MIDDLE EAST TECHNICAL UNIVERSITY

I E 3 7 2 S I M U L A T I O N

Term Project:
Waste Transfer Station Part I

Group Name: Jelkala

Burcu Yzak Fato lbi Onur Ylmaz

May 2011, Ankara

Table of Contents
PAGE Table of Contents ............................................................................................................. I. Introduction II. Report ............................................................................................................. 1 2 3

1. Statement of the Problem ........................................................................................ 3 2. Structure of the Model ................................................................................. 2.1 Attributes .......................................................................................... 3 3

2.2 Variables .. 4 2.3 Modules .............................. 6 3. Model .. 8 3.1 Assumptions ................................................................................. 8 3.2 Input Analysis ....................................................................................... 3.2 Model Frame 9 10

3.3 Experiment Frame ............................ 16 4. Pilot Run Results .................................................... 20

4.1 Verification . 20 4.2 SIMAN Summary Report .. 4.3 Alternative Scenarios . III. Conclusion 22 26 27

I.

Introduction

In the project, a transfer station for waste management is simulated. First of all, this report includes statement of the problem which gives detailed information about the problem and the idea behind the model construction. Then, structure of the model is given for showing the details by giving the definitions of attributes and variables used, and explaining the distinguishable modules of the model. Following these, the report includes assumptions made while constructing the model, experiment and model frames and input analysis done in order to fit the given data of arrival times of small trucks that transports loads to the transfer station. In addition to these, verification of the model which is done by using SIMAN Summary Report can also be found. Finally, in order to satisfy the goals of the management, initial thoughts on alternative scenarios are summarized which will be studied in Part II of the project in detail.

II. Report 1. Statement of the Problem

In this term project there is a problem environment which includes a transfer station for waste management which operates continuously. The purpose of the station is to gather and then decompose waste contents and transfer them to related warehouses. The main objective of the transfer station is to operate with the limit of 180 minutes for keeping unit loads of remaining waste at the station. Since, this is a business environment; the second aim is that the station must attain a profit that pays back the investment in two years. In order to find any bottlenecks of the station that prevents it from achieving these goals a simulation model is constructed. Our model approach is based on answering How should a single load visit all the process areas in the station with using the minimum computer time and memory? Therefore, model is constructed considering each process area individually and then sending/receiving messages between them to form a flow. Identifying any problems related to station, it is tried to answer the question How this station could reach these goals? by developing alternative scenarios using the available resources and considering operational changes.

2. Structure of the Model

2.1 Attributes
Attributes can be gathered into three groups as only related to single loads, related to removal operations and the others. PaperAmount PlasticAmount GlassAmount OrganicAmount MetalAmount RestOfLoad Paper amount in a single load, which is uniformly distributed between 5 kg and 10 kg Plastic amount in a single load, which is uniformly distributed between 30 kg and 40 kg Glass amount in a single load, which is uniformly distributed between 10 kg and 20 kg Organic amount in a single load, which is uniformly distributed between 5 kg and 20 kg Metal amount in a single load, which is uniformly distributed between 1 kg and 5 kg Rest of the load which is calculated by subtracting sum of all above amounts from 100 kg, which is the weight of a single load 3

RemovedPlasticAmount

RemovedOrganicAmount

RemovedGlassAmount RemovedPaperAmount

Amount of plastic removed (in kg) after plastic removal operations, calculated using the initial plastic amount and efficiency of the station Amount of organic removed (in kg) after organic removal operations, calculated using the initial organic amount and efficiency of the station Amount of glass removed (in kg) after glass removal operations, calculated using the initial glass amount and efficiency of the station Amount of paper removed (in kg) after paper removal operations, calculated using the initial paper amount and efficiency of the station

RemovedMetalAmount attribute is not used in the model since the entire metal amount is removed in the metal gatherer. ArrivalTime ZipperArrival NumberofLoads OrganicLife OrganicVsCompost Arrival time of the small trucks which are carrying waste loads Time when all removal operations are completed and only remaining waste is left in a single load Number of loads which is carried by the small trucks, calculated using ANINT(UNIF(10,30)) function in Arena Age of organic waste when the small trucks arrive at the station, uniformly distributed between 1 and 2 days Decides whether the organic waste removed will be counted as organic or as compost, assigned by checking the organic life when the trucks arrive at the station for collecting organic waste amount.

2.2 Variables

All variables end with -RemovedOnHand are used to trace the storage level of the related content. This variable is used in order to check whether or not the sending warehouse limit is reached for the related content.

