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This paper describes the development of a cohesive framework for discrete event simulation, and the embedded decision processes of a system being modeled. The work presented in the paper is an effort to develop a scientific base for simulation modeling. The paper addresses the need for separate and structured representations of physical and logical entities of a manufacturing system for simulation modeling. The formal and hierarchical constructs defined for physical and logical entities are based on a state-space representation that allows the integration of physical and logical facets in a model with varying degrees of detail. All the entities of a manufacturing system, from the most primitive to the most sophisticated, can be represented in a model by using one of the symbolic structures provided. The framework also describes the simulation dynamics by using the defined constructs. [ABSTRACT FROM AUTHOR]

This research presents guidelines to design control processes where improving quality is achieved by improving the manufacturing consistency through the use of intelligent process control. Conventional control processes cannot include the theoretical knowledge, experimental knowledge, and expert knowledge available concerning the product. A hybrid intelligent process control (IPC) combining a continuous simulation (CS) and an artificial neural network (ANN) can make this knowledge available to the operator for process control. This paper presents a methodology for combining the CS and ANN to achieve real-time process control. A human-machine interface (HMI) is included in the process to aid operators in communication with the CS/ANN hybrid IPC. The result of the new process is a real-time process control advisor (RTPCa). A case example for the methodology of formulating, formalizing, validating, and evaluating the RTPCa is given. The case studied concerns galvanizing continuous sheet steel at a steel plant. The CS is written in SIMAN, and the ANN in C. The research validates and evaluates the RTPCa using plant data, simulation output, and face validation by plant personnel. The authors conclude that the benefits of the RTPCa over other forms of IPC include better process communication to the operator, robustness to moderate changes in system parameters, the flexibility to retrain the ANN if conditions change dramatically, and the computation speed necessary for real-time process control. This methodology has further applications to other continuous processes where quality is determined by manufacturing consistency of the product, such as in the pulp paper and film processing industries. [ABSTRACT FROM AUTHOR]

This paper proposes a technique for estimating steady-state quantiles from discrete-event simulation models, with particular attention paid to cycle time quantiles of manufacturing systems. The technique is based on the Cornish-Fisher expansion, justified through an extensive empirical study, and is supported with mathematical analysis. It is shown that the technique provides precise and accurate estimates for the most commonly estimated quantiles with minimal data storage and low computational requirements. [ABSTRACT FROM AUTHOR]

This paper describes an approximate analytical method for evaluating the average values of throughput and buffer levels of closed three-machine production systems with finite buffers. The method includes a new set of decomposition equations and a new building block model. The machines have deterministic processing times and geometrically distributed probabilities of failure and repair. The numerical results of the method are close to those from simulation. The method performs well because it takes into account the correlation among the numbers of parts in the buffers. Extensions to larger systems are discussed. [Supplementary materials are available for this article. Go to the publisher's online edition of IIE Transactions for the following free supplemental resource: Appendix of additional numerical results] [ABSTRACT FROM AUTHOR]

This paper presents approximation methods for the performance analysis of long manufacturing lines, i.e. lines with more than two machines and one buffer, that have both quality and operational failures. We describe three different versions of long flow lines that differ in the locations of the inspection stations and in the sets of machines that each inspection station monitors. We explain a transformation method that approximates long manufacturing lines that have quality and operational failures with long lines that only have operational failures. Such lines can be evaluated by decomposition methods. We introduce other approximations to quantify the effects of the separation of inspections from operations. Comparison with simulation shows that the solution methods provide reliable performance estimates. [ABSTRACT FROM AUTHOR]

This paper focuses on the development of an integrated short-term production scheduling simulation model for a complex manufacturing operation. The decision making tool has a front-end user data interface built with Microsoft Access and Visual Basic for Applications software. The model assists production planners to make informed decisions on how best to schedule simultaneously two lanes of daily or weekly production on a unique plastic parts manufacturing line. The advantages and disadvantages (model weaknesses) of using the simulation model, especially as a scheduling tool, are discussed. In this particular application, we find that the advantages far outweigh the disadvantages. [ABSTRACT FROM AUTHOR]

