1.45 Lab Time 9.00–12.00 1.00–4.00
Schedule
Batch B2 B1 B3 slots Slot 1 2
Weekly Planner
Expt. Title of the experiment Expected output / result Expected learning’s from the Marks
No. experiment
CYCLE - I
1 Features of Arena Package Distribution Patterns Understanding the features of the 20
and Input Modeling package, identifying probability
distribution for the given data
2 Simulation of Outputs of Replication Building the model and 20
Manufacturing System I runs understanding of the entered data.
3 Simulation of Outputs of Replication Building the model and 20
Manufacturing System II runs understanding of the entered data.
4 Simulation of Service Outputs of Replication Building the model and 20
Operations I runs understanding of the entered data.
5 Simulation of Service Outputs of Replication Building the model and 20
Operations II runs understanding of the entered data.
6 Statistical Analysis of Graphs Decision Analysis for the graph 20
Simulation Data generated
Assignment 20
 CYCLE – II
7 Features of Promodel Distribution Patterns Understanding the features of 20
Package and Input the package, identifying
Modeling probability distribution for the
given data
8 Simulation of Outputs of Replication Building the model and 20
Manufacturing System I runs understanding of the entered
data.
9 Simulation of Outputs of Replication Building the model and 20
Manufacturing System II runs understanding of the entered
data.
10 Simulation of Service Outputs of Replication Building the model and 20
Operations I runs understanding of the entered
data.
11 Simulation of Service Outputs of Replication Building the model and 20
Operations II runs understanding of the entered
data.
12 Statistical Analysis of Graphs Decision Analysis for the 20
Simulation Data graph generated
Assignment 20
Test 20
Total 300

Class marks + Test total + Assignment Total

CLASS MARKS = ----------------------------------------------------------
(Reduced to 25) 12

Texts books and Reference books:

1. Discrete Event system Simulation – Jerry Banks, John S Carson, II, Berry L Nelson,
David M Nicol, III Edition, Pearson Education, Asia, ISBN - 81- 7808 – 505 - 4.
2. Simulation Modelling & Analysis – Averill M Law, W David Kelton; McGraw Hill
International
Edition – Industrial Engineering series, ISBN – 0-07-100803-9.
Equipment Manuals and catalogues to be referred
1. Arena and Promodel Manuals

Assessments Plan

Sl.No. Component Weightage(%) Final I A Marks

1 Class Work / Background 80%
concepts / 25
2 Tests / Assignment 20%

Faculty In-charge
1. K.S. Badarinarayana
2. K.N. Subramanya Approval of the HOD
3. C.K. Nagendra Guptha
 Department of Industrial Engineering and Management
R.V. College of Engineering, Bangalore – 59

Question Bank

IM 6L8 - Simulation Laboratory Exercises

1. Customers arrive at the Bank and enter a queue to wait for the single teller. When a customer
reaches the teller, he performs his transaction. When the initial transaction is completed, the teller
determines whether the customer must see the supervisor. If this is the case, the Customer moves
to the single supervisor; when finished; the customer returns to the teller queue to re-do his
transaction. If the customer is not required to see the supervisor, after finishing his transaction at
the teller he leaves the bank.

The time between customer arrivals is exponentially distributed with a mean of 5 minutes. The
travel times from the entrance to the teller queue and from the teller to the exit are both 1-minute.
All teller transaction times are normally distributed with a mean of 3.0 minutes and a standard
deviation of 1. Ten percent of the customers are required to see the supervisor. It is possible for a
customer to see the supervisor several times. Travel time to and from the super visor takes 1.5
minutes and the supervisor time follows a triangular distribution (12,15,20)

Collect supervisor statistics on the teller and the supervisor utilisation, customer flow time, the
number in teller queue. Run the simulation for about 8.5 hours day.