All variables tabulated as TotalXRemoved are used in order to trace the total amount of removal for the related content. With the same approach, all variables starting with EarningsOn- are used to trace the sale revenues made on the related content.

MetalRemovedOnHand TotalMetalRemoved EarningsOnMetal

Amount of metal removed (in kg) and stored in metal storage area Total amount of metal removed (in kg) in the system Total profit made on metal removal (in $)

PlasticRemovedOnHand TotalPlasticRemoved EarningsOnPlastic

Amount of plastic removed (in kg) and stored in glass storage area Total amount of plastic removed (in kg) in the system Total profit made on plastic removal (in $)

GlassRemovedOnHand TotalGlassRemoved EarningsOnGlass

Amount of glass removed (in kg) and stored in glass storage area Total amount of glass removed (in kg) in the system Total profit made on glass removal (in $)

TotalPaperRemoved EarningsOnPaper TotalOrganicRemoved OrganicSent CompostSent EarningsOnOrganic EarningsOnCompost

Total amount of paper removed (in kg) in the system Total profit made on paper removal (in $) Total amount of organic removed (in kg) in the system Total amount of organic waste (in kg) which is sent as organic material Total amount of organic waste (in kg) which is sent as compost Total profit made on organic material (in $) Total profit made on compost (in $)

RemainingWasteOnHand TotalRemainingWasteRemoved CostOfLandFilling

Amount of remaining waste removed (in kg) and stored in the storage area Total amount of remaining waste removed (in kg) in the system Total cost of disposing the remaining waste to landfill area (in $)

SellingPrice LandfillCost ConveyorSize DeportingTime

1 dimensional array which holds all selling prices of all types of contents (in $ / kg) Cost of disposing one kg of remaining waste to the landfill area ($ 0.32 /kg) Total available space limit on the conveyor (9 units as given) Time it takes to unload one load of waste from truck (1.2 minutes as given) 1 dimensional array which holds the threshold amount (in kg) of different types of contents for sending warehouse Number of manual process areas in the system (2 areas as given) Number of workers in the first group in manual process area (10 workers as given) Number of workers in the second group in manual process area (10 workers as given)

WarehouseSendingLimit NumberOfManualProcessArea WorkersIn1 WorkersIn2

2.3 Modules

In this part, distinguishable parts of the simulation model are described for clarity:

Small Trucks Porting:

First of all, input analyzer is used to fit the past data of small truck interarrivals to a distribution and the best distribution is found. After a truck is created, number of loads in the truck and age of the organic material in the loads of the truck are assigned according to distributions specified in the project. Then these trucks are sent to port queue to wait for a port to become available. When a port becomes available the truck seizes the port and unloads the waste it carries which takes 1.2 minutes times Number of loads in the truck.

Transforming into Loads and Assigning Waste Content:

Duplicate block is used to transform the trucks into loads and then paper, metal, plastic, glass and organic amounts are assigned to each load according to distributions specified. Then by subtracting these amounts from 100 kg, remaining waste amount is found and total loads entering the system is counted to be able to trace the entities after the model is run.

Crane:
After being counted, loads enter the crane queue to wait for the crane to become available. As soon as the crane becomes available it picks up a load and waits for the conveyor to become available, i.e. have an available space. The crane counter counts the number of loads entering the crane. If the counter is less than 10, namely for the first 9 loads, then the crane puts the load directly on the conveyor. On the other hand, if the counter is greater than 10, then availability of the conveyor is checked and the load is put on the conveyor after conveyor becomes available.

Conveyor:
If the entering load is not the 9th load on the conveyor, then the load enters the conveyors entrance dummy queue waiting for a signal given when number of loads on the conveyor becomes nine. If the entering load is the 9th load on conveyor then it gives a signal and the first load entered the conveyors entrance dummy queue is released. If the metal gatherer is empty then the conveyor drops the load. Otherwise, the load enters the conveyors exit dummy queue waiting for a signal

given when the metal gatherer becomes available. After this signal comes, conveyor drops the load and the load seizes the metal gatherer.

Metal Gatherer:
The duration of the gathering process is assigned as specified in the project. If a manual process area is available then the load releases the metal gatherer by giving signal to the conveyor that releases a load from the conveyors dummy queue. If all manual process areas are busy, then the load enters DummyQ2 waiting for a signal which is given when an area becomes available. After the load releases the metal gatherer, Total Metal Removed and Metal Removed on Hand variables are updated. If metal removed on hand exceeds the warehouse limit, then sent to warehouse by decreasing the metal removed on hand to zero and releasing manual process area. Otherwise the load just releases the manual process area and then it is counted for the number of loads entering the manual process area.

