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Version: 3.5
SigmaFlow VSM and all its documentation are Copyright © 2001 – 2008, Compass Partners, Inc. All
Rights Reserved.
SigmaFlow Coach and all its documentation are Copyright © 2001 – 2008, Compass Partners, Inc. All
Rights Reserved.
SigmaFlow and all its documentation are Copyright © 2001 – 2008, Compass Partners, Inc. All Rights
Reserved.
SigmaFlow Insights and all its documentation are Copyright © 2001 – 2008, Compass Partners, Inc. All
Rights Reserved.
Six Sigma is a registered trademark of Motorola, Inc.
SigmaFlow is a trademark of Compass Partners, Inc.
Microsoft Project is a trademark of Microsoft, Inc.
All other marks are the property of their respective owners.
System Requirements
The minimum system requirements for installing and running SigmaFlow VSM and
SigmaFlow Simulator are listed below:
Windows® XP, Windows® 2000, Windows® Vista
Intel Pentium processor, 300 MHz or greater
Microsoft .Net Framework 2.0
RAM: 256 MB minimum (512 MB Recommended)
Hard Disk: Minimum 100 MB of free hard disk space
Drive: CD-ROM Drive (for installation from CD)
Microsoft Visio 2003 or Microsoft Visio 2007
5 • System Requirements
VSM Overview
SigmaFlow VSM provides a powerful value stream mapping and analysis solution for process
improvement.
6 • VSM Overview
Getting Started with VSM
This section provides a quick overview of various features that can help you to get start your
project with SigmaFlow VSM. SigmaFlow VSM allows users to perform lean benchmarking
analysis prior to doing a full value stream map analysis.
Lean Benchmarking
1. Launch SigmaFlow VSM.
2. On startup screen, click “Create a Value Stream Map” icon. It will launch the drawing canvas
of Value Stream Map on right and stencils on left.
3. Step1: Drop basic process steps on the map using the stencils on the drawing canvas.
4. Step2: Go to tools menu; Tools > Takt Time Calculator and define “Available Work Time”
by setting values in different fields and “Customer Demand”. This will provide the “Takt
Time” as well as “Throughput”.
5. Step3: Next, right click on any shape on the drawing and select “Open Activity Task Pane”.
This will launch the “Task Pane” on the right side of the drawing (if not already displayed).
9 • SigmaFlow VSM
3. Recent Files: Recent file are listed in “Recent Files” section.
For more details on the menu options and the toolbar, please refer to Microsoft Visio help
documents. Following symbols are provided to support value stream mapping:
10 • SigmaFlow VSM
All of the above shapes are organized in 4 different stencils (categories):
1. VSM – All Shapes. Includes all shapes in the value stream mapping solution. Users could
add more to the stencil. Refer to Microsoft Visio help for how to.
2. VSM – General. All general shapes.
3. VSM – Material Flow. Includes all shapes related to material flow.
4. VSM – Information Flow. Includes all shapes related to information flow.
11 • SigmaFlow VSM
1. Title bar
2. Menu bar and menu items
3. Header navigation area
4. Application logo icon
5. Clickable header buttons with drop down items
6. SigmaFlow brand strip
7. Toolbars
8. Task Pane area with drop down selections
9. Drawing canvas
10. Shapes window
11. Stencils
12. Shapes
12 • SigmaFlow VSM
• Header button has a clickable dropdown arrow. You can either go to core pages or click on
the arrow beside it to navigate to a particular page.
• These buttons will open the core pages of the application from which you can browse through
the whole application from data mapping to simulation or settings to reports viewing.
• Upon launch, the drawing page is selected by default and users are allowed to jump to any
page by just clicking on the header icons.
Task Pane
• Task pane is used for viewing/adding/modifying the shape related data. To view the shape
related data in the task pane, click on any of the shape. If task pane is not visible, it can be
activated either from View > Task Pane or by right clicking on the shape and selecting “Open
Activity Task Pane”.
• You can view different task properties (Simulation, Activity Description etc.) by selecting is
from the dropdown arrow of task pane heading.
• Task pane is available for every shape in the stencils
13 • SigmaFlow VSM
Shapes Pane
• Shape pane includes different stencils for drawing and each stencil has a set of shapes that can
be used in drawings. Since SigmaFlow VSM is Visio based application, the working of
shapes pane is similar to Visio.
Drawing Canvas
• Drawing canvas area is reserved for drawing and the functionality is very much similar to
Visio.
14 • SigmaFlow VSM
Header Navigation Area Core Pages
Drawing
• The primary purpose of the drawing header icon is to take the users to the drawing page. The
drawing page is the default page when you launch a new or existing file.
• To create a new drawing, click on the header arrow icon beside the “Drawing” icon and select
the appropriate drawing type.
15 • SigmaFlow VSM
Simulation
• Clicking on simulation header button opens the simulation core page as shown above. From
this page, you can :
o Run simulation – runs a simulation with the default random number stream
o Change random number – starts a new simulation with a new random number
stream to capture the effect of variability
o Make multiple settings – makes multiple runs simultaneously with different random
number streams
o Change clock settings – specifies when and how long the simulation is run
o Addition simulation settings – change setting for calendars, distribution, labels and
more
Note: This feature requires SigmaFlow Simulator license.
16 • SigmaFlow VSM
Tools
• You can access two tools from the tools core page.
1. Takt Time Calculator – defines process demand, throughput, available time and EPE.
2. Data Collection Sheet –collects cycle time data for various activities on the map.
Reports
17 • SigmaFlow VSM
o Value Stream Mapping – identifies bottlenecks, total inventory, throughputs and
effective cycle time based on customer demand
o Lean Six Sigma – analyzes your process based on Six Sigma principle
o Value Analysis – identifies value added, non value added and business value added
activities.
o Custom – customizes your reports as per your needs.
• Simulation reports - lets you view complete snapshot of simulation data
o Simulation Results – provides one page summary of you simulation results
o Trial Results – summarizes the results of multiple runs
o Compare Report - compares various runs side by side
o Profit and Loss statement – views cycle time data by transaction collected by a
portion of or for complete process map
o Transaction Log Report – views activity based costing method based income
statements as per fixed and variable costs defined in the model
Settings
Setting area allows users to set preferences for drawing, numeric data and/or simulation:
• Drawing Settings: Used for basic “file settings” and “preferences” similar to Microsoft Visio
• Numeric Data Settings: Used to define numeric data fields for your map
• Simulation Settings: Used to define “Simulation preferences and “Model settings”
18 • SigmaFlow VSM
Working with Task Pane
Task pane is used to display shape related data properties and is available for all shapes in all
stencils. Following options are available in the Task pane (click on arrow to view these).
1. Getting Started
2. Activity Description
3. Numeric Data
4. Simulation Data
5. Simulation Result
6. Drawing Explorer
Getting Started
Getting started section provides valuable reference links to specific VSM application areas
available on SigmaFlow website.
• Lean Benchmarking
• Value Stream Mapping
• Basic Process Mapping
• Value Analysis
• Business Process Simulation
19 • SigmaFlow VSM
Activity Description
For any shape, define the Activity ID, description and notes. You can apply your custom
formatting to the Notes section.
Numeric Data
One of the most important steps in value stream mapping is capturing and displaying measurement
data for various steps. This, combined with other data defined in Takt Time Calculator helps you
analyze your current state as well as future state. SigmaFlow VSM solution allows you to
capture/define data at individual shape level. To define data at individual shape level, follow the
steps below:
1. Right click on the shape and select “Open Activity Task Pane” (if the Task Pane is not already
displayed). Make sure you see a solid border around the shape along with green nodes.
20 • SigmaFlow VSM
2. Now you should see the activity task pane at the right side of the application. Select
“Numeric Data” from the Task pane dropdown to see the numeric data.
3. Check the box in this column if you wish to display this data on the value stream map on the
drawing. By default, any time you enter a value, this box gets checked. When refreshed, the
data gets displayed just below the shape on the map.
4. You can go directly to Numeric Data Settings by clicking “More field properties” link.
5. The fields listed in the numeric data task pane can be customized through the Settings area
(See Header Navigation area). Numeric data task pane has three different sections; (a)
Method of Analysis, (b) Fields and (c) Calculated fields as described below.
21 • SigmaFlow VSM
• Method of Analysis
o Methodology: Selecting any option will show only those fields in “Fields” and
“Calculated Fields for which “Default On” was selected in the “Numeric Data
Settings” form. Methodology dropdown contains the following options:
Lean Benchmarking
Value Analysis
Value Stream Mapping
Lean Six Sigma
Custom
o Type: Set the type of the object. Used mostly in Value Stream Mapping to define
the shape of the object.
o Predecessor: Dropdown options with all predecessors (if more than one). Required
for “Lean Benchmarking” analysis where a predecessor is required for “Part Arrival
Rate” calculations.
• Fields: This section is context sensitive. The fields displayed here will be based on what is
selected in the “Methodology” dropdown above. Click on “More field properties” link to add
more fields from “Numeric Data Settings”. As you enter data in various fields, the
checkboxes (next to field names) gets checked. The purpose of this checkboxes is to display
the selected fields on the process map (below each object). Please note that you will have to
click on the “Refresh” button to refresh the screen with display fields.
22 • SigmaFlow VSM
o “Cycle Time”: In SigmaFlow VSM, you can set the “Cycle Time” to be a manually
entered number or a calculated number (see below). Selecting “Use Manual Value”
will allow users to enter the value directly in the cycle time data box. Selecting “Use
Calculated Value” will make this field non-editable and convert the “Cycle Time”
name to a hyperlink. Clicking on this link will take the user to Data Collection Sheet
where users can enter detailed cycle time transaction level data. Data Collection
Sheet automatically calculated the average value which will get transferred to the
“Fields” area in the Task pane.
• Calculated Fields: This section includes non-editable calculated fields. The calculations are
based on the data defined in the “Takt Time Calculator” form and the “Numeric Data
Settings” form. For calculation details, please refer to “Numeric Data Settings” section.
Simulation Data
“Simulation Data” task pane allows simulation data to be defined for various object types.
SigmaFlow VSM supports following object types: (a) Work Start, (b) Storage, (c) Work Center,
23 • SigmaFlow VSM
(d) Work Center Storage, (e) Work Finish, (f) Resource, and (g) Pool Resource. We will discuss
each data properties of each type in the Simulation section.
Simulation Result
“Simulation Results” task pane displays simulation results for various object types. We will
discuss each simulation results properties of each type in the Simulation section.
Drawing Explorer
Drawing Explorer is used to explore all the objects in the map in tree view. It can be used to
quickly find the shapes available in various tabs of your process map.
24 • SigmaFlow VSM
Working with Menus
File Menu
New: Use the “New” option to create a new Value Stream Map, Process Map, Process
Map with Horizontal Swimlane, or Process Map with Vertical Swimlane
Open…: Open an existing file from your machine. 3 types of files are allowed to be opened;
VSM files with extension .vsm, Visio files with extension .vsd and Visio template
files with extension .vst
Open Example Library: Open an existing example library file from SigmaFlow default Example
Library Folder
Close: Use this option to close the file
Save: Save the file
Save As…: Save the file with a different name and / or type. SigmaFlow VSM files can be
saved as VSM Drawing files (.vsm), Visio Drawing files (.vsd), Visio Template files
(.vst) and Scalable Vector Graphics (.svg).
Save As Web Page: Save the file as a webpage
Shapes: Allow you to open an existing stencil with shapes
Page Setup…: Page setup properties
Print Preview: Used for print preview
Print: Used for printing the file
Recent Files: List all recently opened files
Exit: Use this option to exit the application
Edit Menu
Undo: To get last drawing changes, click on Undo menu/button.
Redo: To get latest drawing changes, click on Redo menu/button.
Cut: To move drawing shape, select drawing shape(s) and click on Cut menu/button.
Copy: To make identical copy of shape(s), click on Copy menu/button.
Paste: Select any shape(s) from drawing and click Copy button to copy shape(s). Now click
Paste menu/button to paste the selected shape(s) on drawing.
Select All: In order to select all activities / shape(s), click on “Select All” menu.
Delete: To delete drawing activities (shapes, arrows etc), select shape and click “Delete”
menu.
Replace: Clicking on Replace menu will open a dialog box which can be used to find and
replace specified text in shapes in the active drawing.
26 • SigmaFlow VSM
Find what: Specifies the text you want to find. You can type or paste text into this
field. To search using text you previously searched for, click the down arrow and
then click the text on the list.
Replace with: Specifies the text that you want to use as replacement text. You can
type or paste text into this field. To replace with text you previously used, click the
down arrow and then click the text on the list.
Special: Displays a list of special characters for which you can search.
Search:
• Selection: Searches only the current selection.
• Current page: Searches only the current page.
• All pages: Searches all pages in the open drawing.
Options:
• Match case: Finds only those occurrences that have the exact
combination of uppercase and lowercase letters specified in the Find what
box. Matches the case of letters as they were originally typed, regardless of
whether the text has been formatted using Small Caps or All Caps
formatting.
• Match character width: Finds only those occurrences that have the exact
character width specified in the Find what box. For example, the Katakana
alphabet can be represented with a narrow character or a wide character.
• Find whole words only: Finds occurrences that are complete words and
not parts of larger words. For example, if you type for in the Find what box,
all instances of "for" are found but "forest" is ignored.
Replace: Replaces the Find what text with the Replace with text, and then finds the
next occurrence.
Replace All: Replaces all occurrences of the Find what text with the Replace with
text.
SigmaFlow VSM • 27
Find Next: Finds and selects the next occurrence of the text in the Find what box.
Delete Pages: Click on “Delete Pages” will open a dialog box which allows you to delete drawing
pages.
Page: Lists the pages in the drawing file. Select the page that you want to delete
from the list.
Update page names: Select this check box to renumber the remaining pages after
you delete one or more pages. (Applies only to pages that use default names such as
Page-1.)
Find: Click on Find button will open a Find dialog box which can be used to search for
specified text in shapes
28 • SigmaFlow VSM
Find what:
Specifies the text or characters you want to find. You can type or paste text into this
field.
Special:
Displays a list of special characters for which you can search. Clicking a special
character on the list adds it to the Find what box.
Search in:
• Selection: Searches only the current selection.
• Current page: Searches only the current page.
• All pages: Searches all pages in the open drawing.
• Shape text: Searches text stored in text blocks (text block: The text area
associated with a shape that appears when you click the shape with the text
tool or select it with the pointer tool.).
• Shape data: Searches text stored in shape data.
• Shape name: Searches shape names (the name you see under a shape in a
stencil).
• User-defined cell: Searches text stored in user-defined cells in the Shape
Sheet spreadsheet.
Options:
• Match case: Specifies that all found matches must have the exact
combination of uppercase and lowercase letters specified in the Find what
box.
• Match character width: Specifies that all found matches must have the
exact character width specified in the Find what box. For example, the
SigmaFlow VSM • 29
Katakana alphabet can be represented with a narrow character or a wide
character.
• Find whole words only: Specifies that all found matches must be complete
words and not parts of larger words. For example, if you type for in the Find
what box, all instances of "for" are found but "forest" is ignored.
Found in: Identifies that matching text was found in a text block, or shows the name
of the shape, shape data, or user-defined cell in which matching text was found.
Find next: Searches for the next occurrence of the text in the Find what box.
Check Spelling: Click on Check Spelling button will open a Spelling dialog box which can be used to
correct spelling mistakes in drawing.
View Menu
Shapes Window: Go to View menu and click Shapes Window will show/hide Shapes/Stencil
window.
Pan & Zoom Window: Use Pan & Zoom Window to zoom to magnify the drawing area,
30 • SigmaFlow VSM
• On the View menu, click Pan & Zoom Window.
• In the Pan & Zoom window, if you do not see a red box, drag to create
a red box.
• Resize the red box to fit the area that you want to magnify. The larger
the box, the more that you see of the page and the less the shapes are
magnified. The smaller the box, the less you see of the page and the
more the shapes are magnified.
Task Pane: Use Shapes Window option to show / hide Take Pane window.
Toolbars: On the view, point to Toolbars, will show a list of available toolbars which
will allow you to show/hide toolbar.
Rulers: Each drawing window has vertical and horizontal rulers that show
measurements at the scale (scale: A measure of the relationship between
actual distances and distances represented in a VSM drawing.
The intervals of the ruler correspond to the measurement units you set in the
Page Setup dialog box.
The units that appear on the ruler and the location of the zero point (zero
point: (1) the location of the 0 on the horizontal or vertical ruler. (2) The
point in the drawing window where the zero points of each ruler intersect.
By default, the zero point is the lower-left corner of the drawing page.), or
starting point, for both rulers are set in the Ruler & Grid dialog box.
When you move shapes in a drawing, faint lines appear on the rulers to
indicate the position of the shapes.
Show Grid: You can use this tool to show/hide vertical and horizontal Grid lines of
drawing
Snap To Grid: This option allows you to change snap property turn on or off (snap: The
ability of shapes, guides, grid lines, and other elements to pull shapes and
other elements into position when they are moved and sized.)
Header & Footer: The header and footer only appear on the printed drawing and on the screen
in print preview mode, not on the drawing page.
Header:
SigmaFlow VSM • 31
• Left: Specifies text that appears in the upper-left corner of the
page. You can type up to 128 characters. To add
automatically generated file information, such as the
page number or current date, click the arrow to the right
of the box, and then click an option.
• Center: Specifies text that appears in the top center portion of the
page. You can type up to 128 characters. To add
automatically generated file information, such as the
page number or current date, click the arrow to the right
of the box, and then click an option.
• Margin: Specifies the distance from the text to the edge of the
page. For a header, the distance is measured from the top
of the header text to the upper edge of the page.
Formatting > Choose Font: Click to open the Choose Font dialog box,
where you can set font type, font style, font size, and other text formatting
options.
Footer:
• Margin: Specifies the distance from the text to the edge of the
page. For footer, the distance is measured from the
bottom of the footer text to the lower edge of the page.
Zoom: You can use Zoom tool to magnify the drawing. You can set zoom value by
clicking arrow next to the zoom toolbar box and then click a zoom level.
32 • SigmaFlow VSM
Insert Menu
New Page: Click on New Page in view menu will open Page Setup dialog box which
contains multiple tabs. Page Properties tab will be selected by default which
allows you to add new page along with setting different properties.
Type: Lists properties for either the drawing page (the foreground page
(foreground: The top page of a drawing. Shapes on the foreground
page appear in front of shapes on the background page and are not
visible when you edit the background of the drawing.)) or the
background page (background: A page that you can assign to
another page to create multiple layers in a drawing. You can see
the shapes on a background when the page it is assigned to is
displayed. You must display the background page to select or edit
the background.).
Name: To change the name of the drawing page, type a name containing
up to 31 characters.
Background: Lists the names of the background pages in the drawing. The
background you select in this list is assigned to the current page. If
you haven't created a background page, the only item that appears
in the list is none.
Comments: To add a comment to the current drawing page, go to Insert menu, click
Comment. Type a comment of any length, and then click outside the
comment text box. Do any of the following:
• To view the comment text, click the comment tag.
SigmaFlow VSM • 33
• To reposition a comment, click the comment tag, and then drag it
to another location.