If the supervisor takes a 15-minute break in the morning, a 60-minute lunch break and 15 minute
afternoon break. If he is meeting with a customer he will finish this activity then takes a full
break.
The supervisor also must attend to bank emergencies. According to the experience of a similar
bank branch, the frequency of the emergencies is about twice per day. Actual data recorded at
that branch for the time required to deal with each emergency will be used for this analysis. If the
emergency occurs when the supervisor is away from the office, he will deal with it upon his
return. Run the simulation for an 8.5-hour day. Collect statistics on the teller and supervisor
utilization, customer flow time and number in teller queue.
Travelers arrive at the main entrance door of an airline terminal according to an exponential
interarrival-time distribution with mean 1.6 minutes. The travel time from the entrance to the
check-in is distributed uniformly between 2 and 3 minutes. At the check-in counter, travelers wait
in a single line until one of five agents is available to serve them. The check-in time (in minutes)
follows a Weibull distribution with parameters  = 7.76 and =3.91. Upon completion of their
check-in, they are free to travel to their gates. Create a simulation model, with animation, of this
system. Run the simulation for 16 hours to determine the average time in system, number of
passengers completing check-in, and the average length of the check-in queue.

Modify the check-in problem by adding agent breaks. The 16 hours are divided into two 8 hours
shifts. Agent breaks are staggered, starting at 90 minutes into each shift. Each agent is given one
15-minutes break. Agent lunch breaks (30 minutes) are also staggered, starting 3½ hours into
each shift. Compare the result of this model to the result without agent breaks.

2. Develop a model of a simple serial two-process system. Items arrive at the system with a mean
time between arrivals of 10 minutes. They are immediately sent to process 1, which has an
unlimited queue and a single resource with a mean service time of 9 minutes. Upon completion,
they are sent to process 2, which is identical to process 1. Items depart the system upon the
 completion of process 2. Performance measures of interest are the average numbers in queue at
each process and the system cycle time. Using a replication length of 10,000 minutes, make the
following four runs and compare the results:
Run1 : exponential interarrival times and exponential service time.
Run 2: constant interarrival times and exponential service times.
Run 3: exponential interarrival times and constant service times.
Run 4: constant interarrival times and constant service times.

3. Two different part types arrive at the same system for processing. Part Type 1 arrive according to
a lognormal distribution with a log mean of 11.5 hours and log standard deviation of 2.0 hours
(note that these values are the mean and standard deviation of this lognormal random variables
itself). These arriving parts wait in a queue designated for Part Type 1’s only until an operator is
available to process them. The processing time follows a triangular distribution with parameters
5, 6, and 8 hours. Part Type 2 arrives according to an exponential distribution with mean of 15
hours. These parts wait in a second queue until the same operator is available to process them.
The processing time follows a triangular distribution with parameters 3, 7 and 8 hours. After
being processed by the operator, all parts are sent for processing to a second operations that does
not require an operator, which has processing time distributed as triangular with parameters of
4,6 and 8 hours. Completed parts exit the system. Assume that the times for all part transfers are
negligible. Run the simulation for 5,000 hours to determine the average cycle time for all parts
and the average number of items in the queues designated for the arriving parts.

4. Parts arrive at a single workstation system according to an exponential interarrival distribution

with mean 21 seconds. Upon arrival the parts are processed. The processing time distribution is
TRIA(16, 19, 22) seconds. There are several easily identified visual characteristics that determine
whether a part has a potential quality problem. These parts, about 10%, are sent to a station where
they undergo an extensive inspection. The remaining parts are considered good and are sent out
of the system. The inspection-time distribution is 96 plus a WEIB(48.5, 4.04) random variable, in
seconds. About 14% of these parts fail the inspection and are sent to scrap. The parts that pass
the inspection are classified as good and are sent out the of the system. Run the simulation for
10,000 seconds to determine the number of good parts that exit the system, the number of
scrapped parts, and the number of parts that are inspected (either completely or partially).

