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SIM Factory with Production Lines (External Tables Usage)

In this example, we will learn how to modify production using the extended model of the Factory object with the help of external tables.

For a better understanding of this scenario and its structure, you can watch a demo video of this example.

Problem definition

We consider a supply chain in South Korea comprising:

  • 2 factories in Cheonan and Wonju producing smartphones and tablets
  • Customers in the 40 largest cities of the country
  • Distribution center in Seongnam-si

We plan to start selling new models of the devices, and we expect to hold:

  • 1% of smartphones’ market share
  • 0.5% of tablets’ market share
Specifications

Production load is evenly distributed between the two factories.

Production process comprises two steps:

  • Assembly (3 minutes)
  • Packaging (5 minutes)

Each factory has 3 production lines with different capacities:

  • 2 assembly lines (one line per product type)
  • 1 packing line processing all types of products
Extension summary

The advantage of anyLogistix is the ability to extend any object using AnyLogic simulation software built-in as an extension editor.

In this example, we are using an extension (Extended Factory) of a factory model with two production lines. It helps us to analyze the production process.

The default settings for these factories are located in the external tables. Here we can see two tables:

  • ext_data — contains general parameters of factories (here we can change the time spent on performing each process)
  • lines_capacity — contains data of the amount of product, that each line can process at the same time.

The data from these tables is used by the extension to customize the settings and animation of each factory.

During the simulation runtime we can open the internals of each facility by selecting the object we want to observe and clicking the Show animation link.

Factory internal work structure consists of different states of products and operations with them. The production begins after receiving the production order. If we’re unable to instantly produce the ordered amount, it is added to the Waiting for production storage. The production process and the production lines are defined for operations for both products. They are shown at the bottom of the scheme (different colors mean different states of the product: raw, assembled, packaged). When the packaging is finished products are stored in the Finished goods warehouse.

During the simulation run, we can create an unscheduled production order from the factory internals screen, to test the system (press the Order button). Also, we can change line capacities in the Lines utilization section to test the resilience of the selected factory (note that all changes made will affect only this facility).

Goal

Analyze the extended model of the factory. Do you think the capacity of the production lines is sufficient to satisfy the new daily production plan?

Results

Let us run a Simulation experiment and analyze the results.

In the Profit and Loss Statement tab, we can see that we gain profit at the end of the simulated period. But if we open the Service Level tab, we can see there was an issue with delivering products to the customers. This service level is unacceptable for us, so let us find the origin of the issue.

The result of the experiment shows that the current capacity of the production lines is insufficient to satisfy the production plan: initial stock at the DC Seongnam-si allows to maintain the maximum service level until the production backlog exceeds its size.

Let us open the Available Inventory tab and analyze the Available Inventory Including Backlog chart. We can see the gradual decrease in the available number of smartphones and tablets in the Wonju factory. The inventory of the Cheonan Factory is stable, which means that issue is in the Wonju Factory. As the demand is separated equally between the factories, let us check the differences in factories settings. The lines_capacity external table shows that the capacity of the assembly line for the Wonju factory is lower than the capacity for the Cheonan Factory.

Set the Line 5 Capacity value to 4 and run the experiment again.

The result shows increase in profit and improvement in the service level. The Assembly action at the Wonju factory is not blocking production now.

anyLogistix extensions are built using AnyLogic extension editor and help to simulate your unique processes, which cannot be defined by the default options to create a powerful and flexible simulation model.

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