• To edit or delete a comment, right-click the comment tags, and
then clicks Edit Comment or Delete Comment.
Hyperlinks: Click on Hyperlink will open this dialog box to create a link between a
shape and drawing page and another drawing page or another file.
Picture: On the Insert menu, point to Picture, and then click From File. Locate the
folder that contains the picture you want to insert, click the picture file, and
then click Open.
Object: On the insert menu, click Object will open Insert Object Dialog box.
34 • SigmaFlow VSM
Create New: Inserts selected object type from Object type list.
Create From File: Inserts the contents of the file as an object into
your document so that you may activate it using the program which created
it.
Display as icon:
Inserts selected object type from Object type list in your drawing. It will be
displayed as an icon.
SigmaFlow VSM • 35
Format Menu
Text: Clicking on Text option will open Text Dialog box with the following
options:
36 • SigmaFlow VSM
Size: Sets the point size of selected text. A point is a traditional
measure used by typesetters and is equal to 1/72 of an
inch.
General:
To assign a custom color, click More Colors. In the Colors dialog box,
define the new color.
Language:
Specifies the language setting.
Transparency:
Specifies how opaque or transparent the text is. Zero percent is completely
opaque, and 100 percent is completely transparent.
Line: This dialog box options apply formatting settings such as pattern, weight,
color, ends and corner rounding to lines and arcs in a selected shape.
SigmaFlow VSM • 37
Line:
Pattern: From the list, select none, solid lines, dashed lines, or a
mixed pattern.
Weight: From the list, select the line thickness you want, or
specify a custom line thickness.
Color: Select from among the colors available in the color
palette.
Cap: Select round or square line caps to have the end of a line
appear rounded or squared. You can see this setting only
if the line weight is very thick.
Transparency: To set the transparency of the selected line from 0 percent
to 100 percent, move the slider.
Line ends:
Begin: Select the line end you want for the begin point of the
selected shape.
End: Select the line end you want for the end point of the
selected shape.
Begin size: Specify the size of the begin point of the selected shape.
End size: Specify the size of the end point of the selected shape.
Round Corners: Rounds the corners of the selected shape or shapes; the
higher the number, the rounder the corners.
Fill: These dialog box options apply fills (fill: The color and pattern inside a
closed shape.
38 • SigmaFlow VSM
Fill:
Pattern: Displays the current pattern for the selected shape's fill.
Select a new pattern, which can be blank or transparent
(None or pattern 0), solid (pattern 1), a bitmap pattern
(patterns 2 through 24), or a gradient pattern (patterns 25
through 40).
Pattern color: Select from among the colors available in the color
palette.
Shadow: These dialog box options apply shadow effects to selected shape(s).
SigmaFlow VSM • 39
Style: Sets the shadow style for the selected shape. Page Default
sets the shape to follow the page shadow style settings.
Corner Rounding: This dialog box displays buttons that apply different degrees of corner
roundness to a selected shape or shapes.
40 • SigmaFlow VSM
When you perform operations such as fragmenting and intersecting on
shapes that have round corners, the round corners are replaced by arcs.
Aspect ratio: Locks the ratio between a shape's height and width so that
its proportions won't change when you resize it.
SigmaFlow VSM • 41
Rotation: Locks a shape so that you cannot rotate it by using the
Rotation tool. You can still rotate a 1-D shape by
dragging its endpoints. To lock a 1-D shape against
rotation, you must lock its width.
Begin point: Locks the begin point of a 1-D shape to a specific location
so that it cannot be moved.
End point: Locks the end point of a 1-D shape to a specific location
so that it cannot be moved.
From selection: Locks the shape so it cannot be selected. For this setting
to take effect, you must also select Shapes in the Protect
Document dialog box.
From group formatting: Locks the formatting (color, fill, line, and
shadow) in sub-shapes so that they do not change if the
grouped shape is formatted. You can still format a sub-
shape by selecting it.
From theme colors: Locks the shape so that it does not change if a
color theme is applied.
From theme effects: Locks the shape so that it does not change if an
effects theme is applied.
42 • SigmaFlow VSM
Interaction style: Specifies whether a shape behaves like a line
(one-dimensional shape) or a box (two-dimensional
shape).
SigmaFlow VSM • 43
on drop option under Miscellaneous for the individual
shapes.
44 • SigmaFlow VSM
When a shape in a group is selected, the entire group is
selected.
SigmaFlow VSM • 45
When a shape in the group is clicked twice, the entire
group is selected.
Group data: Sets the group display order for text or shapes you've
created with the drawing tools. Hide hides the group's
text or shapes that you've created by using the drawing
tools except for a group's connection points or control
handles.
46 • SigmaFlow VSM
Define Styles: Use this dialog box to create, edit, rename, or delete styles (style: A
collection of attributes that has a name and is saved with a template or
drawing file.).
When you finish defining or revising a style, click this button to add the
new or revised style to the Name list and keep the dialog box open.
Delete: Deletes the style selected in the Name list. Any shapes
formatted with the deleted style are reformatted with the
Based on style. Any local formatting previously applied
to the shapes is preserved.
Rename: Opens the Rename Style dialog box, which displays the
name of the style selected in the Name list.
Includes:
Change: If a style is selected in the Name box, the Text, Line, and
Fill dialog boxes display the current style's attributes; if
no style is selected, the dialog boxes display either default
attributes or attributes for the style in the Based on box.
SigmaFlow VSM • 47
Text: Opens the Text dialog box, in which you can define text
attributes for the style.
Line: Opens the Line dialog box, in which you can define line
attributes for the style.
Fill: Opens the Fill dialog box, in which you can define fill
attributes for the style.
Hidden Style: Select this check box to hide the selected style. The style
name will not appear in the Style dialog box; it will only
be available from the Define Styles dialog box and in the
Drawing Explorer window.
Preserve local formatting on apply: Select this check box and click
the Apply button to have the style to the selected shapes
but keep any formatting you've already applied, such as
making text bold.
Create guide and glue shapes to it: Creates a guide and glues
selected shapes to the guide to retain the
alignment. When you move the guide, the shapes
move with it.
Grouping: You can group shapes together to move them all at once and then ungroup
the shapes to move them independently.
48 • SigmaFlow VSM
Create Group: Click the Pointer tool, drag a selection net (selection net:
A means of selecting more than one shape at a time by
dragging the Pointer tool to define an area that encloses
all the shapes to be selected.) around all the shapes that
you want to group and click Create Group.
UnGroup: Click the Pointer tool, drag a selection net (selection net:
A means of selecting more than one shape at a time by
dragging the Pointer tool to define an area that encloses
all the shapes to be selected.) around all the shapes that
you want to ungroup and click Ungroup.
Add to Group: To add a shape to a group, select both the shape and the
group to which you want to add the shape and click Add
to Group.
Rotate or Flip: Click the Pointer tool, drag a selection net (selection net: A means of
selecting more than one shape at a time by dragging the Pointer tool to
define an area that encloses all the shapes to be selected.) around all the
shapes that you want to flip.
Layout Shapes: With certain types of connected drawings, such as flowcharts and network
diagrams, you can use the Re-layout Shapes and Configure Layout
commands on the Shape menu to move shapes into position quickly after
you place them on the drawing page.
Placement:
Style: Click this option to set the style for how the shapes will
be laid out. Look at the preview to see if what you select
SigmaFlow VSM • 49
is what you want. Click Circular for drawings with no
direction, such as network drawings.
Direction: Click this option to set the direction that is used to place
shapes. Look at the preview to see if what you select is
what you want.
Alignment: Click this option to set how the shapes are aligned. This
option is enabled only if you select the Hierarchy
placement style.
Connectors:
Style: Click this option to set the type of drawing path, or route,
that is used to connect shapes. Look at the preview to see
if what you select is what you want.
Apply settings to: Determines whether drawing lays out only the
selected shapes or all of the shapes on the current page.
Enlarge page to fit drawing: Select this check box to enlarge the
drawing page to accommodate the drawing when shapes
are automatically laid out
Tools Menu
Takt Time Calculator: Launches the Takt Time calculator. Use this to define available time,
customer demand, EPE etc. Provides Takt Time and Throughput
information.
Data Collection Sheet: Collect Cycle time transactional data for each individual activity if required.
Simulation Menu
Note: To view the simulation menu, you will need to have the license for SigmaFlow Simulator.
SigmaFlow Simulator is an add-on to SigmaFlow VSM application. Please contact SigmaFlow for
licensing details. The Simulation menu contains the following options:
Simulator S:
50 • SigmaFlow VSM
Change Random Number and Run: Start a new run with a new random number stream
to capture the effect of variability.
Make Multiple Runs: Make multiple runs simultaneously, each with a different random
number stream and view the results in the Trial Results report.
Change Clock Setting: Lets you set the clock properties such as time unit, Start time, Warm
up period, Simulation run time etc.
Simulation Settings: Provides options to define/create different simulation objects such
as distributions, calendars, labels etc.
Simulation Preferences: Launches the Simulation preferences page to set the default model
behavior.
Help Menu
Microsoft Visio Help: Launches Microsoft Visio help
SigmaFlow Help: Launches SigmaFlow online help
SigmaFlow Reference Manual: Launches PDF version of SigmaFlow Reference Manual
Log File: Launches SigmaFlow log file. All SigmaFlow errors are logged in this log
file.
Unlock or Update License: Launches SigmaFlow license administrator window for users to
unlock or update license
Check for Updates: Allows users to do check for updates
About SigmaFlow: Provides the latest version of SigmaFlow VSM
SigmaFlow VSM • 51
Seeing all toolbar buttons
You can resize to display more buttons, or you can show all buttons on a toolbar. To see a list of
buttons that won't fit on a built-in, docked toolbar, click Toolbar Options at the end of the toolbar.
When you use a button that is not displayed on the toolbar, that button is moved to the toolbar, and a
button that has not been used recently is dropped to the Toolbar Options list.
Selecting a Shape
To work with a shape, you first select it on the drawing page, and then perform your task: apply
formatting, move the shape, align it, add text, or add data properties for example.
1. Click the Pointer tool on the Standard toolbar and then point to the shape on the drawing
page you want to select.
2. When the pointer turns into a four-headed arrow, click the shape.
To work with a shape, you first select it on the drawing page, and then perform your task: apply
formatting, move the shape, align it, add text or data properties, for example.
1. Click the Pointer tool on the Standard toolbar and then point to the shape on the drawing
page you want to select.
52 • SigmaFlow VSM
2. When the pointer turns into a four-headed arrow, click the shape.
Creating a Sub-Process
Sub-processes can be created for any shape on the drawing. Creating a sub-process creates a new
page with the same name of parent shape. Please note that some of the fields (ex. Cycle time) become
non-editable after it is converted to sub-process. All the data will now be calculated (rolled up)
according to the sub-process shape. To convert an activity shape into a sub-process, right click on the
shape to open the context menu and select “Create Sub-Process”.
SigmaFlow VSM • 53
Including Shape in Reports
When you exclude the shape, you will have less right click context menu option for this shape. You
can bring this shape back in reports by right clicking on the shape and selecting “Include in Reports”.
54 • SigmaFlow VSM
2. Header Icons (drop down menu): Click on “Settings” Header icon dropdown menu and select
“Numeric Data” from settings menu.
SigmaFlow VSM • 55
Salient features of “Numeric Data Settings” form include:
1. “Revert” button: This button is used to undo any changes in Numeric Data Settings form.
2. A change setting for drop down option (methodology) includes Lean Benchmarking, Value
Stream Mapping, Lean Six Sigma, Value Analysis and Custom. Based on the option selected
from the drop down, only check box value will change (check /uncheck). Users have the
option of excluding/including (uncheck/check) these boxes for any solution.
3. Numeric Data Settings form has following columns:
Column Description
Name
Checkbox. These checkboxes are used for:
a. Checked field will become the default field for that solution (Lean Six
Sigma, Lean Benchmarking etc).
b. Field will show in Task Pane and Reports (Lean Six Sigma, Lean
Benchmarking etc)
Field Name Name of the lean field to be used in various shapes on the map for
display/analyses purposes.
Field Type Drop down option to define the field type. Options include Processing time,
NVA time, Changeover Time, Inventory Amount, etc.
Data Type Data types. Options include Number, %, String, Date etc.
Data Format Option to shows whether the field is calculated or Manual.
Function Dropdown option to define Accumulation Rule. Options include Sum,
Average , Min, Max etc.
Default Unit Dropdown option to define unit. Options include Hours, Minutes, Seconds
etc.
Editing a Field: You can edit different field properties like default unit, function etc. by
either clicking on the field name or right clicking on the field name and selecting “Edit Field”
menu option. Once you select “Edit Field” option, a form will open form where the
appropriate data can be edited.
56 • SigmaFlow VSM
Adding a Field: To add a new field click on the “Add Field” button available below the top
table. Provide necessary information like Field Name and other properties in the “Add Field”
form. Once you save, this newly added field will appear in the Fields list. Please note that this
new field will be available for all solution methodologies but the check box value will only
check for that methodology that was selected at the time of creating field.
Deleting a Field: In order to delete fields from “Numeric Data Settings” form, click on the
“Trash” icon to the right of the field. If the “Trash” icon does not appear next to the field
name, this field cannot be deleted.
4. Definitions: Fields. Following is a combined list of all the fields in the Numeric Data
Settings form.
Field Name Description
Cycle Time It could be either Manual or Calculated. The time for one
product to move through a process step. This is
sometimes also referred as Total Cycle Time and / or
Processing Time. When Calculated option is used, users
are required to enter raw data in “Data Collection Sheet”.
SigmaFlow VSM • 57
NVA Time The time in a process step that a customer is not willing to
pay for
Changeover Time The time taken to change from producing one type of
product to another type of product.
Number of Resources Numbers of workers at a step
Resource Availability % The % of time operators are available for this step in the
process
Number of Shifts # of shifts for this step
Inventory Time Amount of time required to process a certain amount of
inventory
Inventory (#) Number of pieces between or at a process step
Transport Time This is the time from production of a batch at the
supplying resource to the arrival at the consuming
resource.
Transport Frequency Transportation Frequency
Defect (DPU) % % Defect at this step
Yield % for Defect It could be either User Entered or Calculated. % Yield at
this step. When Calculated option is used, then it is
(100% - Defect %)
Rework % % Rework at this step
Scrap % % Scrap at this step
Target Cycle Time It could be either Manual or Calculated. If Calculated, it
is calculated statistically and is equal to Six Sigma
Projected Cycle Time from Data Collection Sheet.
Number of Machines / Total number of machines at a station. Used for Lean
Station Benchmarking.
Machine Availability % % Availability of a machine
Move Batch Size Number of items in a move batch
5. Definitions: Calculated Fields. Following is a list of all the calculated fields in Numeric
Data Settings form.
Field Name Definitions
DPMO (PPM Defect) Defect Per Million Opportunities
= Average Defect (DPU) % x 1,000,000
Defect Sigma (No Shift) = NORMSINV(1- Average Defect (DPU) %/100)
Defect Sigma (1.5 Shift) = Sigma Value for Defect (No Shift) + 1.5
Yield % to Takt Time If Average Cycle Time = User Entered, then (Yield % to
Takt Time = 100%).
If Average Cycle Time is "Calculated", then this value
comes from Data Collection Sheet.
Cycle Time (Six Sigma Two Formulas:
Projected MAD) (a) If Average Cycle Time = User Entered, then (Cycle
Time (Six Sigma Projected MAD) = Average Cycle Time
+ 0.2 x Average Cycle Time). OR
58 • SigmaFlow VSM
x Average Operator Availability %) x (Number of
Machines x Average Machine Availability %)) +
(Changeover Time / Process Batch Size)
Cycle Time Score (Six Sigma) Good/Bad score. Calculated using the following
formula.
IF (Effective Cycle Time (Six Sigma Projected (MAD))
<= Takt Time, then "Good" ELSE "Constraint)
Cycle Time Sigma (No Shift) = NORMSINV(Yield % to Takt Time/100)
Cycle Time Sigma (1.5 Shift) = Sigma Value for Cycle Time (No Shift) + 1.5
Effective Cycle Time Greater of "Average Cycle Time" and "Total NVA
Time") /((1-Average Defect (DPU) % ) x (Total Number
of Operators x Average Operator Availability%) x (Total
Number of Machines x Average Machine Availability
%))] + [Changeover Time/Process Batch Size]
Takt Time Calculated based on the data defined in Takt Time
calculator. Changes based on # of shifts for individual
shapes.
Cycle Time Score Good/Bad score. Calculated using the following
formula.
If (Effective Cycle Time <= Takt Time, then "Good"
ELSE "Constraint)
Available Time / Shift Calculated based on the data defined in Takt Time
Calculator form. Changes based on # of shifts for
individual shapes.
Available Time / Day Calculated based on the data defined in Takt Time
Calculator form. Changes based on # of shifts for
individual shapes.
Total Inventory (#) Sum of all the fields (top section of Data Property form
for which Field Type = Inventory #)
Total Inventory Time Sum of all the fields (top section of Data Property form
for which Field Type = Inventory Time)
Lead Time (Process Boxes) Lead time for the process box. Calculated using the
following formula
If (Total NVA Time >= Total Processing Time, Total
NVA Time, Total Processing Time)
Lead Time (Inventory Boxes) Lead time for the Inventory shapes. Calculated using the
following formula
Greater of "Total Inventory Time" or [Total Inventory # *
Takt Time in Seconds / Available Seconds Per Day]
Value Add Time Value Add time for the object. Calculated using the
following formula
If (Total NVA Time >= Total Processing Time, then 0,
Else (Total Processing Time - Total NVA Time))
Right First Yield % Calculated using the following formula:
= (1 - Average Scrap % - Average Rework %) * 100
Traditional Yield % Calculated using the following formula:
= (1 - Average Scrap%/100) * 100
Process Batch Size Read from Takt Time Calculator
Workstation Capacity = Total Number of Machines per Station / Effective
Cycle Time
Part Arrival Rate If No Predecessor, then it is = "Throughput (Per Second)
from Takt Time Calculator
SigmaFlow VSM • 59
If Predecessor is defined, then it is = Predecessor's Part
Arrival Rate x Predecessor's Yield
Workstation Utilization % = Part Arrival Rate to a Machine x Effective Cycle Time
/ Total Number of Machines per Station
Wait in Batch Time = (Move Batch Size -1) x Effective Cycle Time
Raw Cycle Time = Effective Cycle Time + Wait in Batch Time
6. In addition following new fields have been added as Calculated Fields for calculating various
components of “Workload Balancing Graphs”.
60 • SigmaFlow VSM
(Machine Availability % / 100)))) * (Effective Six Sigma
Projected (MAD) Cycle Time - (Changeover Time/
Process Batch Size) - Base Cycle Time (LSS Graph)))
*LSS = Lean Six Sigma
2. Header Icon (drop down menu): Click on Tools Header Icon dropdown menu and select Takt
Time Calculator from tools menu.
3. Toolbar menu: Go to Tools menu and select Takt Time Calculator menu option (Tools > Takt
Time Calculator).