5. An office that dispense automotive license plates has divided its customers into categories to
level the office workload. Customers arrive and enter one of three lines based on their residence
location. Model this arrival activity as three independent arrival streams using an exponential
interarrival distribution with mean 10 minutes for each stream. Each customer type is assigned a
single clerk who processes the application forms and accepts payments. The service time in
UNIF(8,10) minutes for all three customer types. After completion of this step, all customers are
sent to a second clerk who checks the forms and issues the plates. The service time for this
activity is UNIF(2.66, 3.33) minutes for all customer types. Develop a model of this system and
run the simulation for 5,000 minutes.

A consultant has recommended that the office eliminate the step of differentiating between
customers and use a single line with three clerks who can process any customer type. Develop a
model of this system, run it for 5,000 minutes and compare the results with the first system.

6. Customers arrive at an order counter with exponential interarrivals with a mean of 10 minutes. A
single clerk accepts and checks their orders and processes payments, UNIF(8, 10) minutes. Upon
completion of this activity, orders are randomly assigned to one of two available stock persons
who retrieve the orders for the customers, UNIF(16, 20) minutes. These stock persons only
retrieve orders for customers who have been assigned specifically to them. Upon receiving their
orders, the customers depart the system. Develop a model of this system and run the simulation
 for 5,000 minutes.

A bright, young engineer has recommend that they eliminate the assignment of an order to a
specific stock person and allow both stock person to select their next activity from a single order
queue. Develop a model of this system, run it for 5,000 minutes and compare the results to the
fist system.

7. a) Simulate a simple processing system which consists of a drilling machine and the processing
time varies according to Triangular distribution of minimum 1, value 3 and maximum 6. The
part enters the system with a random exponential value of 5 minutes. And then leaves the
system. All time units are in minutes. Animate the resource and queue. Simulate the
process for 20 minutes. Plot number waiting at drilling center queue and number busy at drill
press. And report the following data
 the average total time in the system (part) and
 utilization of drill press
 the last part number which entered the system
 number of parts which leaves the system
 average and maximum number of parts in process (wip)
 Make 5 replications of the above simulation. And observe the changes in
output. Tabulate the readings.

b) Modify the above model with all of the following changes:

 Add a second machine to which all parts go immediately after exiting the first machine for a
separate kind of processing (rewash). Processing times at the second machine are the same
as for the first machine. Gather all statistics as before, plus the time in queue, queue length
and utilization at the second machine.
 Immediately after the second machine, there’s a pass fail inspection that takes a constant 5
minutes to carry out and has an 80% chance of passing result; queuing is possible at
inspection, and the queue is first in and first out. All parts exit the system regardless of
whether they pass the test. Count number that fail and number that pass, and gather statistics
on the time in queue, queue length and utilization at inspection center.
 Add plots to track the queue length and number busy at all three stations. Run the simulation
for 480 minutes.

8. Travelers arrive at the main entrance door of an airline terminal according to an exponential
inter-arrival time distribution with mean 1.6 minutes. The travel time from the entrance to the
check-in is distributed uniformly between 2 and 3 minutes. At the check-in counter, travelers
wait in a single line until one of five agents is available to serve them. The check-in time follows
a weibull distribution with parameters β = 7.76 and α = 3.91. Upon completion of their check-in,
they are free to travel to their gates. Create a simulation model, with animation, of this system.
Run the simulation for 16 hours to determine the average time in system, number of passengers
completing check-in, and the average length of the check-in queue.

9. An office that dispenses automotive license plates has divided its customers into categories to
level the office workload. Customers arrive and enter one of the three lines based on their
residence location. Model this arrival activity as three independent arrival streams using an
exponential interarrival distribution with mean of 10 minutes for each stream. Each customer
type is assigned a single clerk who processes the application forms and accepts payment. The
service time is unif (8, 10) minutes for all three-customer types. After completion of this step, all
customers are sent to second clerk who checks the forms and issues the plates. The service time
for this activity is UNIF (2.66, 3.33) minutes for all customer types. Develop a model of this
system and run the simulation for 5,000 minutes.
 A consultant has recommended that the office eliminate the step of differentiating between
customers and use a single line with three clerks who can process any customer type. Develop a
model of this system, run it for 5000 minutes and compare the results with the first system.