Manual Process Area:

Using the given formulas in the project, removal time of materials by each worker group and percent removed for each material are calculated once and Expressions element is used in order to let the model run efficiently.

Plastic and Glass Removal:

After plastic and glass are removed, Plastic Removed on Hand and Total Plastic Removed variables; and Removed Plastic Amount attribute are updated. If plastic removed on hand exceeds the warehouse limit, then plastic removed on hand is decreased to zero, total revenue is calculated and plastic is sent to warehouse. With the same approach used in the plastic removal, glass removal operations, variable and attribute updates are conducted.

Paper and Organic Removal:

After paper and organics are removed, Removed Paper Amount attributes and Total Paper Removed variables are updated and paper is sold and total revenue is calculated. Then Removed Organic Amount and Total Organic Removed are updated and manual process area is released by giving signal to metal gatherer after counting the number of loads leaving the manual process area. Then the load is duplicated, one of them goes to zipper and one of them enters to the organic waste queue which waits organic trucks that come once in 36 hours. If age of the organic is 7

more than 3 (assigned by using the attribute Organic Life and the tally that calculates the time passed after the load entered the system) then it becomes compost and sold, otherwise it is sold as an organic. Then total revenues earned from compost and organic are calculated.

Zipper:
After Remaining Waste On Hand is updated, if it is less than 100 kg then the load enters the End Queue waiting for a signal coming when remaining waste on hand becomes greater than 100. If remaining waste on hand is greater than 100, then a signal is given so loads waiting in the End Queue are released and disposed. At his time the zipper is seized and a 2 minute-delay occurs. After Total Remaining Waste Removed is calculated, zipper is released and the cost of disposing the remaining waste to the landfill area is calculated.

3. Model
3.1 Assumptions
These assumptions are made when a simulation model is constructed for the given problem:

First of all, when plastic, glass or paper removals are to leave the station to another warehouse, it is assumed that the trucks can carry all the removals which is accumulated. For instance, considering plastic amount, when accumulated level reaches 1000, all plastic amount will be carried without any consideration about how larger the accumulated value than 1000. Since contents of single loads, which are given in uniform distribution levels, are very small when compared to 1000, it is acceptable to assume that all accumulated value can be carried at once.

Secondly, since in the first part of the project it is only asked to model this environment, number of workers and resources are taken as given and they are only considered in the alternative scenarios.

Thirdly, since any length of the simulation is not given, and the steady state does not seem possible with given system features, the replication length is chosen according to where we run out of entities due to ARENAs license agreement and limitations.

Fourthly, past 500 interarrival data for trucks are used for calculating the interarrival time of the trucks in the following planning horizon. In other words, it is assumed that in the following periods, trucks will be arriving with the theoretical distribution which is calculated from past data.

3.2 Input Analysis

As mentioned in the assumptions above, small truck arrivals are found by using the past data of 500 interarrivals. Using the given .dst file in Arenas Input Analyzer following output is retrieved:

Function Sq Error ------------------------------Gamma 0.00141 Distribution: Gamma Weibull 0.0016 Erlang 0.00223 Expression: GAMM(27.8, 1.07) Exponential 0.00223 Beta 0.00361 Square Error: 0.001411 Lognormal 0.006 Normal 0.0483 Triangular 0.0791 Uniform 0.123 Gathered from the output of Arena Input Analyzer Distribution Summary

As can be seen from the output, the best theoretical distribution which fits to given past data is Gamma distribution with the given parameters. Therefore, interarrival distribution for small trucks is used as what is taken from Input Analyzers output.

3.2 Model Frame

0$ 64$ 1$ 4$ 5$ 2$ 6$ 3$ CREATE, COUNT: ASSIGN: QUEUE, SEIZE, DELAY: RELEASE: DUPLICATE: 1:GAMM(27.8,1.07):MARK(ArrivalTime):NEXT(64$); SmallTruckEnter,1; NumberofLoads=ANINT(UNIF(10,30)): OrganicLife=UNIF(24*60,48*60); PortQ; 1,Other: Port,1:NEXT(2$); DeportingTime*NumberofLoads,,Other:NEXT(6$); Port,1; NumberofLoads-1,ContentAssignment:NEXT(ContentAssignment);

ContentAssignment ASSIGN:

PaperAmount=UNIF(5,10): MetalAmount=UNIF(1,5): PlasticAmount=UNIF(30,40): GlassAmount=UNIF(10,20): OrganicAmount=UNIF(5,20); 25$ ASSIGN: RestOfLoad=100(PlasticAmount+PaperAmount+MetalAmount+GlassAmount+OrganicAmount); 36$ COUNT: LoadsEnteredSystem,1; 55$ QUEUE, CraneQ; 8$ SEIZE, 1,Other: Crane,1:NEXT(37$); 37$ 56$ DELAY: COUNT: 2,CraneStorage,Other:NEXT(56$); CraneC,1;
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9$ CraneRelease Conveyor 58$

BRANCH, RELEASE: QUEUE, SEIZE,

1: If,NC(CraneC)<10,CraneRelease,Yes: If,NR(ConveyorR)>=8,CraneDummy,Yes; Crane,1; Conveyor; 1,Other: ConveyorR,1:NEXT(ConveyorBranch); 1: If,NR(ConveyorR)==9,Equal9,Yes: Else,Dummyy,Yes; 9; Dummy; 9,1:NEXT(CheckMetGath); 1: If,NR(MetalGatherer)==0,ReleaseConveyor,Yes: If,NR(MetalGatherer)==1,ConvDummy,Yes; ConveyorR,1; 1,Other: MetalGatherer,1:NEXT(7$); UNIF(2,2+MetalAmount),,Other:NEXT(13$); 1:

ConveyorBranch BRANCH, Equal9 Dummyy 54$ CheckMetGath SIGNAL: QUEUE, WAIT: BRANCH,

ReleaseConveyor RELEASE: MetalGath SEIZE, 7$ 13$ DELAY: BRANCH,

If,NR(ManualProcessArea)<MR(ManualProcessArea),ReleaseMetalGatherer,Yes: If,NR(ManualProcessArea)==MR(ManualProcessArea),DummyQ2,Yes; ReleaseMetalGatherer RELEASE: MetalGatherer,1; 10$ SIGNAL: 7; 28$ ASSIGN: MetalRemovedOnHand=MetalRemovedOnHand+MetalAmount: TotalMetalRemoved=TotalMetalRemoved+MetalAmount; 11$ BRANCH, 2:
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ManualProcess SEIZE, 34$ 14$ COUNT: DELAY:

Always,ManualProcess,Yes: If,MetalRemovedOnHand>=WarehouseSendingLimit(1),MetalWarehouse,Yes; 1,Other: ManualProcessArea,1:NEXT(34$); ManuelEnter,1; DelayExp*(PlasticAmount+GlassAmount),,Other:NEXT(26$);

26$ ASSIGN: PlasticRemovedOnHand=PlasticRemovedOnHand+PlasticAmount*EfficiencyExp(1): RemovedPlasticAmount=PlasticAmount*EfficiencyExp(1): TotalPlasticRemoved=TotalPlasticRemoved+PlasticAmount*EfficiencyExp(1); 15$ BRANCH, 2: If,PlasticRemovedOnHand>=WarehouseSendingLimit(2),PlasticWarehouse,Yes: Always,RemoveGlass,Yes; PlasticWarehouse ASSIGN: EarningsOnPlastic=EarningsOnPlastic+PlasticRemovedOnHand*SellingPrice(2); 27$ ASSIGN: PlasticRemovedOnHand=0; 50$ DISPOSE: No; RemoveGlass 16$ ASSIGN: BRANCH, TotalGlassRemoved=TotalGlassRemoved+GlassAmount*EfficiencyExp(2): RemovedGlassAmount=GlassAmount*EfficiencyExp(2): GlassRemovedOnHand=GlassRemovedOnHand+GlassAmount*EfficiencyExp(2); 2: If,GlassRemovedOnHand>=WarehouseSendingLimit(2),GlassWarehouse,Yes: Always,PaperOrganic,Yes;

GlassWarehouse ASSIGN: EarningsOnGlass=EarningsOnGlass+((GlassRemovedOnHand)*SellingPrice(3)); 30$ ASSIGN: GlassRemovedOnHand=0; 52$ DISPOSE: No;

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PaperOrganic 31$

DELAY: ASSIGN:

DelayExp*(PaperAmount+OrganicAmount),,Other:NEXT(31$); RemovedPaperAmount=PaperAmount*EfficiencyExp(3): TotalPaperRemoved=TotalPaperRemoved+PaperAmount*EfficiencyExp(3);

32$ ASSIGN: EarningsOnPaper=EarningsOnPaper+((RemovedPaperAmount)*SellingPrice(4)):NEXT(RemoveOrganic); RemoveOrganic ASSIGN: RemovedOrganicAmount=OrganicAmount*EfficiencyExp(4):