SigmaFlow VSM • 61
Available Work Time: Captures basic working time parameters. Available Time Per Shift
and Available Time Per Day are calculated as follows:
Mean Time between Setups Every Part Every (EPE) / Number of Products
Process Batch Size Mean Time between Setups x Throughput
62 • SigmaFlow VSM
1. SigmaFlow automatically calculates the Mean, Standard Deviation, and Six Sigma Projected
Mean Average Deviation Cycle Time. Mean Cycle Time is then transferred from here to the
Data Property forms.
2. By default, “Data Collection Sheet” shows only those activities for which “Cycle Time:
dropdown (in the Task Pane) was set as “Use Calculated Value”. Users can bring in more
activities by clicking the “Show/Hide Columns” icon in the Data Collection Sheet. These
activities will show up in the “Data Collection Sheet” as non-editable data.
3. Data Collection Sheet also has the capability of “Freezing” the column, show/hide columns
(If hidden, use the Show/Hide columns icon to show the column again), and converting the
column data to Manual or Calculated. Please note that if the data is already Manual, then
converting it to Calculated with use the “Mean” cycle time data and use it for all rows.
SigmaFlow VSM • 63
Customizing Data Collection Sheet
Clicking on customize button will open Customize Form.
64 • SigmaFlow VSM
It allows you to add, remove and set order of columns that you want to view in Data Collection Sheet.
There are two list boxes (Available Columns and Selected Columns) will show you a list of available
and selected columns. You can add or remove column either by double click on column name or select
multiple columns by pressing Ctrl Key, click column name then click Select or Remove button to add
or remove selected columns. Once you add or remove column(s), click save button to save changes.
You can also set the order in which columns will appear by selecting column name in Selected
Columns list and click Up and Down buttons to order them. You can also select multiple columns by
pressing Ctrl Key, click column name and click Up and Down buttons. Once you set columns in
certain order, click save button to save changes.
Scorecards
Once all the data has been captured for all the steps, you are ready to analyze this through scorecards.
Major enhancements have been made in scorecards so you can access all scorecards from one single
form by selecting scorecard dropdown option. You can launch scorecard through following ways:
1. Header Icons: Click on Reports Header Icon, click any scorecard report (Lean
Benchmarking, Lean Six Sigma etc.) under Scorecards Heading at reports page.
Note: If you don’t see “Simulation Reports” section in your version of the VSM application
then you will require upgrade license for simulation features. Please contact
sales@sigmaflow.com for upgrade purchase.
SigmaFlow VSM • 65
2. Header Icons (drop down menu): Click on Reports Header Icon dropdown menu and select
any report (Lean Benchmarking, Lean Six Sigma etc) from menu.
66 • SigmaFlow VSM
i. Takt Time Calculator: Used to launch “Takt Time Calculator” directly from
scorecard. Once you change any value through Takt Time Calculator and click save
button, scorecard values will get updated automatically.
ii. Graph: It can be used to view different scorecard graphs such as Workload
Balancing Graphs, Value Analysis Graphs, Lean Benchmarking Graphs etc.
iii. Calculation Method: It can be used to set scorecard calculation method.
Customizing Scorecards
Clicking on customize button on a scorecard will open Customize Form. Customize form has links for
both “Column” customization and “Row” customization as shown below:
Columns:
Allows you to add, remove and set order of columns that you want to view in your report. The two list
boxes (Available Columns and Selected Columns) shows available and selected columns for that
specific report respectively. You can add or remove columns either by double clicking on the column
name or by selecting multiple columns by pressing (Ctrl + Click) on the column names, and then
clicking on [Select >>] or [Remove] button.. All columns can be removed from report except the
“Activity” column. Once you have added or removed column(s), click [Save] button to save changes.
SigmaFlow VSM • 67
You can also set the order in which columns will appear on report by selecting column name in
“Selected Columns” list and then clicking the Up and Down buttons to order them. You can also
select multiple columns by pressing (Ctrl and Click) key simultaneously on the desired column names
and then clicking the Up and Down buttons. Once you set columns in certain order, click save button
to save changes.
Rows:
Clicking on Rows link will show you another form which allows you to select or remove rows in your
specific report. A drop down will show you a list of drawing pages that you will have in your drawing
along with two list boxes that shows you the available and selected rows based on the page selected
from dropdown list. Please note that you can order rows the same way you can order columns.
68 • SigmaFlow VSM
You can add or remove rows either by double click on row name or select multiple rows by pressing
Ctrl Key, click row name then click Select or Remove button to add or remove selected rows. Once
you add or remove rows(s), click save button to save your changes.
SigmaFlow VSM • 69
The process of benchmarking the process involves the identification the four key parameters. With
these one can characterize whether a process is "lean" or "fat" given the values of four fundamental
process parameters. The fundamental process parameters are:
a. Throughput (TH) = throughput, measured as the average output of a production process
(machine, station, line, plant) per unit of time. In SigmaFlow VSM, it can be captured in
“Takt Time Calculator”
b. Work in process (WIP) = total work in process, which consists of inventory between the
start and end points of a routing. In SigmaFlow VSM, a simple process can be defined with
basic process steps and inventory at each step can be captured through “Data Property” of
each shape.
c. Bottleneck rate (BNR) = bottleneck rate of a line, defined as the rate of the station with the
highest utilization. Based on the parameters entered, Bottleneck Rate is automatically
calculated in Lean Benchmarking Report.
d. Raw process time (RPT) = raw process time, which is the sum of the mean effective process
times of the stations in a line. This is also automatically calculated in Lean Benchmarking
report.
e. For convenience, also calculate "critical WIP." It equals the product of bottleneck rate (BNR)
and raw process time (RPT): Critical WIP is the minimum amount of WIP needed to
maximize throughput in the best case.
Lean benchmarking scorecard and Lean Benchmark summary results can be switched by clicking
Scorecard and Summary links respectively.
70 • SigmaFlow VSM
Lean Benchmarking Conclusions, Results, Analysis, Constraints, Throughput and Cycle Time
summary are defined based on the following calculations:
Field Description / Formula
Conclusion Throughput > Throughput (best case)
== > IMPOSSIBLE
Throughput = Throughput (best case)
== > BEST CASE
Throughput > Throughput (practical worst case)
== > LEAN
Throughput = Throughput (practical worst case)
== > MARGINAL
Throughput > Throughput (worst case)
== > FAT
Throughput = Throughput (worst case)
== > BEST CASE
Throughput < Throughput (worst case)
== > BEST CASE
Result IF Bottleneck Rate = 0
== > Missing Cycle Time or Machine Data
Throughput > Throughput (best case)
== > Demand Exceeds Process Capability
Throughput = Throughput (best case)
== > Demand Equals Process Capability
Throughput > Throughput (practical worst case)
== > Process Is Lean
Throughput = Throughput (practical worst case)
== > Process Is Marginally Lean
Throughput > Throughput (worst case)
== > Process Is Fat
Throughput = Throughput (worst case)
SigmaFlow VSM • 71
== > Process Is Excessively Fat
Throughput < Throughput (worst case)
== > Process Is Excessively Fat
Analysis Show detailed analysis information about result and
conclusion.
Constraints List of all activities for which “Cycle time Score” has a value
of “Constraint”
Throughput Summary Displays the reason behind the “Conclusions” (Lean, Fat etc.)
Cycle Time Summary Displays the reason behind the “Conclusions” (Lean, Fat etc.)
Following are the calculated fields used in Lean Benchmarking Summary (middle section):
Field Description / Formula
Demand Read from Takt Time Calculator
Throughput Requirement Read from Takt Time Calculator
Work In Process Sum of all “Inventory #” at all the process steps
Critical Work in Process = Bottleneck Rate x Raw Process Time
Raw Cycle Time Sum of all the “Raw Cycle Time” for all the process steps
(from Lean Benchmarking > Scorecard)
Process Cycle Time = Work in Process / Throughput
Bottleneck Stations Activities with highest value of WorkStation Utilization
Bottleneck Rate Select the “Workstation Capacity” value for machine whose
Station Utilization is highest (from Lean Benchmarking >
Scorecard)
The “Best Case”, “Practical Worst Case” and “Worst Case” calculations are as follows:
Field Description / Formula
Throughput (Best Case) = Work in Process / Raw Process Time, IF Work in Process
<= Critical WIP
= Bottleneck Rate, IF Work in Process > Critical WIP
Throughput (Practical Worst = Work in Process x Bottleneck Rate / (Critical WIP + Work
Case) in Process -1)
Throughput (Worst Case) = 1 / Raw Process Time
Cycle Time (Best Case) = Raw Process Time, IF Work in Process <= Critical WIP
= Work in Process / Bottleneck Rate, IF Work in Process >
Critical WIP
Cycle Time (Practical Worst = Raw Process Time + (Work in Process -1)/Bottleneck Rate
Case)
Cycle Time (Worst Case) = Work in Process x Raw Process Time
72 • SigmaFlow VSM
Following actions are allowed in the “Scorecard”:
i. Use “Function” logic at the total row to apply the accumulation logic rule for that
particular column. Function option includes: Sum, Multiply, Mean, Median, Average,
Min, Max etc.
ii. Check/Uncheck checkboxes for the rows that you would like to include in the calculation
for function logic.
iii. “Refresh” button can be used to update scorecard result.
iv. “Revert” button can be used to undo changes.
SigmaFlow VSM • 73
Following are the calculated fields used in the Throughput Chart:
Field Description / Formula
Work in Process X-axis value with an increment of uniform interval of 10
Best Throughput If Work in Process value <= Critical Work In Process then
= Work in Process value / Raw Process Time
Else
= Bottle Neck Rate
Practical Worst = (Work in Process value * Bottle Neck Rate) / (Critical
Throughput Work In Process + (Work in Process value - 1))
Worst Throughput = (1 / Raw Process Time)
Actual Throughput = Demand Throughput
74 • SigmaFlow VSM
= Work in Process value / Bottle Neck Rate
Practical Worst Cycle =(Raw Process Time + (Work in Process value - 1) /
Time Bottle Neck Rate)
Worst Cycle Time =(Work in Process value * Raw Process Time)
Actual Cycle Time =Process Cycle Time
SigmaFlow VSM • 75
Following actions are allowed in Value Stream Mapping scorecard:
1. Use “Function” logic at the total row to apply the accumulation logic rule for that particular
column. Function option includes: Sum, Multiply, Mean, Median, Average, Min, Max etc.
2. Check/Uncheck checkboxes for the rows that you would like to include in the calculation for
function logic.
3. “Refresh” button can be used to update scorecard result.
4. “Revert” button can be used to undo changes.
Following are the calculated fields used in summary section of Value Stream Mapping scorecard:
Field Description / Formula
Demand Read from Takt Time Calculator
Work In Process Sum of all “Inventory #” at all the process steps
Process Yield Multiply value for “Yield % for Defect” at all the process steps
Constraint List of all activities which “Cycle time Score” field has a value of
“Constraint”
Additional Units Required to = Demand x (100% - Cumulative Yield %)
achieve 100% demand
76 • SigmaFlow VSM
3. “Print Chart” button to print chart directly.
4. “Show Data Table” link: You can also see chart data by clicking small arrow at “Show Data
Table” heading.
SigmaFlow VSM • 77
Scorecard: Lean Six Sigma
Lean Six Sigma Scorecard includes Six Sigma specific fields for reporting. Lean Six Sigma Scorecard
can be seen by selecting Lean Six Sigma from scorecard dropdown option.
Constraint List of all activities which “Cycle time Score” field has a value of
“Constraint”
Additional Units Required to = Demand x (100% - Cumulative Yield %)
achieve 100% demand
78 • SigmaFlow VSM
1. “Copy Chart” button to copy chart and paste in into some other application like Microsoft
Word, Excel etc.
2. “Copy Data” button to copy chart data and paste in into some other application like Microsoft
Word, Excel etc.
3. “Print Chart” button to print chart directly.
4. “Show Data Table” link: You can also see chart data by clicking small arrow at “Show Data
Table” heading.
Scorecard: Custom
Custom Scorecard includes custom/all fields for reporting. Custom can be seen by selecting Custom
from scorecard dropdown option.
SigmaFlow VSM • 79
Following actions are allowed in Value Stream Mapping scorecard:
1. Use “Function” logic at the total row to apply the accumulation logic rule for that particular
column. Function option includes: Sum, Multiply, Mean, Median, Average, Min, Max etc.
2. Check/Uncheck checkboxes for the rows that you would like to include in the calculation for
function logic.
3. “Refresh” button can be used to update scorecard result.
4. “Revert” button can be used to undo changes.
Following are the calculated fields used in summary section of Value Stream Mapping scorecard:
Field Description / Formula
Demand Read from Takt Time Calculator
Work In Process Sum of all “Inventory #” at all the process steps
Process Yield Multiply value for “Yield % for Defect” at all the process steps
Constraint List of all activities which “Cycle time Score” field has a value of
“Constraint”
Additional Units Required to = Demand x (100% - Cumulative Yield %)
achieve 100% demand
Custom Graph
Clicking on graph icon will launch Workload Balancing Graph for Value Stream Mapping. Following
actions are allowed:
1. “Copy Chart” button to copy chart and paste in into some other application like Microsoft
Word, Excel etc.
2. “Copy Data” button to copy chart data and paste in into some other application like Microsoft
Word, Excel etc.
3. “Print Chart” button to print chart directly.
80 • SigmaFlow VSM
4. “Show Data Table” link: You can also see chart data by clicking small arrow at “Show Data
Table” heading.
SigmaFlow VSM • 81
Scorecard: Value Analysis
This report is instrumental in helping process professionals prioritize the high impact areas for process
improvement. It shows the user where the highest return on investment (ROI) is - indicating where
they should spend the majority of time researching. By filling out the Lean Data fields you will be able
to see the largest portion of, for example, Non Value Add time. If you notice that the majority of your
money is being spent in Department 2, then you might want to do research on Department 2 before
spending time researching Department 1.
The Value Analysis Scorecard allows you to work with the most current information provided in the
activity task pane (Methodology = Value Analysis). The data is consolidated with the process graphic
and the results are self-calculating. This scorecard has three different views; Time, Cost, Resources
and Yield.
Selecting any one of them will update the scorecard grid accordingly while keeping the summary
section of the scorecard unchanged. Following actions are allowed:
1. Use “Function” logic at the total row to apply the accumulation logic rule for that particular
column. Function option includes: Sum, Multiply, Mean, Median, Average, Min, Max etc.
2. Check/Uncheck checkboxes for the rows that you would like to include in the calculation for
function logic.
3. “Refresh” button can be used to update scorecard result.
4. “Revert” button can be used to undo changes.
82 • SigmaFlow VSM
The summary section contains the following calculated fields when Time is selected from dropdown
option:
Field Description / Formula
Cycle Time As-Is = Total Cycle Time
Cycle Time To-Be = Total Cycle Time - NVA Time
Cycle Time Improvement = As-Is Cycle Time – To-Be Cycle Time
Cycle Time Opportunity = Improvement / As-Is Cycle Time
Cycle Time Most NVA by % = Activities with the largest NVA by %
Cycle Time Most NVA by Value = Activities with the largest NVA by value
SigmaFlow VSM • 83
Value Analysis > Cost
The summary section contains the following calculated fields when Cost is selected from dropdown
option:
Field Description / Formula
Processing Cost As-Is = Total Processing Cost
Processing Cost To-Be = Total Processing Cost – NVA Cost
Processing Cost Improvement = As-Is Processing Cost As-Is – To-Be Processing Cost
Processing Cost Opportunity = Improvement / As-Is Processing Cost
Processing Cost Most NVA by % = Activities with the largest NVA by %.
Processing Cost Most NVA by Value = Activities with the largest NVA by value.
84 • SigmaFlow VSM
Value Analysis > Resources
The summary section contains the following calculated fields when Resources is selected from
dropdown option:
Field Description / Formula
# of Resources As-Is = Total # of Resources
# of Resources To-Be = Total # of Resources - NVA Resources
# of Resources Improvement = # of Resources As-Is - # of Resources To-Be
# of Resources Opportunity = Opportunity / # of Resources As-Is
# of Resources Most NVA by % = Activities with the largest NVA by %.
# of Resources Most NVA by Value = Activities with the largest NVA by value.
SigmaFlow VSM • 85
Value Analysis > Yield
Analysis Section: Value Analysis scorecard report has following analysis sections in summary
section.
Cycle Time NVA Analysis: Following are the fields used in Cycle Time NVA Analysis
Field Description / Formula
Rate per Time Unit = User entered field
Frequency of Occurrence = User entered field
Estimated NVA Reduction % = User entered field
Total Savings Opportunity = (Rate /Time unit) x (Frequency of Occurrence) x (Estimated NVA
Reduction % / 100)
Yield Analysis: Following are the calculated fields used in Yield Analysis
Field Description / Formula
Rolled Throughput Yield % Multiply of all “Right First Yield%” at all the process steps
Final Traditional Yield % Multiply of all “Traditional Yield %” at all the process steps
86 • SigmaFlow VSM
Value Analysis Graphs
Click on graph icon will launch Value Analysis Absolute and Relative charts. You can switch between
them by clicking Absolute and Relative link respectively.
Absolute Chart
1. Useful when focus is to compare the task duration irrespective of their VA, BVA and NVA %
2. Displays the chart in absolute time units. Easy to differentiate long vs. small tasks
3. Users have the option of selecting the time unit in which they want the chart to be displayed
Following actions are allowed in the Value Analysis Absolute Analysis Graph:
1. “Copy Chart” button to copy chart and paste in into some other application like
Microsoft Word, Excel etc.
2. “Copy Data” button to copy chart data and paste in into some other application like
Microsoft Word, Excel etc.
3. “Print Chart” button to print chart directly.
4. “Show Data Table” link: You can also see chart data by clicking small arrow at
“Show Data Table” heading.
Relative Chart
1. Useful when focus is to compare VA, BVA, and NVA % irrespective of the task duration
2. Displays the relative %. Easy to identify NVA activities
3. Difficult to differentiate very long vs. very short tasks. For ex. a task (Task1 - 5 minutes
long may have 90% NVA) and another task (Task2 - 20 days long may have only 30%
NVA). The % chart will ask you to focus on Task1 as opposed to Task2.
SigmaFlow VSM • 87
Following actions are allowed in the Value Analysis Absolute Analysis Graph:
1. “Copy Chart” button to copy chart and paste in into some other application like
Microsoft Word, Excel etc.
2. “Copy Data” button to copy chart data and paste in into some other application like
Microsoft Word, Excel etc.
3. “Print Chart” button to print chart directly.
4. “Show Data Table” link: You can also see chart data by clicking small arrow
at “Show Data Table” heading.
88 • SigmaFlow VSM
Simulation Overview
Introduction
Simulation is a disciplined process of building a model of a system or design, and performing
experiments with this model, to analyze and understand the behavior of selected characteristics of the
system or design, and to evaluate operational strategies to manage the system or design. With
Simulation, users can allocate more time studying “what-if” scenarios. This chapter introduces the
basic concepts behind discrete event simulation. The term system as used in this chapter includes
existing processes, products, services, and designs, as well as proposed processes, products, services,
and designs.
Simulation lets you explore an electronic model of the project you manage - whether the project is a
process, a portion of your process, or a hospital, or an administrative center, or whatever. The type of
model it provides is time-based, and takes into account all the resources and constraints involved, and
the way all these things interact with each other as time passes. This means that the model really can
match reality - so something you try in the model will behave the same way as it would in the real
organization.