In this paper, a structure and architecture for the rapid realization of a simulation-based real-time shop floor control system for a discrete part manufacturing system is presented. The research focuses on automatic simulation model and execution system generation from a production resource model. An Automatic Execution Model Generator (AEMG) has been designed and implemented for generating a Message-based Part State Graph (MPSG)-based shop level execution model. An Automatic Simulation Model Generator (ASMG) has been designed and implemented for generating an Arena simulation model based on a resource model (MS Access 97) and an MPSG-based shop level execution model. A commercial finite capacity scheduler. Tempo, has been used to provide schedule information for the Arena simulation model. This research has been implemented and tested for six manufacturing systems, including The Pennsylvania State University CIM laboratory. [ABSTRACT FROM AUTHOR]

We present a general manufacturing-cell simulation model for evaluating the effects of world-class manufacturing practices on expected cell performance. The modular structure of the simulation provides the flexibility to analyze a wide variety of manufacturing cells. We formulate a comprehensive annualized cost function for evaluation and comparison of alternative cell configurations. A case study involving assembly of printed circuit hoards illustrates the potential benefits of using this tool for cell design and analysis. The simulation model is intended for use in a two-phase approach to cell design that is based on simulated experimentation and response surface analysis as detailed in a companion paper. [ABSTRACT FROM AUTHOR]

We present a two-phase approach to design and analysis of manufacturing cells based on simulated experimentation and response surface methodology using a general manufacturing-cell simulation model. The first phase involves factor-screening simulation experiments to identity design and operational factors that have a significant effect on cell performance as measured by a comprehensive annual cost function. In the second phase of experimentation, we construct simulation (response surface) metamodels to describe the relationship between the significant cell design and operational factors ( the controllable input parameters) and the resulting simulation-based estimate of expected annual cell cost (the output response). We use canonical and ridge analyses of the estimated response surface to estimate the levels of the quantitative input factors that minimize the cell's expected annual cost. We apply this methodology to an assembly cell for printed circuit hoards. Compared to be current cell operating policy. the simulation metamodel-based estimate of the optimum operating policy is predicted to yield average annual savings of approximately $425 000, which is a 20% reduction in annual cost. In a companion paper, we detail the structure and operation of the manufacturing-cell simulation model. [ABSTRACT FROM AUTHOR]

In this paper an analytical approximation for the performance of non-homogenous asynchronous Flow Production Systems (FPSs) with finite buffers is presented. Generally distributed stochastic processing times as well as breakdowns and imperfect production are considered. The procedure explicitly accounts for simultaneous blocking and starving. The approximation is based on the decomposition of an M-station-line into M -- 1 two-station-lines which are analyzed with the help of a GI/G/ I /Nmax queueing model. Numerical comparisons with exact and simulation results for hypothetical as well as for real-life flow-lines indicate that the procedure provides accurate results. [ABSTRACT FROM AUTHOR]

Collision detection is a critical aspect of Virtual Reality (VR)-based simulation of manufacturing processes. Despite the significant progress that has been made in developing efficient, exact collision detection algorithms for convex objects, limited and slow progress has been reported in developing collision detection algorithms for general, nonconvex objects. To narrow this gap we introduce the concept of virtual objects which extends the applicability of exact collision detection algorithms to nonconvex objects. The outcome of our methodology is the fast creation of convex objects for a class of frequently encountered nonconvex manufacturing objects that can be used in any existing collision detection approach. The collision detection technique described in this paper is best suited for interactive simulation and animation applications where a high accuracy of object contact modeling is required. Examples include virtual assembly; mobile robot simulation; robotic painting; robotic welding; and coordinate measuring processes. [ABSTRACT FROM AUTHOR]

Aggregate models of detailed scheduling problems are needed to support aggregate decision making such as customer order acceptance. In this paper, we explore the performance of various aggregate models in a decentralized control setting in batch chemical manufacturing (no-wait job shops). Using simulation experiments based on data extracted from an industry application, we conclude that a linear regression based model outperforms a workload based model with regard to capacity utilization and the need for replanning at the decentralized level, specifically in situations with increased capacity utilization and/or a high variety in the job mix. [ABSTRACT FROM AUTHOR]

This paper investigates possible implementations of the autonomous agents concept in flexible manufacturing control. The implementation issues and the effectiveness of different control architectures and algorithms are analyzed by means of a simulation model of a flexible job shop. Extensive experimental results are reported, allowing the evaluation of the trade-off between the degree of autonomy and system performance. [ABSTRACT FROM AUTHOR]