Application of a discrete event simulation for robust system design of a melt facility

This paper presents a methodology to identify robust operating regions through the selection of controllable factory variables, using discrete event simulation. A casting plant melt facility was used as an industrial test bed to develop these techniques. A robust system design was determined by response surface analysis of key production parameters. Furthermore, robust operating policies that maximise throughput, while minimizing work-in-progress and thus energy consumption were identified.

Linking discrete event simulation models using HLA

The increasing usage of discrete event simulation packages for modeling and analyzing manufacturing and logistics has led to a need for connecting simulation models together at runtime. One such methodology for linking discrete event simulation models together has been developed for this research and this paper demonstrates the usage of this linking method. A unified simulation model is developed from two submodels developed using different simulation packages.

Optimising discrete event simulation models using a reinforcement learning agent

A reinforcement learning agent has been developed to determine optimal operating policies in a multi-part serial line. The agent interacts with a discrete event simulation model of a stochastic production facility. This study identifies issues important to the simulation developer who wishes to optimise a complex simulation or develop a robust operating policy. Critical parameters pertinent to 'tuning' an agent quickly and enabling it to rapidly learn the system were investigated.

Managing realtime information flow between distributed discrete event simulation models

Investigates the creation of a method for the connection and communication of commercial off the shelf discrete-event simulation packages for simulation models of manufacturing systems. Through this research a method to connect different commercial off the shelf discrete-event simulation packages was successfully developed facilitating parallel development of models and the creation of extremely large models.

Potential applications of discrete-event simulation and fuzzy rule-based systems to structural reliability and availability

This chapter discusses and illustrates some potential applications of discrete-event simulation (DES) techniques in structural reliability and availability analysis, emphasizing the convenience of using probabilistic approaches in modern building and civil engineering practices. After reviewing existing literature on the topic, some advantages of probabilistic techniques over analytical ones are highlighted. Then, we introduce a general framework for performing structural reliability and availability analysis through DES. Our methodology proposes the use of statistical distributions and techniques – such as survival analysis – to model component-level reliability. Then, using failure- and repair-time distributions and information about the structural logical topology (which allows determination of the structural state from their components’ state), structural reliability, and availability information can be inferred. Two numerical examples illustrate some potential applications of the proposed methodology to achieving more reliable and structural designs. Finally, an alternative approach to model uncertainty at component level is also introduced as ongoing work. This new approach is based on the use of fuzzy rule-based systems and it allows the introduction of experts’ opinions and evaluations in our methodology.

Discrete event simulation enabled high level emulation of a distribution centre

Emulation facilitates the testing of control systems through the use of a simulation model. Typically emulation has focused on low level control, to ensure that resources within a system are commissioned correctly. Higher level control that deals with complex issues such as throughput, in-system time and stacking, has not received as much attention. In this paper, a higher level agent-based emulation framework was proposed. Then an emulation model for a distribution centre is described that can test distribution centre level algorithms directly. This methodology also allows playback of real world operations, making it an ideal tool to analyse problems with performance of commissioned systems.

A dynamic time warped clustering technique for discrete event simulation-based system analysis

Abstract This paper introduces a novel approach for discrete event simulation output analysis. The approach combines dynamic time warping and clustering to enable the identification of system behaviours contributing to overall system performance, by linking the clustering cases to specific causal events within the system. Simulation model event logs have been analysed to group entity flows based on the path taken and travel time through the system. The proposed approach is investigated for a discrete event simulation of an international airport baggage handling system. Results show that the method is able to automatically identify key factors that influence the overall dwell time of system entities, such as bags that fail primary screening. The novel analysis methodology provides insight into system performance, beyond that achievable through traditional analysis techniques. This technique also has potential application to agent-based modelling paradigms and also business event logs traditionally studied using process mining techniques.

Evaluation of tender solutions for aviation training using discrete event simulation and best performance criteria

This paper describes a novel discrete event simulation (DES) methodology for the evaluation of aviation training tenders where performance is measured against “best performance” criteria. The objective was to assess and compare multiple aviation training schedules and their resource allocation plans against predetermined training objectives. This research originated from the need to evaluate tender proposals for the Australian Defence Aviation Training School that is currently undergoing aviation training consolidation and helicopter rationalization. We show how DES is an ideal platform for evaluating resource plans and schedules, and discuss metric selection to objectively encapsulate performance and permit an unbiased comparison. DES allows feasibility studies for each tender proposal to assure they satisfy system and policy constraints. Consequently, to create an objective and fair environment to compare tendered solutions, what-if scenarios have been strategically examined to consider improved implementations of the proposed solutions.