TotalOrganicRemoved=TotalOrganicRemoved+OrganicAmount*EfficiencyExp(4); 35$ COUNT: ManuelLeave,1; 18$ RELEASE: ManualProcessArea,1; 47$ TALLY: TimeAtStation,INT(ArrivalTime),1; 19$ SIGNAL: 8; 17$ DUPLICATE: 1,Zipper:NEXT(OrganicWasteQ); OrganicWasteQ 39$ 43$ 44$ QUEUE, WAIT: ASSIGN: BRANCH, OrganicWasteQueue; 1,NQ(OrganicWasteQueue); OrganicVsCompost=((OrganicLife+TNOW-ArrivalTime)<=3*24*60); 1: If,OrganicVsCompost==1,OrganicSending,Yes: Else,CompostSending,Yes;

OrganicSending ASSIGN: EarningsOnOrganic=EarningsOnOrganic+RemovedOrganicAmount*SellingPrice(5): OrganicSent=OrganicSent+RemovedOrganicAmount; 46$ TALLY: TimeWhenOrganicOrCompost,INT(ArrivalTime),1; 45$ DISPOSE: No; CompostSending ASSIGN: EarningsOnCompost=EarningsOnCompost+RemovedOrganicAmount*SellingPrice(6): CompostSent=CompostSent+RemovedOrganicAmount:NEXT(46$); Zipper ASSIGN: RemainingWasteOnHand=
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RemainingWasteOnHand+RestOfLoad+(PlasticAmountRemovedPlasticAmount)+(GlassAmount-RemovedGlassAmount)+(PaperAmountRemovedPaperAmount)+(OrganicAmount-RemovedOrganicAmount) :MARK(ZipperArrival); 20$ BRANCH, 1: If,RemainingWasteOnHand>=100,Zip,Yes: Else,DisposalOfLoadEntity,Yes; Zip ASSIGN: RemainingWasteOnHand=RemainingWasteOnHand-100; 63$ SIGNAL: 55; 22$ SEIZE, 1,Other: Zipper,1:NEXT(23$); 23$ DELAY: 2,,Other:NEXT(49$);

49$ ASSIGN: TotalRemainingWasteRemoved=TotalRemainingWasteRemoved+100; 24$ RELEASE: Zipper,1; 48$ TALLY: TimeWhenZipped,INT(ArrivalTime),1; 60$ TALLY: ZippingInterval,TNOW-ZipperArrival,1; 33$ ASSIGN: CostOfLandfilling=CostOfLandfilling+100*LandfillCost:NEXT(DisposalOfLoadEntity); DisposalOfLoadEntity QUEUE, 61$ WAIT: 62$ TALLY: 21$ DISPOSE: EndQueue; 55; ZippingInterval,INT(ZipperArrival),1; No;

MetalWarehouse ASSIGN: EarningsOnMetal=EarningsOnMetal+(MetalRemovedOnHand)*SellingPrice(1); 29$ ASSIGN: MetalRemovedOnHand=0; 51$ DISPOSE: No; DummyQ2 12$ QUEUE, WAIT: DummyQ2; 8,1:NEXT(ReleaseMetalGatherer);
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ConvDummy 53$ CraneDummy 57$ 59$ 38$ 40$ 42$ 41$

QUEUE, WAIT: QUEUE, SEIZE, RELEASE: CREATE, SIGNAL: COUNT: DISPOSE:

ConveyorDummy; 7,1:NEXT(ReleaseConveyor); DummyQ; 1,Other: ConveyorR,1:NEXT(59$); Crane,1:NEXT(ConveyorBranch); 1,36*60:36*60:NEXT(40$); 1,NQ(OrganicWasteQueue); OrganicTruckLeft,1; No;

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3.3 Experiment Frame

PROJECT, ATTRIBUTES: "IE372 - Term Project","Jelkala",,Yes,No,No,No,No,No,No,No,No,No,No; PlasticAmount,DATATYPE(Real): NumberofLoads,DATATYPE(Real): OrganicLife,DATATYPE(Real): OrganicVsCompost,DATATYPE(Real): RemovedPaperAmount,DATATYPE(Real): PaperAmount,DATATYPE(Real): RestOfLoad,DATATYPE(Real): GlassAmount,DATATYPE(Real): RemovedOrganicAmount,DATATYPE(Real): RemovedGlassAmount,DATATYPE(Real): ArrivalTime,DATATYPE(Real): OrganicAmount,DATATYPE(Real): MetalAmount,DATATYPE(Real): RemovedPlasticAmount,DATATYPE(Real): ZipperArrival,DATATYPE(Real); CraneStorage; 8,MetalRemovedOnHand,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 9,TotalMetalRemoved,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 10,EarningsOnMetal,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 11,PlasticRemovedOnHand,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 12,TotalPlasticRemoved,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 13,EarningsOnPlastic,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 14,GlassRemovedOnHand,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real):
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STORAGES: VARIABLES:

15,TotalGlassRemoved,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 16,EarningsOnGlass,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 17,TotalPaperRemoved,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 18,EarningsOnPaper,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 19,TotalOrganicRemoved,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 20,OrganicSent,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 21,CompostSent,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 22,EarningsOnCompost,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 23,EarningsOnOrganic,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 24,TotalRemainingWasteRemoved,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 25,RemainingWasteOnHand,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): 26,CostOfLandFilling,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real): ConveyorSize,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real),9: SellingPrice(6),CLEAR(System),CATEGORY("NoneNone"),DATATYPE(Real),2.55,0.05,0.76,0.28,0.17,0.10: LandfillCost,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real),0.32: DeportingTime,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real),1.2: WarehouseSendingLimit(2),CLEAR(System),CATEGORY("NoneNone"),DATATYPE(Real),300,1000: NumberOfManualProcessArea,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real),2: WorkersIn1,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real),10: WorkersIn2,CLEAR(System),CATEGORY("None-None"),DATATYPE(Real),10; QUEUES: EndQueue,FirstInFirstOut,,AUTOSTATS(Yes,,): OrganicWasteQueue,FirstInFirstOut,,AUTOSTATS(Yes,,): ConveyorDummy,FirstInFirstOut,,AUTOSTATS(Yes,,): Dummy,FirstInFirstOut,,AUTOSTATS(Yes,,): DummyQ,FirstInFirstOut,,AUTOSTATS(Yes,,): PortQ,FirstInFirstOut,,AUTOSTATS(Yes,,): Conveyor,LowValueFirst(ArrivalTime),,AUTOSTATS(Yes,,): DummyQ2,FirstInFirstOut,,AUTOSTATS(Yes,,): CraneQ,FirstInFirstOut,,AUTOSTATS(Yes,,);

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RESOURCES: 1,CompostTruck,Capacity(1),,Stationary,COST(0.0,0.0,0.0),,AUTOSTATS(Yes,,),EFFICIENCY(1,): 2,OrganicTruck,Capacity(1),,Stationary,COST(0.0,0.0,0.0),,AUTOSTATS(Yes,,),EFFICIENCY(1,): 4,Port,Capacity(2),,Stationary,COST(0.0,0.0,0.0),,AUTOSTATS(Yes,,),EFFICIENCY(1,): 5,Crane,Capacity(1),,Stationary,COST(0.0,0.0,0.0),,AUTOSTATS(Yes,,),EFFICIENCY(1,): 6,Worker,Capacity(20),,Stationary,COST(0.0,0.0,0.0),,AUTOSTATS(Yes,,),EFFICIENCY(1,): 7,ManualProcessArea,Capacity(2),,Stationary,COST(0.0,0.0,0.0),,AUTOSTATS(Yes,,),EFFICIENCY(1,): 8,Zipper,Capacity(1),,Stationary,COST(0.0,0.0,0.0),,AUTOSTATS(Yes,,),EFFICIENCY(1,): 9,MetalGatherer,Capacity(1),,Stationary,COST(0.0,0.0,0.0),,AUTOSTATS(Yes,,),EFFICIENCY(1,): ConveyorR,Capacity(9),,Stationary,COST(0.0,0.0,0.0),,AUTOSTATS(Yes,,),EFFICIENCY(1,); COUNTERS: LoadsEnteredSystem,,Replicate: ManuelLeave,,Replicate,"cikanlar.dat": SmallTruckEnter,,Replicate: ManuelEnter,,Replicate: CraneC,,Replicate: OrganicTruckLeft,,Replicate; TimeWhenZipped: TimeWhenOrganicOrCompost: ZippingInterval: TimeAtStation,"TimeAtStation.dat"; 8,TotalMetalRemoved: 9,MetalRemovedOnHand: 10,EarningsOnMetal: 11,TotalPlasticRemoved:
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TALLIES:

DSTATS:

12,PlasticRemovedOnHand: 13,EarningsOnPlastic: 14,TotalGlassRemoved: 15,GlassRemovedOnHand: 16,EarningsOnGlass: 17,TotalPaperRemoved: 18,EarningsOnPaper: 19,TotalOrganicRemoved: 20,TotalRemainingWasteRemoved: 21,RemainingWasteOnHand: 22,CostOfLandfilling: 24,CompostSent: 25,EarningsOnCompost: 26,OrganicSent: 27,EarningsOnOrganic: 45,NC(ManuelLeave),,"outs.dat": NQ(OrganicWasteQueue): NSTO(CraneStorage): NQ(CraneQ): NQ(Dummy): NR(ConveyorR): NR(MetalGatherer): NR(ManualProcessArea): NR(Crane): NQ(Conveyor); OUTPUTS: REPLICATE, EXPRESSIONS: (0.7/10));
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NC(ManuelLeave),"outputdavg.dat"; 1,0.0,(24*60*30),Yes,Yes,0.0,,,24.0,Minutes,No,No,,,No,No; DelayExp,DATATYPE(Native),0.12/LOG(11): EfficiencyExp(4),DATATYPE(Native),(1-(0.6/10)),(1-(1.8/10)),(1-(0.3/10)),(1-

4. Pilot Run Results

4.1 Verification

Number of trucks arrived to facility and the loads flowing in the facility should be consistent:

SmallTruckEnter x Expected Number of Loads = LoadsEnteredSystem

Theoretical Number of trucks arrived (1) Expected number of loads per truck (2) Expected number of loads ported (3) Number of single loads entered the waste removal area 1420 20 28400

Output Results

Explanation

E[UNIF (10,30)] 28237 10012 (1) x (2)

Every load entered the system should be traceable:

LoadsEnteredSystem =

NQ(CraneQ) + NR(Crane) + NR(Conveyor) + NR(MetalGatherer) + NR(ManualProcessArea) + Number of entities left the station

28237 = 18224 + 1 + 9 + 1 + 2 + 10000

Our model works correctly, in other words our model is valid to investigate such system, because the results are consistent with the statistical expectations before any simulation run:

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Theoretical Number of trucks arrived (1) Expected number of loads per truck (2) Expected number of loads ported (3) Number of single loads entered the waste removal area (4) Expected total metal amount removed (5) Expected total plastic amount removed (6) Expected total organic removed (7) Expected organic shipped to warehouse (8) 1420 20 28400

Output Results

Explanation

E[UNIF (10,30)] 28237 10012 (1) x (2)

30036 329394,8 116389,5 93111,6

30117 329030 116160 4776,2

(4) x E[UNIF(1,5)] (4) x E[UNIF(30,40)] x (1-0,6/10) (4) x E[UNIF(5,20)] x (1-0,7/10) (7) x E(UNIF(1,2)+UNIF(0,1.5) <= 3 ) *

* It is assumed that the time spent in the removal area is very small when compared to a day.

Only the last value is not consistent, this is because, in the real model there are long queues before any lot enter the waste removal area. Therefore, usually, the three day limit for the organic wastes, which will be sent to warehouse, has been already exceeded even when the lot is picked by the crane.

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4.2 SIMAN Summary Report

ARENA Simulation Results Department of Industrial Engineering Summary for Replication 1 of 1

Project: IE372 Analyst: Jelkala Replication ended at time Base Time Units: Minutes TALLY VARIABLES : 43200.0 Minutes

Run execution date : 5/19/2011 Model revision date: 5/19/2011

Identifier Average Half Width Minimum Maximum Observations _______________________________________________________________________________________________ TimeWhenZipped TimeWhenOrganicOrCompost ZippingInterval TimeAtStation 13502. 14579. 7.1233 13500. (Corr) (Corr) .03084 (Corr) 58.987 1432.8 .19669 49.726 27288. 27986. 23.740 27296. 3286 10000 13283 10000

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DISCRETE-CHANGE VARIABLES

Identifier

Average

Half Width

Minimum

Maximum

Final Value

___________________________________________________________________________________________________

TotalMetalRemoved MetalRemovedOnHand EarningsOnMetal TotalPlasticRemoved PlasticRemovedOnHand EarningsOnPlastic TotalGlassRemoved GlassRemovedOnHand EarningsOnGlass TotalPaperRemoved EarningsOnPaper TotalOrganicRemoved TotalRemainingWasteRemoved RemainingWasteOnHand

15034. 148.89 37957.

(Corr) 2.0517 (Insuf)

.00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000

30117. 299.99 76151.

30117. 254.26 76151.