10. Using the input analyzer, open a new window and generate a new data file containing 50 points
for an Erlang distribution with parameters: Exp mean 12, k = 3 and offset = 5. Once you have
the data file, perform a Fit all to find the “best” fit from among the available distributions.
Repeat this process for 500, 5000 and 25,000 data points, using the same Erlang parameters.
Compare the results of the fit all for the different sample sizes.

11. This system represents the final operations of the production of two different scaled electronics as
shown in figure.

The first units, named Part A, are produced in an adjacent department, outside the bounds of this
model; with inter arrival times to our model being exponentially distributed with a mean of 5
minutes. Upon arrival, they're transferred to the Part A Prep area. At the Part A Prep area, the
mating faces of the cases are machined to assure a good seal, and the part is then deburred and
cleaned; the process time for the combined operation at the Part A prep area follows a TRIA (1,
4, 8) distribution. The part is then transferred to the sealer.

The second units, named Part B, are produced in a different building, also outside this model's
bounds, where they are held until a batch of four units is available; the batch I is then sent to the
final production area we are modeling. The time between the arrivals of successive batches of
Part B to our model is exponential with a mean of 30 minutes. Upon arrival at the Part B Prep
area, the batch is separated into the four individual units, which are processed individually from
here on. The processing at the Part B Prep area has the same three steps as at the Part A Prep
area, except that the process time for the combined operation follows a TRIA (3, 5, 10)
distribution. The part is then sent to the sealer.

At the sealer operation, the electronic components are inserted, the case is assembled and sealed,
and the sealed unit is tested. The total process time for these operations depends on the part type:
TRIA(1 3, 4) for Part A and WEIB(2.5, 5.3) for Part B (2.5 is the scale parameter  and 5.3 is the
shape parameter ). Ninety-one percent of the parts pass the inspection and are transferred
directly to the shipping department; whether a part passes is independent of whether any other
parts pass. The remaining parts are transferred to the rework area where they are disassembled,
repaired, cleaned, assembled, and re-tested. Eighty percent of the parts processed at the rework
oven are salvaged and transferred to the shipping department as reworked parts, and the rest are
 transferred to the scrap area. The time to rework a part follows an exponential distribution with
mean of 45 minutes and is independent of part type and the ultimate disposition (salvaged or
scrapped).

Collect statistics in each area on resource utilization, number in queue, time in queue, and the
cycle time (or total time in system) by shipped parts, salvaged parts, or scrapped parts.
Simulation run is for four 8-hours shifts or 1920 minutes.

12. (a) Raw stock enters the system at input_pallet and goes to the splitter. From the there pieces
travel to the lathe, the mill, and then to heat_treat. From heat_treat, a batch goes to the
output_pallet and a finished product leaves the output_pallet to Exit.

Input_pallet

Splitter Lathe Mill

Heat_treat
EXIT
Input_pallet

(b) In part a, we have raw stock arrive at the input_pallet where it is routed to a splitter. From the
splitter, five pieces leave and go to the lathe. From there, pieces go to the mill. The pieces
then go to heat treat where they are combined and output as a batch. The batch then goes on
the output pallet where five of them are combined into finished product routes to exit.

(c) It is the same process as part (a) & part (b). We should have determined that heat_treat was
one of the major offenders in terms of bottlenecks. In order to correct this we are going to
add another heat_treat unit. We are also going to inspect the parts from which we will
determine that 25% are rejects. To give us more on-screen information, we will set up
variables and keep track of the following: WIP, rejected parts and completed parts.

13. I. Generate a random Variate for a triangular distribution with range (1, 10) and mode at x=4.
Test the goodness of fit and plot the relevant graphs.