With simulation you can quickly try out your ideas at a fraction of the cost of trying them on the real
organization. And, because you can try ideas quickly, you can have many more ideas, and gain many
insights, into how to run the organization more effectively. Simulation is also a communication tool. It
can be used to communicate the ideas among various team members. In summary:
• Simulation is the process of building a model of an existing or proposed system and experimenting
with the model to understand and improve the system.
• Should be viewed as a “What-if” tool that allows an experiment with alternative strategies to see
what impact those decisions have on overall system performance.
• Simulation lets you Test and Experiment in a Risk Free way at virtually no Cost and in a fraction
of the Time otherwise required.
• Simulation can be Discrete or Continuous
Discrete: System state changes at discrete points in time
Continuous: System state changes continuously with respect to time.
SigmaFlow Simulator is Discrete Event Simulation software and the rest of the discussions in this
chapter will pertain to discrete event simulation only.
Simulation Overview • 89
Discrete Event Simulation – Application Areas
There are a number of potential areas for application of discrete event simulation. The range of
application areas is extremely large and there are numerous examples of the use of simulation in
service industries, manufacturing (batch and process) and office environments. Examples of actual
simulation studies performed in several of these industries can be found on numerous websites.
One area where simulation is commonly used is in systems design or developing new systems,
particularly those that involve a high capital investment. In designing a new system, experiments can
be performed using a simulation model that would otherwise be impossible to carry out on the actual
system since it is not yet implemented. Simulation can significantly reduce the time required to debug
and fine-tune a proposed system or design. For example, you can use simulation can be used to test
the performance of a new clinic to ascertain the possible output, the level of utilization of
nurses/doctors, and any potential problems. Further investigations can be carried out to determine an
effective and efficient way to schedule patients, rooms, doctors, nurses while maximizing the clinic’s
throughput.
Simulation is being used in a variety of manufacturing and service industries. A list of some of the
industries that are currently benefiting from the use of simulation is given in Table 1 below. Table 2
lists the application areas and the purpose of using the simulation tool.
Table 1: Manufacturing and Service Industries Using Simulation Methods
Manufacturing Industries Service Industries
Appliance Public Services
Automotive Learning institutions
Aerospace Restaurants
Electronics Banking
Heavy Equipment Healthcare
Glass and Ceramics Government
Textile Disaster Planning
Food and Beverage Waste Management
Foundries Transportation
Petrochemical (Oil and Gas) Distribution
Furniture Aerospace-military
Semiconductor Hotel Management
Amusement Parks
Table 2: Simulation Application Areas
Application Areas Used For
Six Sigma management Elimination of variation and waste
Business Process Management Understanding the dynamics of wait-time
People/Transport Flow Measuring the effects of variances
Supply chain management Predicting wait time accurately
Call Center Financial Significance
Plant/Facility Layout Production/Customer Scheduling
Plant Productivity Improvement Resource Planning
Maintenance planning Work Prioritization
Packaging Inventory Management
Material Handling Quality Management
Bank Operations, Transaction Task Assignment
Processes, Loan Management Throughput Analysis, Capacity Analysis
Technology Selection: Manual vs. Automated
90 • Simulation Overview
When to use Simulation?
As seen in Tables 1 and 2, simulation can be applied in many different areas and can be used for
numerous process improvement efforts. But some of these improvements could be made without
simulation, so the real question is 'Why use simulation instead of another method?' Not all problems
that can be solved with the aid of simulation should be solved using simulation. If the objective is to
understand work flow sequence, then a simple flow diagram will suffice. For simple problems like
finding the effective capacity of an operation, or the cumulative scrap rate of a system, simple
mathematical calculations can be used. The following are some of the situations in which simulation
can be considered an appropriate tool.
• Simulation is an appropriate tool if developing a mathematical model for a new/existing system is
too difficult or impossible. By building/testing a simulation model of such systems, users can
predict the outcomes for possible courses of action without making a large investment in the
experiments. Experimenting with a representation (model) of the system is a better way to
determine whether or not the proposed solution is a good solution.
• Simulation is an appropriate tool if the system being studied has interdependent random variables.
Random events are part of life and problem solvers cannot control the occurrences of these events.
However, they can predict the consequences of these events and their likelihood of occurrence.
Disregarding the effect of randomness can result in incorrect conclusions. With this information,
efforts can be focused on maximizing a system’s efficiency by (a) reducing the likelihood of
random events, and /or (b) minimizing the impact from random events. WIP (Work in Process)
levels are a classical example of a performance criterion that can be heavily influenced by random
events (variation). Fluctuations in operation cycle times between consecutive operations can
increase WIP levels and prolong wait time in queues
• Simulation is an appropriate tool if the system dynamics are extremely complex. Complexity is
determined by the inter-relational characteristics and interdependencies of people, equipment,
methods, material and policies, and variability in the system.
• Simulation is an appropriate tool to observe system behavior over time. For example, what is the
impact when something occurs in relation to other incidents? How do we see the effect of arriving
patients into the emergency room over a period of time? What if a patient arrives in the emergency
room when there is no doctor to attend?
Simulation Overview • 91
Advantages of Simulation
Simulation provides Six Sigma team members with the following advantages, they are:
• Understanding the cause and effect relationships in a system.
• Identifying bottlenecks, constraints, and barriers in a system.
• Reducing the cost of experimentation on a system. With simulation, users can build a model to
evaluate proposed designs, specifications and changes without having to commit resources to
build the actual system. Users can also evaluate various alternatives such as effects of policies,
procedures, new techniques without having to disrupt the actual system - which may or may not
exist yet.
• Predicting future outcomes of a system. For example, what happens if 5 new people are hired over
the next few months? Or, what happens to total patient waiting time if the scheduled service times
for a physician are switched from the morning hours to the afternoon hours?
• Providing repeatability to study a system by running the simulation model multiple times.
• Allowing time compression and expansion in which to study a system. Users can control the speed
of the simulation from the user interface to understand the phenomenon under consideration to
make judicious decisions.
Simulation is intuitively simple and elegant. PC based simulation software provide menu driven
options that makes is easy to use and enter data. This software facilitates communication, builds
consensus, and prepares for change. Further, it is an effective and exciting training tool for team
members because it fosters learning about the assumptions underlying a system.
92 • Simulation Overview
7. Batching rules
Output Results (Effect):
1. Inventory (with the exception of opening inventory)
2. System benchmarks (production, throughput, cycle time)
3. Service levels (time in system, queue time)
4. Equipment and labor utilizations
Simulation Terminology
This section outlines some terminology frequently used when discussing simulation methods.
Definition of a System
A system is a collection of interacting components that transform inputs into outputs toward a common
aim, called a mission statement. It is the job of management to optimize the entire system toward its
aim. This may require the sub-optimization of selected components of the system; for example, a
particular department in an organization may have to give up resources to another department in the
short run to maximize profit for the overall organization.
Systems exist in all facets of organizations, and an understanding of them is crucial. Many people
mistakenly think only of production systems. However, administration, sales, service, human
resources, training, maintenance, paper flows, interdepartmental communication, and vendor relations
are all systems. Importantly, relationships between people are systems. Most systems can be studied,
documented, defined, improved, and innovated.
Simulation Overview • 93
advanced by the time required by individual events. Most manufacturing and service systems are
discrete event systems.
A continuous event is an action without pause. The cholesterol level of a patient, the flow of oil into a
tanker, and the volume of a soda tank in a restaurant are examples of continuous events. Continuous
events involve a time rate of change and they continue uninterrupted with respect to time in relatively
continuous and regular fashion.
System State is all of the variables that contain the information necessary to describe a system at any
point in time. The state of the system does not refer to whether the system as a whole is busy, down or
idle. The state of a system is actually described by the values of all the individual state variables in the
system. A state variable might be the number of entities in a particular queue or the status (busy, idle,
down) of a particular resource.
94 • Simulation Overview
A dynamic model is a model that is influenced by time and defines the system using a set of
numerical equations. Dynamic models differ from static models because they are event driven. The
occurrence of an event can change the values of the variables used in a computation. System behavior
and performance are derived by averaging the responses observed over the occurrences of a large
quantity of events. The state of the model changes over time using a simulation clock. Many service
and manufacturing systems can be represented using a dynamic model, for example, schedule changes,
equipment failure, WIP levels, equipment utilizations, customer arrival rates, test times, wait times,
defects, and engineering changes are all systems that can be represented using dynamic models.
Simulation Overview • 95
on system experts to establish the validity of the results for a new system, that is, a system that does
not yet exist.
Additionally, the animation feature of a simulation software package can help establish the validity of
a simulation model. Although animation makes it easier to validate a simulation model, decisions
concerning the validity of a simulation model should be based on a statistical analysis of the generated
results. Some validation techniques are:
1. Compare simulated results with actual results (for existing systems)
2. Use experts to validate simulated results for systems that do not yet exist.
3. Use multifunctional teams to review inputs and outputs of the model.
4. Use sensitivity analysis to study the conditions of parameters under different conditions.
96 • Simulation Overview
Several standard probability distributions are frequently used with stochastic simulations. Details of
other probability distributions commonly used in simulation can be found in many simulation
textbooks.
It is important to use probability distributions that are representative of the stochastic processes they
are imitating. Many simulation packages contain features that will automatically find standard
probability distributions which are representative of empirical data. There are also other software
packages, such as ExpertFit, BestFit, and Stat:Fit that you can use to identify the distribution that fits
the empirical data.
Simulation Overview • 97
• Conditional Events are simulation events that occur only when one or more conditions have
been satisfied, or events have occurred (for example, the departure of a customer from a
waiting line when a service agent becomes available or the shipment of an order when all of
the line items have been pulled and consolidated).
A. Problem Definition
As a simulation specialist, identify main issues / problems and find out how the process works
currently. Thoughts on the concerns will give you a good idea of what variables are important to
model the process. At this stage you might, of course, decide that simulation is not the way and the
problem may perhaps be solved using simple spreadsheets or some other technique.
B. Level of Detail?
Think about the level of detail that it would be appropriate to build into the model. For example, do
you need to include every part of every operation at each machine/process, or is it more appropriate to
simply model the output of whole departments and how they interact with each other? Putting too
much detail in a model means it costs more of your time to build and can also cloud the issues which
the decision maker is interested in.
C. How Broad?
Think about how wide to make the model. Can you limit the boundaries of the model to the process
itself, or do you need to also include the systems that affect supply of raw materials to the process?
This phase is much more important than it may seem. Experience is that the consultant’s first idea of
what simulation model is appropriate is never much like the simulation model at the ‘end’ of the study.
98 • Simulation Overview
This is not because the consultant was necessarily wrong, but because the client’s needs evolve
throughout the process.
Model Building
Model building is considered an art and a science. Developing expertise as a simulation modeler
requires an understanding of system dynamics, knowing how to capture these dynamics, and knowing
one or more simulation languages. Simulation model builders set up an initial model, define the
logical relationship between its activities, and analyze the results.
Flowcharts
A simulation model requires a flowchart to visualize the system under study. A flowchart is a
computer representation of a system as defined by the software used to develop the model. A
simulation consists of drawing a process with objects (things like queues and processes) on the screen
with a default structure (routing) between them and work items which flow through the process. While
building the model, there are many things that need to be considered to provide an accurate abstraction
of the system being modeled.
Entities
Entities are the subject of the simulation model and are the things that flow through the process, wait in
queues, are stored in storages and are generally worked on. Examples include parts/products, customer
calls, customers, transactions, documents, etc. Just as in real life, entities can assume different
identities at different times. For example, different entities may get assembled into a single entity
(assembling 4 tires and a chassis to get one entity “car”), may get split into multiple entities (a single
purchase order getting split into three different copies) or grouped together so that they can be
processed at once (batch of cookies going into an oven where each entity still maintains its own unique
identity).
Entities in a system may be of different types and can have different characteristics such as type, color,
ID, and due date. These are defined through features called attributes (also known as labels or
parameters). Attributes are very powerful and if understood and used correctly, they can reduce the
model size tremendously. Attributes can be used to make dynamic decisions based on some
characteristic of an entity. Attributes are like variables and each individual entity can have different
values for each of its attributes. Values of these attributes can be changed during the simulation as they
get processed at different process steps. For example, an attribute called color can have a value of
“white” before going to the painting station (process step) which can be modified to “red” as it comes
out of the painting station.
The attributes of an entity can be explained with the help of a simple example. You can think of an
attribute as a label on a pair of jeans that includes information about waist size, inseam length, and
style. The attributes of the jeans are on a label that goes wherever the jeans go. Anyone can find out the
attributes of a particular pair of jeans by looking at the label on the jeans.
Simulation Overview • 99
arrival time distribution for an entity is key to any simulation. Inter-arrival means defining the
time units between the arrivals of any two entities. Most simulation packages use inter-arrival
times, as opposed to arrival rates which are the opposite of inter-arrival times. Different types
of arrivals can be modeled, for example, time based (appointment based), random (customer
support calls), or time dependent (slow hour versus rush hour traffic). Some of the common
examples of arrivals include: customers arriving at a service center, production orders arriving
at a factory, customers arriving at a bank, patients arriving at a hospital, calls arriving at a call
center, and patents waiting to be processed by a United States patent office.
Arrivals of entities
Entities arriving into a system are usually defined by entity type, arrival quantity, arrival
frequency, and arrival pattern. The arrival of entities into systems or designs can follow any
one of the following arrival patterns.
o Random Arrivals: Random arrivals are entities that arrive into a system, or step in a
system, such that the arrival of one entity does not depend on the arrival of another
entity.
o Scheduled Arrivals: Scheduled arrivals occur when entities arrive independently of
one another according to a predefined schedule. These arrivals may occur in
quantities greater than one and at an exact or probabilistic time. If the arrival time is
probabilistic, the model needs to define the mean time, the variability around the
mean time, and the shape of the distribution of arrival times, so as to allow for the
arrival of early or late entities. Examples of scheduled arrivals include:
a phone company scheduling the arrival time of a technician for a service
call
a nurse scheduling the arrival time of a patient for a doctor’s appointment
a marketer planning the schedule for the release of a new service.
an engineer scheduling the release of a new design
o Time dependent arrivals (arrivals within a period): Time dependent arrivals are
modeled using different probability distributions at different times of the day. These
types of arrivals frequently start out slow at the beginning of a cycle, reach a peak
part way through the cycle, and then taper off towards the end of the cycle. Some
examples of time dependent arrivals are:
customer arriving at a restaurant (lunch and dinner times are busy hours)
phone calls arriving into a call center for customer service (8:00am-9:00 am
and 12:00 – 1:00pm are busy hours)
vehicles entering a highway (morning are evening are rush hours).
• Storage/Queue/Waiting Area/Buffers: Storage objects are used anytime an entity might
have to wait for processing to absorb the variation in the system. Storages are the places
where entities get routed to for processing, waiting, or decision making and generally have a
holding capacity. When there are multiple entities in storage, many rules can be applied to the
order in which they are processed by activities. These include first-in-first-out, last-in-last-
out, priority assignment, longest queue, shortest queue, and the age of an entity. Process steps
with processing times greater than zero are usually preceded by a storage facility. Examples
of situations in which a storage objects are needed include: products awaiting shipment, raw
material waiting to be used, people waiting to board an airplane and people standing in line at
a bank/ticket counter. Frequently, modelers neglect to use storage objects.
• Processes: A process is anything that performs work on an entity. For modeling purposes,
the exact nature of the process (machining, greeting customers, making decisions,
transporting, inspection etc.) is irrelevant. Depending on the task being performed on an
entity, a process can also be used to split, combine, group, or ungroup entities. Modelers can
Modeling Distributions
Probability distributions can be used to model an existing system if team members collect data and use
a curve fitting application to identify an appropriate probability distribution.
Performing Experiments
Once a simulation model has been built, the next step is to design and perform a series of experiments
using the model to see how to improve the actual system under study. Experiments are usually
conducted to:
• find the value of a critical performance measures and/or associated input variables
• compare different design rules, management strategies, system configurations, and/or
• determine the sensitivity of the system (expected change in performance) to changes in one or
more input variables
When optimizing a system, a simulator identifies the input variables and it’s optimum value.
Experiments are conducted by manipulating the value of these variables and determining the effects of
these manipulations output or performance measures. There are several decisions that need to be made
before experimentation can begin. They are:
• Determine if the objective of the model is to study the steady state condition. If so determine
the warm-up period.
• Decide if the process is a terminating or a non-terminating system.
• Determine the number of runs for the model: single or multiple runs, and the number of
replications for each system configuration.
• Determine the total length and the initial starting conditions for each simulation run.
• Decide on the type of probability distributions to use for each of the input variables (process
times, batch sizes, inter-arrival times, etc.).
• Set the simulation clock to define the length of each simulation run.
• Establish appropriate calendar working days and shift patterns for each simulation run.
• Decide what data to collect and choose appropriate data capturing mechanisms.
• Examine, validate and change (if necessary) the default parameters of the simulation package
being used to model the system under study.
• Collect data from each simulation run for analysis.
G. Verification
The first of these steps is to verify that the model is running in the same way that the real world would
work in the same circumstances. In theory there is a need to do this every time you make a change to
the model, but clearly this would be impractical. If the simulation is a model of an existing process (or
other system which actually exists) then this verification stage is just a matter of ensuring the model
behaves as the real process currently does. So you can put some actually customer orders (for example)
into the model and see if they are handled in the same way and in the same time as they are in the real
process.
The only way to verify a model of a new process (which does not yet exist) is to carefully experiment
with the model, watching (both the animated screen and the performance measures) to see if the
changes you see are reasonable in the light of changes you make to the input to the model (such as
It is very easy to omit this stage in the excitement and urgency of trying to help your client find a
solution. Omitting it is also one of the easiest ways to loose a client’s faith in your work when they see
the model show some result which is not only intuitively wrong but proves to be caused by a mistake!
Modern simulation software packages generate large amounts of valuable data which can be analyzed
to interpret the effects of input variables, and their interactions, on the critical performance measures.
Simulation output is summarized in reports that include: (a) “Snapshot Results” at any point in time,
(b) “Results Summary” from a single run (c) “Results Summary for multiple runs” (Trials), and (d)
“Compare Report” for multiple scenario comparisons.
There are two common methods used for output analysis. A simple method is to explore the model
visually with subject matter experts. This provides an opportunity to gain an understanding of how the
different parts of the model interact with each other and how the performance measures can be
affected. It is done by running the model and watching the entities move around on the computer
monitor. With numbers and colors changing on the screen, you can see where bottlenecks are building
up. By changing the modeling parameters and watching the effects of these changes you can gain a
knowledge and understanding of the way the system behaves. A sophisticated method is to perform
statistical analyses on the output to obtain insights into the process under study.
As discussed earlier, stochastic simulation is based on models which use random numbers. In such
models, random numbers, random number streams, and random number seeds play an important role
when running simulations and analyzing their results. In stochastic models, the distribution of the data
generated is dependent on the random numbers that are used to create the distributions of the input
variables. Thus, the outputs generated from stochastic inputs are stochastic. This means that different
random number seeds (and hence different random numbers) will generate different output results.