Improving casthouse throughput using discrete-event modeling

The scheduling of metal to different casters in a casthouse is a complicated problem, attempting to find the balance between pot-line, crucible carrier, furnace and casting machine capacity. in this paper, a description will be given of a casthouse modelling system designed to test different scenarios for casthouse design and operation. Using discrete-event simulation, the casthouse model incorporates variable arrival times of metal carriers, crucible movements, caster operation and furnace conditions. Each part of the system is individually modelled and synchronised using a series of signals or semaphores. in addition, an easy to operate user interface allows for the modification of key parameters, and analysis of model output. Results from the model will be presented for a case study, which highlights the effect different parameters have on overall casthouse performance. The case study uses past production data from a casthouse to validate the model outputs, with the aim to perform a sensitivity analysis on the overall system. Along with metal preparation times and caster strip-down/setup, the temperature evolution within the furnaces is one key parameter in determining casthouse performance.

Benchmark generation algorithm for stochastic mixed model assembly shop simulation and optimization

The Operations Research (OR) community have defined many deterministic manufacturing control problems mainly focused on scheduling. Well-defined benchmark problems provide a mechanism for communication of the effectiveness of different optimization algorithms. Manufacturing problems within industry are stochastic and complex. Common features of these problems include: variable demand, machine part specific breakdown patterns, part machine specific process durations, continuous production, Finished Goods Inventory (FGI) buffers, bottleneck machines and limited production capacity. Discrete Event Simulation (DES) is a commonly used tool for studying manufacturing systems of realistic complexity. There are few reports of detail-rich benchmark problems for use within the simulation optimization community that are as complex as those faced by production managers. This work details an algorithm that can be used to create single and multistage production control problems. The reported software implementation of the algorithm generates text files in eXtensible Markup Language (XML) format that are easily edited and understood as well as being cross-platform compatible. The distribution and acceptance of benchmark problems generated with the algorithm would enable researchers working on simulation and optimization of manufacturing problems to effectively communicate results to benefit the field in general.

Simulation-based support tool for operator performance in batch manufacturing

In industry, the workload and utilization of shop floor operators is often misunderstood. In this paper, we will present several real case studies, using Discrete Event Simulation (DES) models, which allow us to better understand operators in a batch manufacturing environment. The first study investigates labour in a machining plant consisting of multiple identical CNC machines that batch produce parts. The second study investigates labour in an eight station, gravity die casting rotary table. The results from these studies have shown that there can be potential improvements made by the production planners in the current labour configuration. In the first case study, a matrix is produced that estimates what the operator's utilization levels will be for various configurations. From this, the preferred operator to machine ratio over a range of cycle times is presented. In the second study, the results have shown that by reducing the casting cycle time, the operator would be overloaded. A discrete event simulation of these two cases highlighted areas that were misunderstood by plant management, and provided them with a useful decision support tool for production planning.

Toward a synergy between simulation and knowledge management for business intelligence

The adoption of simulation as a powerful enabling method for knowledge management is hampered by the relatively high cost of model construction and maintenance. A two-step procedure, based on a divide and conquer strategy, is proposed in this paper. First, a simulation program is partitioned based on a reinterpretation of the model-view-controller architecture. Individual parts are then connected, in terms of abstraction, to guard against possible changes that resulted from shifting user requirements. We explore the applicability of these design principles through a detailed discussion of an industry case study. The knowledge-based perspective guides the design of architecture to accommodate the need of emulation without compromising the integrity of the simulation program. The synergy between simulation and a knowledge management perspective, as shown in the case study, has the potential to achieve the objectives of rapid development of models, with low maintenance cost. This could, in turn, facilitate an extension of the use of simulation in the knowledge management domain.

A generalised data analysis approach for baggage handling systems simulation

Airport baggage handling systems are a critical infrastructure component within major airports, and essential to ensure smooth luggage transfer while preventing dangerous material being loaded onto aircraft. This paper proposes a standard set of measures to assess the expected performance of a baggage handling system through discrete event simulation. These evaluation methods also have application in the study of general network systems. Results from the application of these methods reveal operational characteristics of the studied BHS, in terms of metrics such as peak throughput, in-system time and system recovery time.