II. The weekly demand has been found to have a Poisson distribution with mean 2.5 items per
week. Generate 100 values of X, the demand per week, using random numbers. Test the
goodness of fit and plot the relevant graphs.

III. Lead times have been found to be exponentially distributed with mean of 3.7 days.
Generate 100 random lead times from this distribution. Test the goodness of fit and plot the
relevant graphs.

IV. Regular maintenance of a production routine has been found to vary and has been modeled
as normally distributed random variable with mean 33 minutes and variance 4 minutes.
 Generate 100 random maintenance times, with the given distribution. Test the goodness of
fit and plot the relevant graphs.

V. A machine is taken out of production after every 5 hours if it fails. By running similar
machines until failure, it has been found that time to failure, X, has the Weibull distribution
with scale parameter = 8, shape parameter = 0.75 and location parameter = 0. Test the
goodness of fit and plot the relevant graphs.

14. Consider a two-station serial packaging / labeling process. Cartons enter the system and are
moved to the packaging station to be closed by a packager. After cartons have been closed, they
are transferred to the labeling station, at which they are processes on one of two identical
labelers. After labeling, the cartons are transferred to a warehouse where they exit the system.

The packager requires cleaning and adjusting every 4 hours; this process takes 15 minutes. The
labelers do not require any maintenance.

The time between carton arrivals at the system entrance is exponentially distributed with a mean
of 12 minutes.

The packaging time follows a uniform distribution with a minimum of 9 minutes and a maximum
of 13 minutes. The labeling process follows a normal distribution with a mean of 18 minutes and
a standard deviation of 3 minutes.

The transfer between the stations is unconstrained. The transfer time from the system entrance to
the packager is 1 minute. The transfer time between the packager and labeler is 1.5 minutes. The
transfer time from the labeler to the warehouse is 1 minute.

Simulate this operation for one 8.5 hours shift and determine the utilization of the three
machines, as well as the average number of cartons waiting for the machines at each station. In
addition, determine the average time a carton spends in the system (from the system entrance to
the warehouse) and the total number of cartons completed and sent to the warehouse.

15. People arrive at a newspaper stand with an inter-arrival time that is exponentially distributed with
a mean of 0.5 minutes. Fifty-five percent of the people buy just the morning paper, while 25%
buy the morning paper and Wall street journal. The remainder buy only the wall street journal.
One clerk handles wall street journal sales, while another clerk handles morning paper sales. A
person buying both goes to the wall street journal clerk. The time is takes to serve a customer is
normally distributed with a mean of 40 seconds and a standard deviation of 4 seconds for all
transactions. Collect statistics on queues for each type of transaction. Suggest ways for making
the system more efficient. Simulate for 4 hours.

16. Colour Monitors arrive at the workbench from the monitor queue, Empty boxes arrive at the
workbench through the box queue, monitor is placed in the box (Joined) and the full box travels
through the shipping queue and arrive at the loading zone. Pallet arrives at the loading zone
through the pallet conveyer, where the boxes are loaded on the pallet and the box travels through
the shipping conveyer to the shipping. The Full boxes are then unloaded from the conveyor from
there it exit the system. (Pallet conveyor length 20 and speed 20 (accumulating) – Shipping
conveyor length 60 and speed 20 (accumulating) – queues are with a capacity of 5 and length is
20. Build the model for the above situation and run the model for about 10 hours and collect the
statistics and examine the outputs.

17. People arrive at a barbershop at the rate of one every 4.5 minutes. If the shop is full (ie can hold
five people altogether), 30% of the potential customers leave and come back in 60  20 minutes.
 The other leave and do not return. One barber gives a haircut in 8  2 minutes, whereas the
seconds talks a lot and it takes 12  4 minutes. If both barbers are idle, a customer prefers the
first barber. (Treat customers trying to reenter the shop as if they are new customers). Simulate
this system until 30 customers have received a haircut.
(a) What is the average time spent in the shop?
(b) What is the average time spent getting a haircut (not including delay)?
(c) What is the average number of customers in the shop?