This problem is further complicated by the fact that there could be many different random input
variables (each using its own random number seed) that interact with each other during a simulation
run. Clearly, running a simulation once is inadequate to get any kind of precise estimate of the expected
behavior of the system; it is a sample of size one. Multiple and independent model replications are
always required with stochastic simulations and the statistical analysis of the output generated by them
is a critical prerequisite for making valid conclusions.
H. Warm-up Period
A warm-up, or start-up, period is the time frame needed for a system to reach ‘steady-state’. The
warm-up period is generally ignored in steady-state simulations and is only used for investigating the
effects of transient conditions, such as starting up a new factory or performing changes within an
existing facility. The steady-state period of the simulation must be studied to ensure that no long term
trends exist, such as continual build up of inventory in the system, that suggest the model (hence the
real system) will be unstable and unworkable.
A warm-up period is commonly used in manufacturing systems to fill up the system with initial
inventory before collecting data. On the other hand, a warm-up period is not commonly used in service
systems or terminating simulations because the initial number of customers waiting is always zero at
the beginning of the simulation period.
You may need to find a suitable ‘run-in’ or ‘warm-up’ time for your model. Models of factories
usually need a warm-up time because your model is likely to start empty (no products at any of the
machines), but real factories do not start each week without any work-in-progress! A situation where
you would not need a warm-up time in a simulation model might be when you are simulating the start
up of a new process, where you happen to be interested in its first day’s operations, or where you are
simulating a situation which starts each day empty: like a shop, or a car park, or an airport. However,
Most simulation packages contain facilities to set a ‘warm-up’ time during which results are either not
collected, or which can be separated off from the main results collection time.
But how do you decide how long to make the warm-up time? There is a simple procedure for this.
1. Decide what measures of performance are of interest to you. For example you might be interested
in the number of products leaving the process, or the utilization of a machine or the length of a
queue. If there is more than one then you might want to carry out this procedure for some, or all,
of the measures that interest you and use the longest warm-up time indicated. Let’s just assume
you are interested in the number of products leaving the process.
2. Run the model for a short period of time. The amount of time you run the model for is rather
dependent on what you are simulating but if the total time you wanted to run the simulation for
was, say, a week (see below for how to decide this) then you might make this “short period of
time” an hour. It needs to be an amount of time in which you might expect to get a few products
out of the process. Anyway, having run the model for, say, 60 minutes, records the number of
products that have emerged from the process. This will almost certainly be zero for the first 60
minutes! This is because of the nature of the need for a warm-up time. No products will have
reached the end of the process yet!
3. Run the model for another 60 minutes (or whatever time you have chosen) and record how many
products left the process in the second 60-minute period, i.e. the number that emerged between 60
and 120 minutes - not the total at the end of 120. Keep doing this and you should end up with a
table looking something like this:
This is the difference between the total output after 180 minutes and the total output after 240
minutes.
I. Accuracy of Results
The procedure described here can be handled for you, fully automatically by SigmaFlow, but it is
described here so that you can fully understand to principles involved. Once some insights have been
gained it is important to test the resulting ideas, especially if there are a number of competing ideas and
it is difficult to see visually which is best. Remember that a simulation (usually) contains random
numbers and if you are simulating a week’s production when you explore the model visually, you may
be seeing results that apply only to one week (perhaps a lucky week when few of the machines broke
down!). A different week might give you slightly (or very) different results.
This procedure described here gives you a step-by-step way to ensure your results are valid. Even if
you do not feel a need to go as far as calculating the statistics, you should do the first part and run the
simulation model with a number of different set of random numbers.
All simulation packages allow you to change the random numbers so you can also see what happens
when the random numbers are different. They do this by allowing you to set the ‘stream’ of random
numbers that will be used. Most packages have many thousands of ‘streams’ of random numbers built
into them so there is no limit on the number of different weeks you can simulate in the process.
But wait a moment - why are we only simulating a week’s production? Why not a year, or an hour?
What is the right length of time to simulate? The answer is simple. Simulate an amount of time that
makes sense to your client in terms of the performance measure you are using. For example if you
simulate the process for a year and report to your client that you expect the process to produce 14,500
boxes in a year this might be useful information in itself but might hide the information that any given
week’s production might be as low as zero or as high as 500. Conversely, your client may be
unconcerned by information about the output in any given hour. Choose a time that makes sense to the
client. The decision about what time to choose will become clearer when we see (next) what we will
do with the information we get.
Let’s assume we choose to simulate the process for one week at a time and with each random number
stream we get a different number of products completed by the end of the week. This information can
be really useful to your client for making decision with - but it has to be presented in a useful and valid
way for it to be of genuine use. This section is all about how to do this.
Once we get to this stage of a simulation study we are normally doing these runs and recording the
results because we want to compare two or more alternative decisions that we cannot easily distinguish
between visually. Let’s assume we have two alternatives and we have run the simulation 30 times for
each of these alternatives. For each run (of a week plus warm-up time) we have used different random
numbers and obtained the following output figures:
We could do more many more runs of the models but in practice running a simulation model of a
complex process for even one week can take a long time, and your client may not be able to wait.
A simple statistical procedure can help here. With limited time to do a limited number of simulation
runs we cannot give our client a precise long term average, but if we could tell our client what range
we expected the long term average to be inside this might be good enough.
In addition to the information we have so far we could calculate the standard deviation of the
individual results:
Alternative
One Two
Mean: 245.8 270.5
Standard Deviation: 33.1 33.3
But this only tells us the variability of the individual results. We are interested in how safe our average
figure is. If we had time to do another batch of 30 runs, would its average be different? If we did 30
batches of 30 runs what would be the variability of the averages?
Fortunately for us there is an applicable statistical relationship, which provides a method of predicting
the standard deviation of the averages from the standard deviation of the individual results that we
have just calculated.
We can now calculate confidence limits for our average to report to our client.
As 95% of normally distributed numbers are within 2 standard deviations of their average then:
Showing this type of picture to your client can help understanding especially if you change the numeric
production count information into profit or cost. The above picture shows that it is just possible to
distinguish (statistically) between these two alternatives.
1. You cannot distinguish between the two alternatives. It is not reasonable to report any difference
between them to your client because the average for alternative one could be as high as 257 and
the average for alternative two could be as low as 254.
2. You could do more runs because (take a look at the way the range is calculated) the larger the
number of runs the smaller the predicted standard deviation of the averages: so the smaller the
range. Of course this does not mean the two ranges will definitely separate if you do more and
more runs - it simply means your figures are getting more and more accurate. You may move
towards something like this:
1. Perform five runs of each of your alternatives, each run using a different random number stream.
2. Calculate the average and standard deviation for each of your alternatives.
Conclusion
SigmaFlow has been designed specifically to match with the above recommended way of conducting
simulation studies. In particular it recognizes that a crucial aspect of simulation studies is being able to
build and change models very quickly - so that the thinking process (the process of gaining insights
into how a system can be improved) is not interrupted.
This section assumes that the user has the basic understanding of how to draw the process maps.
Please visit Microsoft Visio help (SigmaFlow drawing is based on Microsoft Visio drawing engine).
When drawing your process map, you are drawing onto the screen a number of drawing objects. These
are things like Processes (which perform work), queues and decision points. These are joined by
routing arrows (lines), which describe the default route which work-items take as they move through
your simulation. Work-Items are simply things that you work on in your organization (like products,
or people, or paper work, or patients etc.)
Please note that you must have a valid SigmaFlow Simulator license to view the Simulation related
menu items and task panes and to conduct a successful simulation run. Once the license is applied to
the application, all simulation related properties become available automatically.
Following are the main steps required for conducting a successful simulation run:
1. Building detailed process map
2. Setting up object types
3. Defining simulation input data
4. Setting up the simulation clock
5. Setting up results collection
6. Running simulation and collecting results
7. Analyzing the results
To get a head start on simple simulation model building, let us use a case study approach which will
help understand the concepts while we utilize basic features of Simulator. This case study pertains to a
fictitious company called “PrintCo Service Center”.
Overview
PrintCo operates a single, moderately sized printing center. Recently, management has noticed that
service levels have started to decline and there is a belief that customers have to wait too long.
Managements decide to use simulation to:
• See the effect of variability in arrivals and operation times on customer service
• Obtain the right mix and right number of resources
• See the effect of pooling resources (staff) into groups
Operation Details
• The center operates on a 24-hr basis. There are four departments in the service center:
Customer Service, Customer Processing, Production and Payment (Customer Exit).
Customers arrive at the service center at some defined rate.
• As soon as they enter the Customer Service department, they are greeted by the greeters at the
front desk. There are 2 greeters in this department. The front desk employees are charged
with the task of greeting the customers and directing them to the appropriate area. If greeter
is busy they wait in the queue for them to get free. Greeters then direct them to the
appropriate department depending on the customer status (New or Existing). Roughly, 25%
of the customers arriving are new customers.
• If an arriving customer is a new customer, they are directed to the Customer Processing
Department. At that department, Customer processing worker (1 at the moment) takes down
the customer information and enters them into PrintCo’s database. Once this is done, they are
directed to the Production Department.
• If the arriving customer is an existing customer, they go directly to the Production
department.
• There are two kinds of services offered by PrintCo in the Production Department. First is an
Assisted Service and the other is Self Service. Roughly 70% of the customers require service
in the Assisted Service area. The others go for Self Service. In the Assisted Service area,
customers would need full time assistance from the Assisted Service Workers whereas at the
Self Service area, customers would need partial help from the Self Service Workers.
Currently, these workers do not share work between these two services. Currently there are 4
Assisted Service workers and 3 Self Service workers in the Production department.
• Once serviced by the Production department, customers go to Payment or Customer Exit
Department, where they pay for the services and then exit the service center. There are 2
Cashiers in the Payment department.
3. For the Simulation data task pane, click on the dropdown and select “Work Start”. By doing
this we have defined that the “Customer Arrival” shape is the “Work Start” object type.
4. Repeat the above steps to setup the remaining drawing objects as follows. Do not worry about
the data in the task panes for now. We will set the data next after all the object types are
setup.
Object Type Drawing Objects
Work Start Customer Arrival
Storages Front Desk Q, (Storage portion of > New Customer Processing,
Assisted Service, Self Service, Payment Service)
Work Center Front Desk Service, New Customer?, Need Assistance?, (Work
Center portion of > New Customer Processing, Assisted Service,
Self Service, Payment Service)
Work Center Storage New Customer Processing, Assisted Service, Self Service, Payment
Service
Work Starts
Work items enter the model following a specific arrival pattern at Work Starts. Follow the steps below
to define the arrival pattern:
1. Select “Customer Arrival” and go to “Simulation Data” task pane.
2. For Inter-arrival time field, select “Exponential” distribution and enter a value of 5 minutes.
(Exponential distribution is a good distribution to use when the arrivals are random and
independent of each other. If customer were arriving at a constant rate of 60 / hour, then you
will use an inter-arrival time of 1 Minute.)
Storages
Storages are commonly used for defining the capacity limitations and prioritizing the work items. For
this exercise, we are going to leave all the storage data as-is.
Work Centers
Work Centers are used where the actual work takes place. In Simulator, any activity that consumes
operation time such as process steps, decisions, transportation etc. can be assigned the Work Center
object type. We are not going to define the operation times at process steps and route-out % from
decisions shapes.
4. Repeat the same steps for all the steps. Use the operation times from the following table. For
shapes that are “Work Center Storage” object type, click on the “Work Center” link to
activate the work center portion of this object type as shown below:
2. Click on the ‘+’ icon to associate resources to this work center. Please note that resources
must exist on the process map before you can assign them to any work center.
3. Check the box for “Front Desk Workers” to associate (link) Front Desk workers on the Front
Desk Service process step. Click on Save until you are back to the Simulation Data task pane.
2. From the dialog box that opens, select the “Percent” route out type and enter 25% value for
“New Customer Processing” and 75% for “Need Assistance?” as shown below and click on
Save.
Resources
You can modify number of this type of resource available through resources Simulation Data task pane
window. To modify the resource numbers, follow the steps below:
1. Select “Front Desk Workers” and click on the “Shifts” link. In Simulator, all resources work
on a shift and you can define how many resources are available in each shift.
2. Repeat the same for the other resources in the model. For number of resources, use the
following table:
Resources Amount
Front Desk Workers 2
Customer Processing Workers 1
Assisted Service Workers 4
Self Service Workers 3
Payment Service Workers 2
Work Finished
Work Finished object is used to collect the important statistics such as Cycle time, throughput etc.
at the end of the simulation run. For this exercise, we can leave the Work Finished data settings
as-is.
2. Leave the start time as-is. Simulation will run from the start time for a period of Warm Up
Period + Results Collection Period. Set the “Warm Up Period” to 4 Hours and “Results
Collection Period” to 1 Day.
3. Click on [Save] button to save the clock properties.
2. Simulation will run and inform you that the simulation has been completed. Click OK on the
dialog box. As the simulation is run, all the selected results are collected in the Results
Summary report.
SigmaFlow Simulator is discrete event simulation (DES) software. Discrete Event Simulation
software has the following characteristics:
• Discrete Event Simulation is used for modeling systems that change state at discrete points in
time as the result of specific events.
• Most manufacturing and service systems are discrete event.
• Events usually take place at irregular intervals of time
• Simulation time periods are moved with individual events
• Simulation models differ from static models because they are event driven
• Examples: Manufacturing operations, Financial Transactions
Simulator is different from many other software applications because its design is based on some
careful research rather than a desire to exploit a potential market. Our main objective in launching
Simulator is to get simulation used so that it can benefit industry and commerce in the way simulation
should.
One of the main impacts of the above statement is that the way you use Simulator is not based on
programming or statistical data, but on drawing your organization (with the computer’s mouse) on the
screen, and only filling in numerical information where you need it. The data panel is always visible
(users choice) for the object that makes it very intuitive for users to see the data defined. Users do not
have to click and open a separate window, which can be frustrating at times.
However, you can still use Simulator for traditional hard number crunching simulation. It is built with
the expectation that this is the likely finale of most simulation studies. But our experience is that what
people need in a simulation study is:
1. A very quick model to enable them to start thinking about the structure of a situation.
2. To be able to build in numerical information as and when it becomes available but only to the
level of detail that is appropriate for the level of investigation required.
3. As the model is used more, and the people concerned start to home-in on detailed plans for
changes to their organization, to be able to cope with any level of complexity.
4. To be able to obtain easily understood, but rigorous, performance results from the simulation
package.
One and Two above recognize that simulation is a communication and thinking tool, not just an
analytical tool.
Simulation Data
Simulation Data task pane is used to enter the inputs associated with any object. Prior to entering any
inputs, users are required to first define the object type from the dropdown option available at the top
of the Task Pane. There are 7 types of objects in Simulator as shown below:
1. Work Start
2. Storage
3. Work Center
4. Work Center Storage
Following screenshot shows the data properties for object type “Work Center”.
Values associated with any field shown in the Task Pane can be changed and will update the object
immediately. Fields with blue text denotes a hyperlink, which means that by clicking on this link,
Simulation Results
Simulation Results task pane is used to view the outputs associated with any object once the simulation
run has been completed.
Simulation Settings
Simulation Settings is used to set basic simulation preferences and simulation model settings
characteristics. It can be accessed from:
1. The “Settings” header icon and selecting the “Simulation” option, Or
2. Clicking on the “Settings” header icon and selecting the “Simulation” link as shown in the
following image.
Simulation Preferences
Simulation Preferences area is used to set the default preferences for your model. Please note that this
is a file specific settings i.e., options selected here is applicable to the current file only.
Activity Statistics
Activity statistics are statistics recorded by activities, such as contents statistics or queuing time. Some
statistics are affected by whether you include non-working time or not. Remember that working vs.
non-working time for an activity is determined by the activity's calendar.
Suppose a storage has a calendar set at the default calendar: M-F 9AM - 5PM. Now suppose that a
work item arrives at the storage at Monday 4PM, and leaves on Tuesday 10AM. What was the queuing
time for that work item? There are two possible interpretations:
1. Include non-working time: We include the time during which the storage was offline
(Monday 5PM - Tuesday 9AM), so the queuing time was 18 hours.
2. Exclude non-working time: We do not include the time during which the storage was offline,
so the queuing time was 2 hours.
2. You are simulating a milk bottling plant, and the milk bottles must leave the system by a
certain amount of time or it will spoil. The time that it takes to spoil is independent of what
your working hours are, so you would want to include the non-working hours in your "Time
in System" results. Alternatively, you could set your calendars to 24/7 and use resources set
working hours to get the same result.
Labels
Labels are also known as “Attributes”. They are specific to work items. Labels can be attached to any
“work item” going through the simulation model. For example you might attach a label “Illness” to
work item type “Patients” and set this label to a code number as they enter your simulation of a
hospital. Each code number would represent a type of illness and could be used to route the patients
though the different “work centers” in the simulation model. Labels can only contain numbers. Labels
are primarily used to make dynamic decisions based on some characteristic of the work item. Labels
have the following usage in Simulator:
icon: (Creating a new Label) This icon is used to add new labels to the simulation
model. Clicking on this will open the “Add Label” dialog box. Enter the label name and
click on Save to add labels.
Edit Link: (Modifying a Label). The “Edit” link is used to edit the label.
Delete link: Delete link is used to delete a particular label. If a label is used anywhere in the
model, then this link is grayed out and hence cannot be deleted.
To learn more about Labels, please refer to the “Labels” section.
Named Calendars
Calendars let you make your simulation behavior dependent on the current simulation date and time.
Clicking on “Named Calendars” link opens the following “Named Calendars” dialog box.
Edit Link: (Modifying a calendar). The “Edit” link is used to edit the calendar.
Delete link: Delete link is used to delete a particular calendar. If a calendar is used anywhere in the
model, then this link is grayed out and hence cannot be deleted.
To learn more about Calendars, please refer to the “Calendars” section.
Named Distributions
Named distribution window lists all distributions that have been created specifically for this model.
Simulator lets you design your own distributions so that you can describe any variability that your
model might need. In Simulator, you can create your own distributions and then use those in many
places. For example if 50 different machines are work at a given rate, but you want to be able to
change that rate easily, then you can tell each machine that it uses a distribution call “Machine-
Distribution”, and then just change the parameters of “Machine-Distribution”. There are two types of
named distributions; (a) Quantity Distributions and (b) Duration Distributions.
Duration Distributions: These are very similar to quantity distributions, except that they have a unit
of time associated with them. An inter-arrival time of 10 does not make much sense, but an arrival time
of 10 minutes does make sense. You can use these distributions anywhere you need to specify
durations of time.
icon: (Creating a new Named Distribution) This icon is used to add new named distribution to the
simulation model. Clicking on this will open the “Add Distribution” dialog box. Enter the name
of the distribution, select the type of distribution and click on “Save” button to add a distribution to
your model. Once the named distributions are defined, they can be used anywhere in your model.
Edit Link: (Modifying a distribution). To edit the named distributions, click on the “Edit” link next
to the named distribution. The “Edit” link in timing/distribution panels enables you to check and
change the parameters of distribution that you have specially created for you model.
Delete link: Delete link is used to delete a particular distribution. If a distribution is used anywhere in
the model, then this link is grayed out and hence cannot be deleted.