1.6426E+05 (Corr) 491.25 8188.5 61346. 495.85 46246. 36492. 10217. 58103. 2.4305 (Corr) (Corr) 5.1399 (Insuf) (Corr) (Corr) (Corr)

3.2903E+05 3.2903E+05 999.92 16405. 915.30 16405.

1.2301E+05 1.2301E+05 999.79 93362. 73003. 20440. 162.08 93362. 73003. 20440.

1.1616E+05 1.1616E+05 3.2860E+05 3.2860E+05 99.990 84.056 23

1.6405E+05 (Corr) 49.900 .51058

CostOfLandfilling CompostSent EarningsOnCompost OrganicSent EarningsOnOrganic NC(ManuelLeave) NQ(OrganicWasteQueue) NSTO(CraneStorage) NQ(CraneQ) NQ(Dummy) NR(ConveyorR) NR(MetalGatherer) NR(ManualProcessArea) NR(Crane) NQ(Conveyor)

52497. 50680. 5068.0 4531.0 770.28 4993.2 249.83 .46355 8809.7 7.9945 8.9936 .99911 1.8678 .99953 .00000

(Corr) (Insuf) (Insuf) (Insuf) (Insuf) (Corr) (Corr) .00100 (Corr) (Corr) (Corr) (Corr) .00552 (Corr) (Insuf)

.00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000 .00000

1.0515E+05 1.0515E+05 1.1139E+05 1.1139E+05 11138. 4776.2 811.96 10000. 504.00 1.0000 18226. 8.0000 9.0000 1.0000 2.0000 1.0000 .00000 11138. 4776.2 811.96 10000. .00000 1.0000 18224. 8.0000 9.0000 1.0000 2.0000 1.0000 .00000

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COUNTERS Identifier Count Limit _____________________________________________________________ LoadsEnteredSystem ManuelLeave SmallTruckEnter ManuelEnter CraneC OrganicTruckLeft 28237 10000 1420 10002 10012 20 Infinite Infinite Infinite Infinite Infinite Infinite

OUTPUTS Identifier Value _____________________________________________________________ NC(ManuelLeave) 10000.

Simulation run time: 0.02 minutes. Simulation run complete.

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4.3 Alternative Scenarios

According to our simulation outputs and observations, the main problem is the huge accumulation in the storage area before the crane. Given the situation, the time limit of 180 minutes seems unattainable. Although, true utilization of the crane is near 50%, there is a large queue preceding it. This is because; succeeding stations works at almost full utilization levels. Therefore, main purpose of the improvements that could be done on the system should be about increasing resource capacities.

Rather than increasing number or capacities of all resources at once, considering step by step improvements is a more advisable way due to managements consideration about the compensation of the investment within two years. Namely, for instance, one should consider the effects of hiring more workers for the manual process area and duplicating the numbers of the manual process areas by considering both the additional income that firm generate and the cost of the implementation for the company in two cases. The main benefit of increasing number of workers will be that the more workers will gather more collected waste in less time, due to efficiency and time expressions used in the model. Therefore, increase in the worker level at different process areas could yield different profit margins and this should also be considered.

Moreover, there are such details that can be missed. Such as, increasing numbers of or the capacity of conveyors would not be so effective because they are succeeded by a station (metal gatherer) that operates at near full capacity. Also, considering buying a conveyor and a metal gatherer could be more effective rather than just buying one of them. Therefore, such relations among the resources of the facility should be taken into account while deciding on the policy that will be followed.

In addition to those resource capacity improvements, some other options could be beneficial for the profit margins of the firm. Firstly, for instance, separation of the organic could be done at a more upstream station if it is possible, so that the rate of organic waste that turning into compost, which has a lower profit margin, is reduced and sales to the power plant would be increase. Considering organic waste, although it is not mentioned, decreasing interarrival time of the trucks

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could also increase the level of organic waste sent to power plant. Secondly, it is obvious that the station operates continuously but process areas operate discretely, in other words, one load at one time. If this discrete flow could change into a more continuous flow after loads are entered to system, station could benefit more. For instance, when second group of workers are collecting, the first group of workers are idle in manual process area.

III. Conclusion
To conclude, it could be stated that the aim of the Part I of the project was to find alternative scenarios to the given problem by using a simulation model and its output. With this aim, this report gives the problem situation and then the structure of the model which is constructed to simulate the problem environment. Frames and outputs of the model with the assumptions are presented and in the next part, the model is tried to be verified with statistical and numerical methods. In Part II of the project, the alternative scenarios which are given in the last part of this report will be examined and the optimal one will be chosen.

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