18. People arrive at a meat counter at a rate of one every 25  10 seconds. There are two sections:
one for beef and one for pork. People want goods from them in the following proportions: beef
only 50%; port only 30%; beef and pork 20%. It takes 45 25 seconds for a butcher to serve one
customer for one order. All customers place one order, expect that “beef and pork” customer
place two orders. Assume that enough butchers are available to handle all customers present at
any time. How along does it take for 200 customers to be served?

19. In a multiphasic screening clinic, patients arrive at a rate of one every 5  2 minutes to enter the
audiology section. The examination takes 3  1 minutes. Eighty percent of the patients were
passed on to the next test with no problems. Of the remaining 20%, one-half require simple
procedures which takes 2  1 minutes and are then sent for reexamination with the same
probability of failure. The other half sent home with medication. Simulate the system to
determine how long it takes to screen and pass 200 patients. (Note: persons sent home with
medication are not considered “passed”).

20. People arrive at a self service cafeteria at the rate of one every 30  20 seconds. Forty percent go
to the sandwich counter, where one worker makes a sandwich in 60  30 seconds. The rest go
the main counter, where one server spoons the prepared meal onto a plate in 45  30 seconds.
All customers must pay a single cashier, which takes 25  10 seconds. For all customers, eating
takes 20  10 minutes. After eating 10% of the people go back for desert, spending an
additional 10  2 minutes altogether in the cafeteria. Simulate until 100 people have left t he
cafeteria. How many people are left in the cafeteria, and what are they doing, at the time the
simulate stops?

21. Workers come to a supply store at the rate of one every 10  4 minutes. Their requisitions are
handled by one of three clerks; a clerks takes 22  10 minutes to handle a requisition. All
requisitions are then passed to a single cashier, who spends 7  6 minutes per requisition.
Simulate the system for 120 hours.

22. Consider a bank with four tellers. Tellers 3 and 4 deal only with business accounts, while teller 1
and 2 delay with general accounts. Clients arrive at the bank at a rate of one every 3  1 minutes.
Of the clients, 33% are business account clients randomly choose between the two tellers
available for each type of account. (Assume that a customer a line without regard to its length and
does not change lines) business accounts take 15  10 minutes to complete and general accounts
6  5. Simulate the system for 500 transactions to be completed. What percentage of time is each
type of teller busy? What is the average time that each type of customer spends in the bank?

23. An airport has two concourses. Concourses 1 passengers arrive at a rate of one every 15  2
seconds. Concourse 2 passengers arrive at a rate of one every 10  5 seconds. It takes 30  5
seconds to walk down concourse 1 and 35  10 seconds to walk down concourse 2. Both
concourses empty into the main lobby, adjacent to the baggage claim. It takes 10  3 seconds to
reach the baggage claim area from the main lobby. Only 60% of the passengers go to the baggage
claim area. Simulate the passage of 500 passengers through the airport system. How many of
these passengers went through the baggage claim area? In this problem, the expected number
 through the baggage claim area? In this problem, the expected number through the baggage claim
area can be computed by 0.60 (500) = 300. How close is the simulation estimate to the expected
number? Why the difference.

24. A warehouse holds 1000 cubic meters of cartons. There cartons come in three sizes: little (1
cubic meter), medium (2 cubic meters), and large (3 cubic meters). The cartons arrive at the
following rate, little every 10  10 minutes, medium, every 15 minutes; and large, every 8  8
minutes. If no cartons are removed, how long will it take to fill an empty warehouse?

25. Able, Baker and Charile are three carhops at the Sonic Drive-In (Service at the speed of sound),
Cars arrive every 5  5 minutes. The carhops service customers at the rate of one very 10  6
minutes. However, the customers prefer Able over Baker, and Baker over Charlie. If the carhop
of choice is busy, the customers choose the first available carhop. Simulate the system for 1000
service completions. Estimate Able’s, Baker’s and Charlie’s utilization (percentage of time busy)