To learn more about distributions, please refer to the “Distributions” section.
Information Store
Information store is a where you find items of data which can be used in your simulation to measure or
control what is happening. These items of data are “global”. This means anywhere in your model that
icon: (Creating a new Named Information Store variable) This icon is used to add new
information store variables to the simulation model. You can add either the “Number” variable or
a “Spreadsheet” variable. Number variable can hold a single value whereas spreadsheet variable
can add more than one value per variable.
• Adding a “Number” variable:
icon: (Creating a new Transaction Log Setting) This icon is used to add a new segment for all the
transactions in the transaction log. For example, in the following example, you are defining a
segment from “Customer Arrival” entry point to “Front Desk Service” exit point. The transaction
log in this scenario will collect the cycle time data for all the transactions that pass through this
segment. In addition, users also have the option of collecting the value of any one of the labels
used by these transactions.
Calendars
Calendars let you make your simulation behavior dependent on the current simulation date and time.
You can use calendars to define when each activity and resource in your model is available to work,
such as in the following examples:
1. The calendar for a work start determines when work items can arrive. You can use this to
specify what hours of the day customers can arrive, what days of the week, etc.
2. You can use a calendar to set the working hours for a storage. The calendar will dictate when
work items can flow into or out of the storage. It also affects the storage statistics, so the
recorded queuing time for that storage will not be affected by non-working hours.
3. Calendars are used to specify the shift patterns for resources. For example, you can set a base
amount of resources that is available every day, but also specify that additional resources are
available during peak hours/days/months.
Calendars can also be used in random number distributions, to indicate that arrival or work patterns
change during the course of a day or year. For example:
1. For a restaurant, you can specify peak hours, where customer arrivals are more frequent than
normal. Additionally, you can specify that Friday and Saturday evenings are the busiest time
of the week.
2. For a retail store, you can indicate that customer traffic peaks during the holiday season.
3. In an office or factory, you can indicate that worker productivity is lowest at the beginning
and end of the day, and highest in the middle of the day.
If you define a calendar, you will usually want to share it among several of your activities. A calendar
you define in “Simulation > Simulation Settings > Named Calendars” can be used anywhere calendars
are used.
• Named Calendar: A named calendar can be shared among several activities. Otherwise, you
would have to redefine the calendar for each activity.
Each of the calendars listed above is rather primitive: you cannot use any of them to specify
both working hours (such as 9AM-5PM) and days off (such as weekends and holidays). The
Combination calendar type lets you combine these simpler calendars to precisely define your
desired schedule.
• +New: It is used to create named calendar on the fly. Suppose you are defining a shift
pattern for a resource. You are in the shifts editor and you clicked on the [+] button to add a
new shift. You realize that the shift pattern you are about to define will also be used by other
resources (which means you need a named calendar), but you do not want to have to exit all
your pop-ups and go to “Simulation > Simulation Settings > Named Calendars” to create a
new named calendar. By selecting “New…” from the drop-down, you can create a new
named calendar on the fly, without interrupting your workflow.
• Edit List: This provides a convenient way to manage your list of named calendars.
Simulation Objects
An object in Simulator is something in the simulation model which you normally draw on the screen
and which is normally involved in the work done in the system you are modeling. All objects in
Simulator are based on four basic building blocks that allow you to build up simple models really
quickly using the default values. Simulator object types include:
1. Work Starts
2. Storage (Queues)
3. Process or Work Centers
4. Work Finished
5. (Optional) Resources and Resource Pool (People and other items required to do work at Work
Centers)
All of the basic process mapping shapes can be assigned any one of these object types. For example, if
you have a decision shape in your drawing, then the corresponding object type for this shape would be
“Work Center”. Below are the most common associations of drawing shapes to types”
Work Items
A Work Item is the work that is worked upon in the organization being simulated. Examples are:
1. Patients in a hospital
2. Invoices in an Accounts department
3. Products in a process
Work items are also called entities. These are the things that flow through the process, wait in queues
and are worked upon. Individual work items flow through the work centers in a simulation model.
Work items may have “labels” attached to them. All work items of the same type have the same labels
attached to them but the values in the labels for each individual work item may differ. For example, a
work item type called “Patient” may have a label called “illness” which may be set to 1 for some
patients (for “minor”), 2 for some patients (for “serious”) and 3 for others (“life threatening”). The
values in the label can be changed using actions at Work Centers (or also at Work Starts).
Work Start
A Work Start is a place where work to be done appears in your model for the first time. By
definition, Work Starts are “Active” Object i.e., they push items into the model. You can have as
many “Work Start” objects as you like. Each can feed work into the simulation model using different
statistical distributions (if required). If you want to set the values of labels on your work items as they
enter the model, use “Label Actions” at the work starts. Work Start object has the following
characteristics:
• Inter-arrival Time
Inter-arrival = Time units between arrivals
Will almost always vary randomly
Exponential distribution is often a good choice
• Arrival Types:
Time based (Appointment based)
Random (Customer support calls)
Arrival examples include:
Calendar: Calendar defines the arrival of work items into the model. The arrival rate is applied to the
calendar pattern that you have defined in the model. By default, the calendar is same as the one
defined in the “Clock Properties”. You can modify the calendar for work start if it is different from the
default calendar.
Inter-arrival Time: Define Inter-arrival times
Route Out: Define the routing out options for downstream objects. For Route Out details, please refer
to section on “Routing Out of a Work Center”.
First at Start Time: Selecting “Yes” will generate an item arrival at start irrespective of the
distribution used.
Unlimited Arrivals: Selecting “Yes” will generate an item whenever requested by the downstream
operation. This option will transform the “Work Start” into a passive object that will no longer push
items into the system, rather, it will act as an unlimited source of work items, generating one each time
a connected work center requests one. When “Yes” is selected, the inter-arrival distribution is ignored
(grayed out). Instead, the objects immediately downstream control the inter-arrival time according to
frequency of their requested items. “Unlimited Arrivals” functionality is useful in developing flexible
arrival mechanism that you can turn on and off depending on the time of the day. As an example, try
the following:
Results collected at Work Starts are limited to number of successful and failed attempts to push items
into the system.
Failure: Occurs when a work item has no place to go upon entering the system. These are reported as
“Number Lost”. This usually happens when:
1. Happens when Work Start is directly connected to work center. If work center is busy, the
item cannot be pushed and hence will be lost.
2. Also happens when Work Start is directly connected to storage with limited capacity and
when the storage is full to its capacity.
Checkboxes are used to send the selected result to the simulation reports. To add a new entry in the
Reports, select the checkbox next to the piece of information you want to be displayed in the Reports.
This will be added to the simulation reports immediately and the value on the reports will be
automatically updated from this task pane whenever a simulation run (or trial) ends.
Storage (Queue)
Storage is one of the fundamental objects that make up the structure of your simulation model.
Storages are also known as Buffers and/or Queues. Storage is a place where work to be done can wait
until appropriate resources or work centers are available. Examples of a Storage/Queue include:
• Products awaiting shipment
• Raw material waiting to be used
• People waiting to board an airplane
• People standing in line at a bank/ticket counter
For display purposes and to provide better clarity on the maps, Storages are assumed to be “close to”
the work centers they feed. Storage object has the following characteristics:
• Passive Object – Does not push items into other objects
• Storages are important in any simulation model, but they are often ignored
• Storages absorb variation in the system
• Storages hold items that are waiting to be worked upon
• Almost all activities are preceded by a storage
Work Center
A Work Center is a place where work takes place on work items. Work done at work centers usually
takes up time and sometimes requires the availability of resources. At a work center a work item may
be transformed in some way (perhaps by changing one or more of its labels). After the work is done
the work item may be sent on to another simulation object, or to one of a number of different
simulation objects depending on routing rules that can be specified. To inspect or change the work
center’s parameters, click on the work center on the map and review the information in the work
center’s Simulation Data panel. Work Center has the following characteristics:
• Work Center is an “Active Object”. This means they do things; usually pulling and pushing
the work items.
• Actively pulls items from feeding buffer(s)
• Performs work on each item
• Defining timing is key for any work center
A distribution can be used to capture randomness in processing times
Time defined is the time required to process one item
• Work Center Replicate value determines effective number of Servers/Work Stations/Work
Centers
• Work Centers can modify label values
You can attach resources to indicate which resources are required in order for work-center to function.
Resources are normally used to constrain the work-centers from operating. For timings, you can enter
expressions rather than just numbers. This applies particularly to parameters of distribution (timing)
boxes.
When a work center breaks down, any resources currently held by the work center are
released immediately.
Breakdown Behavior:
Suspend current work: By default, Simulator will suspend the current work upon breakdown
i.e., it will keep the current work item in the work center and break down immediately.
Complete current work: This option allows the model to complete the current work item in
the work center before it breaks down. If work on the current item is delayed during
downtimes, all resources are held within the work center and this time is recorded as being
fully utilized for the resource.
Empty feeding queues: This option allows the work center to complete all the work items in
the feeding queues before breaking down.
Interruptible Storage: Select the storage to where the interrupted items are sent when the work center
in interrupted.
Normally work centers always finish the task they are working on before they consider starting work
on a second work item. However, in some environments low priority tasks are performed which can
be interrupted by other more important jobs.
Set a work center to be “interruptible” by selecting the “Interruptible Storage” from the dropdown
option from the Work Center’s Simulation data Task Pane. This storage will define where the low
priority items will go when they are interrupted by the high priority items. Each interruptible work
center must have a storage object associated with it which will automatically receive interrupted work
items. Please note that such items do not leave the work center using the normal “routing out”
mechanism.
Only work items with a value in their “priority label” greater than the value in the work item being
processed will actually interrupt the work. For a work center to be interruptible, it must be fed by an
object that actively pushes out work (like a work center). Storage objects do not actively feed work
onward; they simply wait for it to be pulled. If you need to have work items in a storage interrupt
work at a work center, simply feed the work items to an intermediate work center, which takes zero
time to process and feeds directly onto the interruptible work center.
A work center can be interrupted in its work on a work item by a work item arriving from another
work center. A work item “X” can “interrupt” (or “preempt”) another work item “Y” if:
1. X is completed at a work center, which directly links to (i.e. not through a storage bin) the
work center where Y is being worked on.
2. The value of X’s priority label is higher than Y’s
3. Y’s work center is set to be “interruptible” (Interruptible Storage is set to “None”).
Work items that are interrupted are removed from the work center and placed in storage. The work
items “Due” label is set to the time that was remaining at the time the task was interrupted. If work at
the second work center (the one which is to be interrupted) requires resources, then before Y is
interrupted there must be sufficient of the resource available to start work on X without taking into
account the resources currently being used by Y.
Segregate Results: Segregates the results by labels and applies to the Content statistics only.
Note: Process Results when Batching: When batches are processed, Simulator provides results
pertaining to the minimum, average, and maximum number of batched items within the work center at
any given time.
Work Center Inventory Statistics
Current Number of work items being processed at the current moment in time.
Minimum The fewest number of work items that were held by the work center
throughout the simulation. The minimum will always be zero unless
1. The work items are processed in a batch
2. Work center’s replication is set to more than 1.
Average Number of items held by the work center averaged across time and weighted
according to time in the work center.
Maximum The greatest number of items that were held by the work center at any point in
the entire simulation.
Jobs Completed The total number of work items that entered the work center throughout the
simulation.
A time graph of the number of items in a work center can, for example, show you patterns of number
of work items held in a work center at any moment in time during the entire run of simulation period.
To see a time-graph, click on an object on the screen (such as a Work Center) and then click the graph
button in the object’s Simulation Results task pane.
Percent of Time: Percentage of time in various states (Waiting, working, blocked, stopped,
changeover)
Resources
“Resources” are items in the simulation model that are required at work centers in order for the work
center to work on a work item. Work centers cannot start work until both a work item is available and
the specified resources are also available. Example of “Resources” includes:
• Person that works on a particular process step / machine
• Special tools for machines
• Beds in hospital ward
Resources can also be shared between the work centers that used them. They are also known as
“shared” or “floating” resources because they “float” between the work centers that require them. The
number of a particular type of resource that is available is set using the resource dialog box.
Resources can be available for only part of the time a simulation model is running if you make use of
shift patterns to describe their availability. Resources can be pooled (or grouped) so that (for example)
Fitters can fit and Operators can operate but either Operators or Fitters can polish. You can set the
resource availability in a shift through the resource dialog box and pooling details in the resource pool
dialog box. At some work centers you can ask for a minimum number of resources and then state that
additional resources will speed up the work.
MIN / MAX: To specify that more than one of a particular resource is required for a task at a work
center, use the MIN and MAX boxes. In the MIN box, specify the minimum number required (this
defaults to 1 and there is no need to use this if you simply need one resource of each type specified at
the work center). If it is possible to reduce the time taken to perform the task by using additional
resources, then enter the maximum number that can be used in the MAX box. The time take to
perform the task will be automatically adjusted as follows:
Actual time = Time with Min Number * (Min Number/Actual Number of Resources Obtained).
Actual Number of Resources Obtained is always as many of the resource type as Simulator finds free
at the time the job starts (subject to the number in the MAX box).
Optionally you can instruct the work center not to load work items until resources are available
(otherwise work items can be taken from queues, but the timing of the work will not start until the
resource can be found).
The Resource Release behavior dialog box lets you say what should happen to work centers, which are
using resources when those resources are removed at the end of a shift. At the end of a shift there may
be a reduction in the number of resources available. If some or all of the resources that are removed
are currently engaged in work at work centers then the behavior tab describes what happens. If
Simulator cannot find one or more of the resources it will not actually hold ANY of the resources. It
always waits until all are available before taking any.
• Finish current work: Behave as if the resource was still at the work center (or stays on late
after the end of the shift) and complete the task in hand - then don’t start another. Vehicles
always complete their task before resources are released at shift end.
• Suspend but resume immediately: Stop the work and hold the work center in suspension
until another resource can be found (perhaps because one finishes work at another work
center).
• Suspend and resume after shift change: As above but don’t let any remaining resources be
used on suspended work centers. Suspended work centers should not be considered for restart
until the next shift change.
Release resources as soon as task is complete: Resources are normally released by a work center as
soon as the task at the work center is complete. However, if a work center is blocked this means that
the resource is freed up before the work center is available to do other work. In cases when resources
are being used to control a sequence of tasks at one real-life work center that is being simulated with a
number of Simulator work centers, this might be undesirable. So this ‘immediate release’ facility can
be switched off for particular work centers. To avoid the above situation, unclick the check box for
‘Release resources as soon as task is complete’.
Require resources before collecting any work items: Resources must be at a work center before the
work center can start work and work items will not normally move to a work center before it can start
work. However, if “collect” routing is used to collect a number of work items into a work center for a
task, then it is possible to de-select the default “Require resources before collecting any work items”
check box in the Resources dialog box.
Collect Chart Data: Select “yes” if you would like to collect resource specific chart data.
Finance: Simulator allows two types of costs to be captured for resources.
• Capital Cost: One time cost for each resource, incurred as soon as the resource is used. The
number of resource units is calculated as the maximum number of resources of this type
employed at any one time during simulation. Ex. If Capital Cost/Resource unit is $10 for
Resource A, and if your model uses a maximum of 6 Resource A members, costs incurred
will be $60.
• Cost/Unit/Time: If a work center requires a resource, each work item processed by the work
center will accumulate not only costs for the work center, but also per time unit costs for each
required resource.
In SigmaFlow Simulator, Traveling resources can be modeled using “Resource Release As” feature. It
provides a powerful mechanism for controlling workflow within a simulation model. At the end of the
processing time, when the work center is ready to release the resource, the work center can transform
the resource into another resource type. When the resource is transformed, the number available of the
source resource is decreased, and the number available of the destination resource is increased. This
transformation is permanent, unless another work center transforms the resources back. This
functionality is useful for modeling following two scenarios:
1. Manage the number of work items in a section of a model
2. Associating a resource to a work item. For example, nurse with a patient, patient with a
stretcher, driver with a car etc. This is explained below with the help of a simple case study.
The leading solution to this problem is traveling resources: allow the “Drive to Company Lot” work
center to release “Airport Lot Drivers” as “Company Lot Drivers”, and allow the “Ride Bus to
Airport” work center to release “Company Lot Drivers” as “Airport Lot Drivers”.
The UI features to support traveling resources include an “Edit” button in the list of resources, and a
“Release resource as:” option in the pop-up that is presented.
The “Company Lot Drivers” resource has its Number of Resources set to 0. This is because in this
particular simulation, all the drivers start at the airport lot.
Results
Suppose we have 10 drivers that move back and forth between the “Airport Lot Drivers” and
“Company Lot Drivers” resources. First, let us look at the graphs for both resources:
As you can see, the Company Lot Drivers graph is the opposite: resources are added gradually via the
Drive to Company Lot process, and then the amount drops suddenly via the Ride Bus to Airport Lot
process.
In fact, when resources travel, the sum of each participating resource’s Available amount at any
particular point in time matches the shift’s amount for that time. For example, if you select a time and
measure the available amount for both Airport Lot Drivers and Company Lot Drivers, you will see that
the sum always adds up to 10 (which is the Number of Resources we set in the Simulation Data pane).
Resource Utilization
The generic formula for traveling resources, where a resource can travel between Resource1,
Resource2, ..., ResourceN, is as follows:
Pool Resources
In Simulator, Pool Resource is a fictitious resource i.e. a pool resource is one that does not really exist
but instead is a combination of other resources. It provides the capability to substitute one resource for
another in a work center’s requirements, providing an “OR” capability and is very effective in
modeling cross-training. Pool resources have certain characteristics, for example:
• A Resource can work in pooled as well as non-pooled activities simultaneously
• Pool resources do not directly use shift patterns or availability
Pool Members
This lists the resources required at a particular work center. Each resource listed must be available
before the work center can start work on a work item. From the “Members” dialog box, select the
resource from the “Select Resources to Add” dropdown to select another resource type for the list.
Click “Delete” link to delete the resource from this list of requirements at this work center.
If the “Scale by factor” option is used, the specified fixed value is multiplied by the sampled
processing times contained in the work center. Therefore, a value of 2.0 doubles the work center’s
processing time and a value of 0.5 will halve the processing time when you select the particular
resource from the pool.
When “Override with” option, the processing time contained in the distribution replaces the
distribution specified by the work center that is referencing the resource pool.
Resource Priority
For pooled resources, the resource priority (or the order in which resources are selected) can be defined
using the “Prioritize Members by” dropdown option. The order of the resources in the list can be
modified using the up/down arrow icons. Simulator includes two priority methods; (a) List Order and
(b) Circulate. The first option, List Order, forces the resources selection to behave as in simple priority
search. Each time the pool attempts to fulfill a request, it will first try to select the resource that is first
in the list. If more than one resource is required, it will select as many as are available, then progress
down the list. This is the default option.
The second option, Circulate, will attempt to rotate the selection between all members of the pool. In
this case, Simulator will remember the last resource that was selected from the pool. The next time
Simulator draws from the pool, it will begin trying at the next resource in the list. Depending on the
random availability of resources, the circulate option may or may not actually smooth the demand
across available resources.
Available: You would only see a difference in this chart if your shift calendars were not 24/7. It is
especially useful when your member resources have different shift patterns, and you want to see how
those shift patterns interact.
