Flexsim Tutorial 8

1. Objective of problem:
 To understand the significance of continuous production system.
 To understand and identify the significance differences between batch production and continuous production.
2. Problem Statement
An automobile ancillary industry is implementing the batch production system in one of the plant located in the western part of India.
The manufacturing plant is producing crank shafts to their customer. The management of automobile ancillary industry has observed a
huge work in process inventory in the production shops. The organization management has decided to upgrade the production process
from the batch production to continuous production. They have given task to the expert team to implement the project with the
acceptance organization employees. To get the acceptance, the expert team has decided to simulate the batch production and continuous
production. They have planned to educate the organization employee to adopt the continuous production instead of batch production by
simulating both the conditions in Flexsim.

Batch Production Setup:

In the present batch production, the organization is performing 22 different operations on 11 operating machinery in the different
production shop. The batch size is 5 per lot. Each set of machines are two only. It is given in Table 1.1. The flow of materials to the
different operative machines in the batch production is given in Figure 1.1. The layout of production shops are given in Figure 1.2. The
milling machines are arranged set 1 to set 3from left side. The grinding machine set 4 is located beside the super finishing operations.
The details of time taken to perform operations on each machine are given in Table 1.1.
 Super Finishing Machine 1
Grinding Machine set 4
Grinding Machine 2

Grinding Machine 3
Grinding Machine 1
Milling Machine- 1

Milling Machine- 2

Milling Machine-3
Lathe Machine- 2
Lathe Machine-1

Lathe Machine 3
Figure 1.1: The flow of materials to the different operative machines in the batch production

Table 1.1: The details of time taken to perform operations on each set of machines

S.No Type of Machine Number of machines Cycle Time/ Process Time in Second s
1 Lathe Machine Set-1 2 187
2 Lathe Machine Set -2 2 92
3 Lathe Machine Set-3 2 90
4 Milling Machine Set-1 2 90
5 Milling Machine Set-2 2 190
6 Milling Machine Set-3 2 200
7 Grinding Machine Set-1 2 88
8 Grinding Machine Set-2 2 90
9 Grinding Machine Set-3 2 100
10 Grinding Machine Set-4 2 198
11 Superfinishing Set-1 2 210
 Figure 1.2: The layout of production shops

Continuous Production set up:

In the Continuous production, the organization is performing 22 different operations on 11 operating machinery in the different production shop. However,
all machines are arranged as per sequence of operations. This kind of model required to establish five different production lines as per operational sequence
on the product. The flow of materials to the different operative machines in the continuous production is given in Figure 1.3. The details of time taken to
perform operations on each machine are given in Table 1.2.

Grinding Machines set4

Super Finishing Machine 1

Grinding Machine 1

Grinding Machine 2

Grinding Machine 3
Milling Machine- 1

Milling Machine- 2

Milling Machine-3
Lathe Machine- 2
Lathe Machine-1

Lathe Machine 3
Figure 1.3: The flow of materials to the different operative machines in the continuous production

Table 1.2: The details of time taken to perform operations on each set of machines

S.No Type of Machine
1 Lathe Machine Set-1
2 Lathe Machine Set -2
3 Lathe Machine Set-3
4 Milling Machine Set-1
5 Milling Machine Set-2
Number of machines Cycle Time/ Process Time in Second s
2 187
2 92
2 90
2 90
2 190
 6 Milling Machine Set-3 2 200
7 Grinding Machine Set-1 2 88
8 Grinding Machine Set-2 2 90
9 Grinding Machine Set-3 2 100
10 Grinding machine set-4 2 198
11 Superfinishing Set-1 2 210
Find Out:

1. Production output per initial 24 hours in both conditions.

2. Inventory level at different work stations in both conditions after 24 hours.
3. Time taken to deliver first finished product from super finishing operation in both conditions.
4. Bar chart for utilization of machines after 24 hours.
5. Bar chart for utilization of each operator after 24 hours.
6. Apply Line Balancing technique to utilize manual resources effectively. How many manual resources are required to perform operations without any
production losses in the aspect quantity?

Please upload flexsim file screen shot of both conditions and by displaying solutions the above set of questions on the screen shot.