Pooled Members: Typical pool results are captured in the Pool Resource Simulation Results task
pane. Pool Members section provides the detailed resource results for each of the pools used in your
simulation. Pooled resources offer simple utilization percentages and detailed statistics. Let us look
at the following table and diagram to analyze the relative effort of the resources within a pool. This
diagram will also help explain some of the percentages breakdown involved in these results.
Each box in the diagram above represents an amount of effort either available or used to satisfy some
demand placed on the Doctors or Nurses. Think of this as the combined effort (available and used)
across all resources. On the left-hand side of the diagram, the combined area of boxes A, B and C
represents the total scheduled time for the Doctors. This includes time available for both pooled and
non-pooled activities. Similarly, the combined total of D, E and F represents the total availability of
the Nurses. Total available time is taken from the resource’s shift patterns, if shift patterns are used.
Box A represents the available Doctor time that was left unused or idle. Box B represents the amount
of available Doctor time that was used on non-pooled activities, while Box C gives the amount of
Doctor time that was used on pooled activities. Boxes D, E and F have similar representations for the
Nurses. Each box is in terms of total person-time units, so if the simulation uses time units in minutes,
effort would be expressed in terms of person-minutes.
Following statistics is reported for each of the pools:
% of Pool: % of pooled effort contributed by this resource. In the diagram it is equivalent to
[C/(C+D)]. Total of all % of Pool should be 100%.
Ex. If a total of 100 minutes were spent by both resources in the pooled effort,
Doctors spent 49.06 minutes and Nurses spent 50.94 minutes.
% of Available: % of time resource was utilized for pooled activities. This is the amount of time a
resource is dedicated to satisfying pool demands, taken as a percentage of the total
available for that resource. In the diagram it is equivalent to [C/(A+B+C)]. Total
does not have to be 100%.
Ex. If Doctor spent 30 Minutes working on a pooled activity and if he/she was
available for 8 hours total, then % of Available would be 6.25%.
% of Use: If the same resource is used for Pooled and Non-pooled activities, then it is a % of
time that was spent for pooled activities. In the diagram it is equivalent to [C/(B+C)].
Utilization %: This is the overall utilization of each resource, including both pooled and non-pooled
activities. Identical to utilization reported for individual resource members. In the
diagram it is equivalent to [(B+C)/(A+B+C)].
Halt Model: Halt a model after a predetermined number of items have been completed.
Segregate Results: Results for a work finished point can be segregated by labels. The segregate
results option permits us to categorize the time-in-system results according to a specific label. We can
then compare time-in-system results across different work item priorities, products, colors, and so on.
This is particularly interesting when using a priority scheme within the system.
Collect Chart Data: Select “Yes” to collect the cycle time histogram data.
Finance: Define revenue collected per item as well as capital cost associated with this activity. If you
have more than one source of revenue (Work Finished points), Profit and Loss statement will show
each source of revenue as a separate line item.
• Capital Cost: It is a one time cost, incurred as soon as the work finished is used. It is
unaffected by the number of work items that pass through the Work Center. You should enter
the capital cost of the Work Finished point amortized across the length of the Simulation
Results Collection Period.
• Revenue / Unit: Revenue numbers are collected at Work Finished Points. You can associate
revenue figures for each completed item
The Y-axis shows the Percentage of work items and the X-axis shows the Cycle time in the system.
The histogram is divided into 10 bars (Maximum time is equally divided into 10 time brackets).
To bring a number of work items into a work center and keep them all as separate work items (so they
leave the work center as the same individual items) but nevertheless process them together as a single
task use “Label Batching” link available in the “Route In” dialog box for that work center. As a
special case, a batch may start in your model as one batch and be immediately split into a number of
individual work items. For more details on “Label batching”, please refer to the section on “Label
Batching”.
Route-in Types
The following route-in types are available in SigmaFlow Simulator.
Circulate
Work Items are taken in order from the locations listed. If an input to the work center does not contain
a suitable item it is ignored and the search continues at the next location in the list.
Ignore Starved Routes: It is opposite of “Ignored Blocked Routes”. Applies to upstream storages and
if it does not find items in one storage, it will go to next until it finds a storage with the items.
Collect
Collect route-in type at a work center lets you collect a number of work items from a number of places.
For example you might want 12 bottles of whisky and 1 box. It makes sure that the work does not
start until they all have been collected. By default a work center does not start collecting the items it
needs until it has all the resources it needs.
If the work center is set to simply collect one work item from each source and each source is a simple
passive object such as a storage, then the Wait for All option (Do not collect until all available) is
available.
Matching causes the work center to collect only items with identical label content. The
“Match by Label” option will search multiple queues for identical Label values, particularly
useful, for example, for matching orders to order paperwork.
• Allows you to combine items by looking for the same value in a particular label
across several items.
• Simulator sorts through each of the source objects to find a match
• In order for Match to work, all the source objects has to be Storages (queues)
• Match option works independently from Assemble option.
If you want your matched items to leave as a single, combined item, check
Assemble
If you want them to proceed together, but remain as distinct items, uncheck
Assemble.
Matching is typically used to re-join items that were split for parallel processing at some
earlier point in the system. For example, consider a three-part work order form that contains a
red page, a yellow page, and a blue page. Each page of the work order is marked with the
same serial number (Label) to aid in tracking. At the beginning of the process, the form is
divided into its individual parts and all of the parts are sent on simultaneously for individual
processing. Because each part of the form meets with its own set of circumstances and delays
along the way, the parts may arrive downstream at different times. Before the work can be
considered complete, however, we must check that all tasks on the work order have been
completed, and document it by matching up the completed red, yellow, and blue forms
carrying the same serial number (label).
The “Do not collect until all available” option tells the work center not to collect ANY of the
required work items from their feeding objects until all the required work items are available.
• If Checked, leave everything in the storage until everything listed is available
• If Unchecked, the work center will start pulling items as soon as they are available.
It will wait for everything listed to be accumulated before the processing would start.
Assemble
“Assemble” (the default selection for “Collect”) pulls together all the items collected into a
single work item. Uncheck this box if you want all the work items kept separate. Assemble,
when checked, assembles 2 or more items into 1 product item. When unchecked, the
assembly process does not take place and the same number items will be produced as
collected.
• If checked, work center collect items from one or more feeding queues, and combine
them into one.
• If Unchecked, work center collect items from one or more feeding queues, process all
the items at the same time, but the items remains separate.
Assembly time-in-system
The “Work Finish” result “Time in System” can be affected by the Collect option. Select the
option that will deliver the work item with the appropriate Time in System.
• Available only when Collect/Assembly Route-in option is selected.
• Allows you to specify how Simulator calculates the time-in-system statistics for the
assembled items.
Expired Only
This method of routing in to a work center tells the work center that it should ONLY except work
items in the feeding “Storage” objects which have waited for at least as long as the shelf life setting for
the storages.
Longest
This option instructs the Work Center to pull items from the queue that contains most work items. The
work center will collect from the storage bin with the longest queue.
Oldest
This option instructs the Work Center to scan the items at the head of the feeding queues, and to select
the item that has been in the simulation longest. This option uses the time that the items have been in
the simulation.
The Oldest and Youngest options use the time the work item has been in the system when identifying
the items to select. If the Use Queue Time option is ticked then the item that has been in the queue for
the longest, in the case of Oldest, or shortest, in the case of Youngest, is selected. If unchecked then
instead of Queue Time, the item that has been in the system for a longest time (or shortest in case of
Youngest) is selected.
Passive
Work centers normally attempt to pull work in and push work out when it is complete. Either of these
can be switched off in the routing in and routing out dialogs. Passive routing means that the object
does not attempt to pull (for passive routing in) or push (for passive routing out).
The Passive rule disables the Pull into the Work Center. This means that the work center will no
longer pull from storages, but will need to be fed work items by another Work Center or Work Start.
Passive is normally used to prevent Routing conflicts where Work Centers are connected to each other.
Youngest
This option instructs the Work Center to scan the items at the head of the feeding queues, and to select
the item that has been in the simulation for the shortest time. This option uses the time that the items
have been in the simulation.
The Oldest and Youngest options use the time the work item has been in the system when identifying
the items to select. If the Use Queue Time option is ticked then the item that has been in the queue for
the longest, in the case of Oldest, or shortest, in the case of Youngest, is selected. If unchecked then
instead of Queue Time, the item that has been in the system for a longest time (or shortest in case of
Youngest) is selected.
Batch by type
This is also known as “Select by Label” i.e. selecting an item by their labels. This method of routing
in to a work center tells the work center to only accept work items that have a certain value in one of
their labels. This can be set by selecting a label that will contain a value, which in your model means
the type of work that it is (e.g. product code, illness type). This allows work center to be selective
about the items that it processes, either by using a fixed or non-fixed label value.
If you do not assign a fixed label value to the work item, the work center simply attempts to select the
next work item with the same label value as the last item it processed. When the work center cannot
find any more of this type of work (in any of the objects which feed it) then it will automatically look
for a new type. When searching for a work item of the same type, the work center will look anywhere
in the queues that feed it (not just at the head of the queue). In summary, “Batching by Type” feature:
• Allows a work center to be selective about the items it processes, either by using a fixed or
non-fixed label value.
• If no fixed label value is assigned, the work center simply attempts to select the next work
item with the same label value as the last item it processed.
Ex. If the first item to enter the work center is red, the center will then process all of the
red items. When no more red items are available, the center will switch to the next color
available (first in the queue)
• If you assign a fixed value, the work center will exclude all items that do not have the
particular fixed value.
Ex. We could use a fixed value to have the work center select only red items and ignore
all other colors.
• Select work items (from same of different feeding queues) that have the same label value.
Destinations
These are set by drawing the routing on the simulation window. The list is basically determined by the
arrows used to connect various objects on the process map. This list shows all the objects that are
connected to this work center with an incoming arrows.
Depending on the routing out discipline, the sequence of the objects in the routing out list can be of
some significance. For example, “priority routing” attempts to send work items to the first object in
the list. To change the sequence, click on one of the name of an object in the list and use the UP and
DOWN buttons.
To change the percentage of work items which are routed to each destination click on the destination
you wish to change and enter the new percentage in the percentage box.
Route-out Types
The following route-out types are available in SigmaFlow Simulator.
Circulate
The first work item will go to the first destination in the list, the second work item to the second,...., the
Nth work item to the Nth destination on the list. The Nth+1 work item with go to the first destination
etc., etc. (Thus the decision about where to go next “circulates” through the list). It is similar to
sending the work out to the destinations in the list in the same way that cards are dealt.
Passive
Passive routing means that the object does not attempt to pull (for passive routing in) or push (for
passive routing out). Work centers normally attempt to pull work in and push work out when it is
complete. Either of these can be switched off in the routing in and routing out dialogs.
“Ignore Blocked Route” does not apply to this type of routing rule.
Percent
The destination work center is decided randomly (like “uniform”) except that the exact percentage
going to each destination can be specified. In the example below 70% of the work goes to Assisted
Service and remaining 30% to Self Service.
Priority
First Destination = First Choice. The priority routing rule sends all work items to the first destination in
the list, unless this is blocked, when the 2nd is tried... and so on.
“Ignore Blocked Route” does not apply to this type of routing rule.
Shortest Queue
This routing method sends Work Items to the queue which is shortest. If one or more of the places to
which work items can be sent is a Work Center then work items will go to the work center if it can
currently take more work, i.e., a work center that can take work immediately counts the same as a
queue with nothing in it. In other words, the work center will send the work items to the place in the
list that has the least amount of work items currently waiting.
“Ignore Blocked Route” does not apply to this type of routing rule.
Uniform
The destination is decided randomly with each destination having an equal chance of being chosen.
Attaching a Label
You can attach a label to a work item as soon as it enters the model through Work Start object. For
“Work Start” object, click on the “Label Actions” to open the Label Action dialog box. To add a
label, select the label from the “Select label to add” dropdown. If the label you require is not in the list
presented select the “+New” option from the dropdown and enter a name for your new label. To edit
existing label, select the “Edit List” option from the dropdown.
Label Actions
Use this dialog box to tell a work center how to change a work item’s labels as they come through the
work center (or other object which can change labels). Action blocks are executed as soon as the work
items task at the work center is completed (before any attempt is made to route the work item out of the
work center).
Label Values
Values in labels can be fixed numbers, coming from distributions or coming from the results of
calculations. U se numbers in labels to, for example, affect the route work items take through your
model. This is the most commonly used method of label values.
Priority Label
Used when some work items may need to interrupt other work items at a work center. Priority label is
also used to segregate results by work item types. The priority label is called “Priority” and you can
add this to your model in the same way as any other label. If a work items does not have this label
then it is said to have zero priority (i.e., the same priority as a work item which has the label, and has it
set to zero). The higher the value of the priority label, the more priority the work item has. This label
should not be confused with other prioritization methods. For example you can prioritize work items
in a queue using any label.
Although the prioritization of queues and work centers can reference any label name, you must use the
Priority label in conjunction with interruptible work centers. In this context, the arrival of a priority
work item will force a work center to stop working on one item, place it aside, and begin working on
the higher priority item. When this higher priority item is completed, work will resume on the
interrupted item continuing from where the work center left off. The amount of time remaining is
recorded on the system label “Due”.
Due Label
If present on a work item, it is set to the amount of time remaining when a work item is preempted by a
higher priority work item at an interruptible work center. Please note that the unit for the “Due” label is
always “Seconds”. Unless you use the “Due” label, the interrupted work items’ operation time at each
attempt will be the full operation time.
Suppose that the operation time for a given work item is 10 minutes, and that the work center was
working on that item for 9 minutes before it was interrupted. If the work item only needs 1 more
minute of work the next time around, you should set the work center’s operation time to use the “Due”
label (which will be set to 60 seconds). However, if the next attempt should take the full 10 minutes,
then you should not use the “Due” label.
The value of the label should be between 1 and N, where N is the number of alternative routing
destinations. If the value is > N the Nth destination will be used. Similarly the 1st is used if the label
is zero or less.
Label Based Route-out – An Example:
• You can use the label values to determine where the work items will be route to after
processing is complete.
• The rule is very simple: the first listed destination is destination 1; the second is 2, and so on.
If a label has a content of 1, then Label based routing will send the work to the first
destination in the list.
• By default, the label values in the list are 1, 2, 3, and so on. If the actual work item label
values do not match the default numbers, they will then go to the last destination listed.
Priority
A number of methods exist for giving aspects of your simulation model priority over other aspects.
Zero is the lowest possible priority (negative values have the same priority as zero). Work items
without the selected label are treated a zero priority. This label (which can have any name) should not
be confused with the “priority label.”
By default all work centers have the same priority (50). The higher the priority value, the more
important the work center is in getting resources. Priority values can be any number between 0
(lowest) and 100 (highest).
Random Numbers
Random numbers enable a simulation model to include the variability that occurs in real life. Each
place where random numbers are used within a model uses a separate stream of random numbers. This
enables a change to be made to one aspect of a model, without affecting the random occurrences that
will happen at other areas. By default, when the clock is set back to the start of the simulation time, all
the random streams are reset to their starting seeds. This means that a second run of the same model
will produce the same results.
1. Simulator automatically assigned the random numbers during the model creating time. When you
select “Change random numbers and run” option, Simulator automatically uses a different random
number set to run the model.
2. All the random numbers are saved with the model so when you run the same model again, it will
generate the same output.
3. In Simulator, random numbers are used at (a) Distributions (unless these are “fixed”) (b) Routing
Out (The uniform and percent options) etc.
Distributions
Many timings and number information in Simulator is given in terms of “Distributions”.
Distributions are used to introduce variability in the model and the sole purpose is to summarize and
replicate the randomness observed in the real system. Typically this enables you to say how long a
process takes, but sometimes it is used to set the value of a label, or other numbers in Simulator.
Distributions are source of values. It is important to note that Simulator itself does not try to fit your
data into a distribution but uses the distributions that were created by modeling real data in a tool like
Statistica, Experfit and/or Bestfit. A typical distribution box in Simulator will look like follows:
Distribution Types
Simulator has two types of distributions namely; (a) Standard Distributions and (b) Custom
Distributions. Standard distributions are the ones that are most commonly available in other curve
fitting applications. Custom distributions are those that are specific to Simulator and can be used to
define your own custom distribution. Following is a list of all distributions in Simulator. To see all
Standard Distributions
Statistical distributions provide a method of simulating the variations that occur in timing (and other
numbers) in any process involving people or machines or anything in nature. Simulator allows you to
create your own distributions, however 16 classical statistical distributions are provided.
Standard Simulator Distributions and Parameters:
Distribution Parameter 1 Parameter 2 Parameter 3
Bernoulli P1: Probability of
success
Beta P1: Alpha 1 P2: Alpha 2
Binomial P1: Trials P2: Probability
Erlang P1: Mean P2: K
Exponential P1: Mean
Fixed P1: Fixed Value
Bernoulli Distribution
Generates a 0 or 1 according to the given probability. Think of it as flipping a (possibly weighted)
coin.
Beta Distribution
Very flexible distribution which can take a very wide variety of shapes including bells skewed in either
direction, almost linear shapes which curve at the end and bells which stop at fixed limit rather than
running out to infinity.
Usage: Proportion of defective items found in a given lot size, Time to complete an activity when very
little or no information is available about the duration of the activity
Binomial Distribution
Provides the total number of successes given a number of trials and the probability of success. A
Binomial distribution could be used to model the number of heads expected in a given number of coin
tosses, even if the coin isn’t fair.
Usage: Number of successes in n trials
Erlang Distribution
Erlang is a composite of repetitive Exponential samples. Thus Erlang 1 (K=1) is the same as
exponential. Erlang 2 is a very left skewed bell chopped at 0. As K increases the shape moves towards
normal but never samples < 0.
Exponential Distribution
(Also knows as Negative Exponential)
Classic distribution used for arrival times of anything where one arrival is independent of the next.
Examples are customers arriving at a store, patients arriving at a hospital. Sometimes it is also relevant
to breakdowns. This is the default distribution used in SigmaFlow Work Start objects.
This distribution peaks at 0. This creates interesting effects because it means most samples are less
than the average, but a few samples are very large. So the few large samples balance the many small
Fixed Distribution
The “Fixed Distribution” is NOT actually a distribution but a fixed number that does not change and is
not random. This enables you to give fixed values, if you need; anywhere that Simulator accepts
distribution information. It also enables you to “Name” values (like “Machine Speed”), which you can
use in many places in your model, then just change one “distribution” when you want to change the
speed of the machines.
A sample from this distribution will always return the value in the “Fixed Value” field. This facility
enables randomness to be removed from an element of the model but also enables “Named”
distributions to be used to return fixed values.
Usage: No variation (constant value)
Gamma Distribution
Rarely used directly but it is an important distribution because it is used to generate other distributions
which have much more use (e.g. Beta, Pearson etc). Similar shapes to Weibull. Unless your data
closely matches gamma use Weibull. Weibull is much faster to generate.
Usage: Time needed to complete a task/group of tasks, Manual tasks such as service times or repair
times
Geometric Distribution
Returns the total number of trials before the first success occurs, where the probability of success in
each trial is P1.
Negative Binomial
Returns the number of failures that occur in a series of trials before P1 successes have occurred, where
the probability of success in each trial is P2.
Normal Distribution
Normal distribution is a classic symmetrical bell-shaped curve that returns 95% of samples within 2
standard deviations of the mean, but is capable of returning rare values in excess of 6 standard
deviations. Used for durations of operations when variability is low.
Usage: Time to perform a task (Processing, Servicing), Measure various types of errors
Example 1: (e.g. operation usually takes 24 minutes but sometimes varies as low as 21 and as
high as 27). Since 95% of samples are within mean +/- 2 “standard deviations”, in the above
case you might use:
Average: 24
Std Dev: 1.5
Poisson Distribution
Often used to model the number of successful outcomes during a given time interval or within a
specified region. A common interpretation for a ‘successful outcome’ is an arrival. This distribution is
strongly tied to an exponential. If the Poisson distribution correctly models the number of arrivals
during a given period, then the time between arrivals (or inter-arrival time) must be exponential.
Usage: Number of Defects per item, Number of times a resource is interrupted each hour
Triangular Distribution
Shape is linear between the minimum and the mode and again from the mode to the maximum. This
distribution is valuable when historical data is extremely limited.
Usage: Limited empirical data is available, Situations where only three pieces of information are
known about a task (Min, most likely, Max)
Example: Ask assemblers on a production line how long it takes to perform an operation. There
response will likely be, “Most of the time it is 10 minutes , but it ranges between 5 and 15.” The
triangular distribution has 3 parameters: Minimum, Modal and Maximum. The mean is calculated by:
(Min + Mode + Max.) / 3
Uniform Distribution
Samples from a uniform distribution are equally spread between the lower bound and the upper bound.
Used when minimum and maximum values are available, but little or no additional data is available.
Every possible value has an equal chance of being sampled (chosen) from this distribution. Uniform
distribution returns an integer value between the minimum and maximum with equal probability of
each value. Unlike Rounded Uniform distribution, the values returned can be any real number in the
interval.
The mean of the value sampled is half way between the two values specified. No sample values occur
outside this range. Tends to be used when it is not possible to collect data about the actual situation but
have the knowledge about the broad range of the data.
Usage: Minimal information available on time, Only Minimum and Maximum are known.
Weibull Distribution
This is a fairly flexible distribution, which can take on quite a few shapes depending on its Alpha
parameter. With Alpha <= 1 it has shapes similar to exponential, but >=2 the shape is more like a wide
lognormal. Weibull distribution is commonly used in engineering to describe the lifetime of an object.
Usage: Time to failure on a piece of equipment, Average life of an electronic component, Time until
failure due to items that wear (bearings, tooling)
Named Distributions
Named distribution window lists all distributions that have been created specifically for this model.
Simulator lets you design your own distributions so that you can describe any variability that your
model might need. In Simulator, you can name distributions and then use those in many places. For
example if 50 different machines are working at a given rate, but you want to be able to change that
rate easily, then you can tell each machine that it uses a distribution call “Machine_Distribution”, and
then just change the parameters of “Machine_Distribution”. There are two types of distributions; (a)
Quantity Distributions and (b) Duration Distributions.
Quantity Distributions: Each of these distributions produces a stream of numbers, or quantities. You
can use them to specify, for example, the batch size for a work center. You can also use them when
defining label actions, since label values are just numbers.
Duration Distributions: These are very similar to quantity distributions, except that they have a unit
of time associated with them. An inter-arrival time of 10 does not make much sense, but an arrival time
of 10 minutes does make sense. You can use these distributions anywhere you need to specify
durations of time. All quantity distributions can be adapted to be duration distributions by attaching a
time unit to them.
Click on [+] icon to add more rows. Click on “Delete” link to remove the existing rows. “Value” and
“Profile %” can be modified by directly editing them in the respective boxes. To move rows up or
down, first click on the empty space between the boxes (Value & Profile%) to highlight and then use
the up/down arrows keys.
Value
This is the value that will be sampled if its particular “percentage chance” occurs. Change these
values by clicking in the appropriate value box.
Profile %
The figures in the “Profile %” boxes are the percentage chance of that particular value being sampled
from the distribution. The percent box shows accurately the percentage chance for the bar you have
just clicked on. You can change a percentage by clicking on the appropriate Profile % box.
Combination Distributions
A combination distribution adds together samples from a number of individual distributions. This can
be used to create special shapes of distribution or to enable unusual circumstances to be added to
normal performance. For example a machine may usually take 5 minutes (with a standard deviation of
1 minute) to perform its work but on 10% of occasions this may take an additional hour. (Use a named
normal distribution in combination with a probability profile distribution that has 60 minutes for 10%
and 0 minutes for 90% of its results).
3. In the window that opens, click on the [+] icon to add a time slot and it’s distribution.
The Time Absolute Distribution dialog lets you add a number of times the thing should happen each
particular time of the day/week/month/year etc. For each time you also give another distribution name
- this lets you say how much variability occurs around the time of day. For example if the morning
mail drop is at 8am but the mail guy is up to 15 minutes late specify 8am and a distribution which
gives values from 0 to 15 (perhaps uniform). If the afternoon mail drop is normally at 2pm but can be
To modify the time, click on the time link. To change the variability, click on the text in the
“Variability” column. If you would like to delete the distribution, click on the “Delete” link.
External Spreadsheets
External distributions allow SigmaFlow to collect timing information from Microsoft Excel (typically
a column of data in Excel), rather than simply using built-in statistical distributions. A typical use of
this facility is to use real data collected from the situation you are modeling, rather than using an
equivalent statistical distribution. This is useful if the data does not match any distribution or you do
not want to include any random elements in your model.
To use the data from external spreadsheet, follow the steps below:
1. Open Excel and enter your data into a column in Excel. Once the data is entered, save the
excel file.
3. Click “Edit” to point to the spreadsheet from where the data needs to be read.
Expressions in Fields
In some fields in Simulator you can enter expressions rather than just numbers. This applies
particularly to parameters of distribution (timing) boxes. For example instead of 13.5 you might type
“Machine Speed” where “Machine Speed” is a Global Data Item you have created in the Information
Store. Another example where the Information store spreadsheet can be used a reference is
MySpreadsheet[8,Label 1], where MySpreadsheet is the name of the Information spreadsheet variable.
Shift Patterns
A SigmaFlow shift pattern lets you define at what times of day (or any time period) parts of your
model work. If all of you model starts and stops at the same times then you do not need to use shift
patterns - instead just set the clock to control the start time and length of each day. Please note that
shifts can ONLY be applied to Resources. To make use of shift patterns, create a Shift Dependent
resource and set up the appropriate Shift Work Patterns for that resource. To define the shifts, click on
the “Shifts” in the Resource Task Pane.
• Click on the “Default” link to define the shift properties. The shift properties dialog box
lets you change the times of day when this shift is “on”. Enter the start time and then the
duration. You can define which days of the week each shift works (or that a shift applies
to all days). If shifts overlap, simulation objects that make use of shifts will normally
assume only one of the shifts is “on” (which ever provides most resources) unless you
change this assumption using the “Overlapping Shift Policy” dropdown. Following
overlapping shift policies are available in Simulator:
o Sum: Sum the resources during the overlapping period
o Max: Use the larger value from the listed shifts. If you have 2 resources in
Shift1 and 5 resources in Shift2, Simulator will use “5” during the
overlapping period.
o First: Pick the number of resources from the top of the list.
• Enter the number of resources in “Amount” box. These are the number of resources that
are going to be available during this time.
• To add a new shift for this resource, click on the [+] icon on top right corner.
• To delete a shift, just click on the “Delete” link.
From Toolbar:
Run Simulation
“Run Simulation” option runs the simulation with the default random number seed. All the results are
collected at the activity level Simulation Results task pane as well as Simulation Reports (if the
checkboxes in the Simulation Results task pane were selected). To run the simulation, select “Run
Simulation” option.
Simulation Reports
Simulation results enable you to collect and review measures of performance. The performance
measures predict how the real system will behave. Simulator collects variety of results for each
object. Some of the important results of common interest and the object they can be collected from are
as follows:
Action Buttons: Every report in Simulator has a set of action buttons that can be used for customizing,
copying, exporting or printing the report.
Customize icon: Use this option to show/hide the columns in your report (rarely used).
Export to Excel: Clicking on this will automatically export the Simulation Results to
Microsoft Excel.
Trial Results
For individual simulation runs, the summary shows the results from the current run. For simulation
trials (multiple simulation runs using different random numbers), the results provide an average as well
as confidence interval calculation (as 95% and 99%). The purpose of a trial is to check the reliability
of results. Let us say you are trying to simulation one week of your organization operations. At the
end of just one run you have simulated one week in your organization. You have a result that is from
one week. Just like real life, that could have been an average week, or a bad week, or a good week.
We have no way of knowing what sort of week it was unless we run a few more of them.
A trial is a run of several weeks and the trial results summarize the results of these several weeks. The
central column of figures gives the result averaged across the weeks in the trial. This gives a guide as
to what we expect the long-term average to be (if we had time to do 1000’s of runs).
The Trial Results window displays the results of the individual runs from the trial along with the
summarized Low 95%, Low 99%, Trial Mean, High 95% and High 99% results.
Confidence Intervals: Simulator automatically estimates confidence intervals for each of your
results. When you use the default trial option to produce 95% confidence intervals, you can reasonably
assume that there is a 95% chance that the true value of any result lies somewhere between the upper
and lower range of its confidence interval.
Customize icon: Use this option to show/hide the columns in your report (rarely used).
Export to Excel: Clicking on this will automatically export the Simulation Results to
Microsoft Excel.
Action Buttons: Every report in Simulator has a set of action buttons that can be used for customizing,
copying, exporting or printing the report.
Customize icon: Use this option to show/hide the columns in your report (rarely used).
Export to Excel: Clicking on this will automatically export the Simulation Results to
Microsoft Excel.
Once the segments have been defined, the transaction log report is automatically generated once the
simulation run is finished. This report lists all the transactions that passed through the system
Transaction logs and charts are NOT AVAILABLE for trails.
Simulator can dynamically allocate costs to work items by taking into account the random processing
times and queuing times. As the model runs Simulator uses all this information to accumulate data on
the flows of money generated by the activities taking place and the resources being used. This
accumulated information is then displayed in summary form in the “Profit & Loss Statement”.
Profit and Loss Statement is generated after you have defined the costs/revenues associated with
various objects and you have run the simulation model. Once the model has run the Profit & Loss
Statement report will show the total bottom line impact of all elements of the model running together.
If you change an aspect of the model and re-run it, you will see the new bottom line (so you can
directly see the total financial impact of the change you have tested).
Each full simulation run will produce a Profit and Loss statement.. P&L Statement will not
list objects if no cost numbers are defined for that object.
Finance overheads occurs once per simulation, and are not affected by the parameters or results of your
simulation. These values will be included in the Profit & Loss Statement Report.
1. SigmaFlow Visio Help: This option launches the Microsoft Office help for Visio. Since
SigmaFlow’s drawing engine is based on Microsoft Visio, users can learn more about the drawing
options directly from Visio.
2. SigmaFlow Help: This option opens the SigmaFlow help window as shown below. The
information can be searched by contents, indexes, or you can search for any specific topic. This is
similar to other Microsoft products.
Many different technical example models are installed to your hard disk when you run the setup
program to install SigmaFlow application. These example files are available in the “Example
Library” folder and can be launched from the File > Open Example Library menu option:
Selecting “Open Example Library…” will open the following dialog box with 2 files and Simulator
folder.
These models were build with the premise that you have gone through the reference manual and
have the basic understanding of all simulation concepts. We have attempted to convey the use of
various simulation concepts through the use of these models. The workings of these models are
explained in detail (step by step) in the SigmaFlow Training Module that can be purchased from
SigmaFlow directly.
This page lists some questions (and their answers) which arise frequently on our phone / fax / email
support lines.
1. Work Start: Incoming links are not allowed for “Work Start” object.
2. Work Finished: Outgoing links are not allowed from “Work Finished” object.
3. Resource: Incoming and Outgoing links are not allowed from “Resource” object.
4. Pool Resources: Incoming and Outgoing links are not allowed from “Pool Resources”
object.
Whenever any of the above conditions are encountered, Simulator will popup the warning
message. You will have to either manually remove these links or disable them (by right
clicking on the link) for simulation purposes.
Q 2: We see that some links in the simulation data task pane are hyperlinks and some are
not.
A: For most properties, the Simulation Data only shows a small, incomplete view of the data. To
get a full editor, you would have to click on the link. In this way, the link was a hint that there
was more that you could do to edit that data. For other properties, such as Finance, you have
the full editor in the Simulation Data pane. Since there is nothing to be gained by opening the
pop-up window just for Finance, we decided to not make it a link.
Q 3: In Simulation Data task pane, there are also some links that are bold and some are
normal.
A: Whenever the default values of these fields are modified, the field links will become bold.
Q 7: What’s the difference between “Numeric data” and “Simulation data” task pane?
A: Data defined in Numeric data task pane is used for Lean benchmarking, Value Stream
Mapping or Value Analysis. Lean data values are used in the reports under Tools > Lean
menu. This data can be captured for individual process activities on the map and it can also
be displayed on the process map. Data defined here is NOT used for simulation purposes.
For data specific to simulation, you will have to use the “Simulation Data” task pane option.
This data cannot be displayed on the map. In addition, Simulation Data allows you to capture
much more advanced level of data and when you run simulation, values from the Simulation
data task pane are used.
Q 8: How many starts (Work Starts) and ends (Work Finished) can my model have?
A: There is no limitation on number of Starts and Ends.
Q 10: I cannot unlock my license. Every time I enter the License ID and password, I get the
following message:
“The information entered was not validated by the server. Please check your information or
try again or contact Technical Support”.
Q 11: If I know nothing about simulation, is there a book you can recommend?
A: Yes, but first read the chapter in the SigmaFlow manual “Simulation Overview”. This will
give you a practical, basic, introduction and give you enough of the theory to get you by. If
you would like to read more we recommend Mike Pidd’s book “Computer SIMULATION in
Management Science” which is published by Wiley.
Q 12: If I have two machines (A and B), which are linked in series, and A cannot start work
until B has finished its previous job, how can I simulate this?
A: Create the 2 work centers and link them together in series. Create a resource called TOKEN
and click on it. Change the number available to 1. Click on each work center in turn and use
their RESOURCES button to say that they need 1 resource each called TOKEN. This way
only one of the 2 work centers can work at any one time.
Q 19: How is Cost field in Numeric Data task pane and Cost(s) data in Simulation data task
pane related?
A: There is no relation between the two.
Q 20: Should I have administrative rights on the computer to install the SigmaFlow
application? How about using the SigmaFlow application once installed?
A: SigmaFlow installation requires administrative rights because our installer copies system files
and adds/modifies registry settings. Once software has been installed and licensed, you do
not need to have administrative rights to use the application.
232 • Index
Histograms 177 Pool Results 171
Pooled Resources 170, 171, 175
Utilization 172
I Preemption 157, 191
Ignored Blocked Route 187 Preference Only 179
Information Store 134 Prioritize 146
Initial Conditions 146 Prioritizing Work Centers 194
Interruption 157, 191 Prioritizing Work in Queues 193
Introduction 219 Priority 187, 191, 193, 194
Priority Label 191
Probability Profile 202
L Probability Profile Distributions 202
Process Mapping 111
Label 186 Process Mapping Steps 50
Label Actions 189 Processing Time 146
Label Based Distributions 193, 208 Profit and Loss Statement 219
Label Based Route-out Pull System 183, 187
An Example 192 Push System 183, 187
Label Based Routing 192
labels 131, 179, 184, 187, 191, 192, 193
Labels 187, 188 Q
Attaching 188
Labels Containing Numbers 190 Questions 228
Labels List 189 Queues 144, 193
Length of Run 131 Quick Replicate 152
Level of Detail 98
List of Destinations 180, 186
List of Distributions 201
R
Longest 183 Random Number Stream 211
Random Numbers 195
Replicate 152
M Required Resources 170
Main Concepts 123 Resource Dependent Timing 171
Matching 181 Resource Dialog Box 163
Maximum Waiting Time 145 Resource Results 165
Min Wait Time 146 Resources 161, 162, 163, 164, 170, 171, 175, 194
Minimum Waiting Time 146 Resources - special uses 162
Model Data Tab 124, 126 Resources Required 170
Multiple Runs 211 Results 105, 107, 131, 144, 148, 159, 165, 172, 176, 177, 211,
214, 215
Results Collection Period 131
N Results Summary Window 214, 215
Revenues 220
Named Distributions 133, 201 Route-in 179
Naming Convention 221 Route-out 179
Normal Distribution 199 Routing 163, 179, 180, 183, 185, 186, 187, 192
Routing In
O Circulate 180
Longest 183
Objects 140, 141, 144, 151, 175 Oldest 183
Oldest 183 Youngest 184
On-line Help 222 Routing Out 185
Ovens 146 Circulate 186
Label 186
Passive 187
P Percent 187
Palletize 177 Shortest Queue 187
Passive 183, 187 Uniform 187
Path Manager Benefits 6 Run 121
Path Manager Navigator 8, 9, 10 Run Length 131
Percent 187 Run Simulation 211
Percentage 179, 187 Running the Simulation 121
Run 121
Index • 233
Runs 211 Variables 134, 208
Verification 102
S
Sampling 133, 193, 201, 204
W
Segregate Results 147 Wait Till Exit Clear 185
Segregation of Results 148, 159, 176 Waiting Time 145, 146, 183
Set Up Times 153, 179 Warm Up Period 131
Setting Operation Times 114, 115 Warm Up Time 131
Setting Route-Out Percentages 117 Warm-Up Time 103
Setting the Clock 120 Weibull Distribution 200
Shelf Life 145, 183 Work Center 208
Shift 164 Work Center Data Properties
Shift Patterns 208 Model Data 151, 161
Shortest Queue 187 Work Center Storage 160
SigmaFlow Modeler 123 Work Centers 151
Simulation Modeling Methodology 109 Work Finished 175
Simulation Modeling Technique Work Finished Data Properties
Guide 98 Model Data 175
Level of Detail 98 Work Item Types 141
Simulation Toolbar 211 Work Items 99, 141
Simulation Window 123 Work Starts 141, 143
Specified Resources 161 Blocked 143
Splitting Work 177 Work Starts Dialog Box 142
Spread Sheets 134 Work to be done 141
Standard Distributions 197 World Set (equivalent) 141
Start-up 146
Statistics 160, 177, 211
Storage 144, 145, 177, 193 Y
Storage Bin Data Properties Youngest 184
Model Data 144
Storage Bins 147
Storage Bins (Queues) 144
Support 228
Systems Requirements 5
T
Time Absolute Distributions 205
Time Dependent Distributions 204
Time Graphs 149
Time of Day 204
timing 197
Timing 195
Toolbars 9
Trials 216
Triangular Distribution 200
U
Uniform 179, 187, 200
Uniform Distributions 200
Unlock 223
Update License 223
Use Queue Time 183, 184
User Defined Distribution 202
Using Label Batching 184
V
Variable Speed Work Centers 162
234 • Index