Flexsim Tutorial 1-8 Submission Report

Assignment Submitted by
Name : Gobinath VP
Roll No. : 2025MB79027
Course : Lean Manufacturing
Software : Flexsim Simulation

Work Integrated Learning Program

Throughput 162

Inference :
1. As per the problem, Machine Operating time is 10 min and if I calculate the output for 4320 min. The theoretical
output is (4320/10) = 432 parts. But the actual output is 162, which is very less.
2. Reason 1 : The parts are arriving in Exponential Distribution meaning (Average arrival time = 10 min), but it
varies in real Environment
3. Reason 2 : As per the Problem Statement, the operator does both Transfer of Material as well as operating the
Machine, So there will be delay due to Operator handling.
4. The machine cannot start without the operator, which is causing the increase in machine waiting time.
5. Due to the above reasons, the Actual throughput is very less 162 for the given conditions and the bottle neck is
Machine + Operator.
6. Quick Suggestion for increasing the throughput would be adding one more operator to the system or
Implementing Automation for Machine Loading.
Tutorial 2
THROUGHPUT ESTIMATION & STAYTIME – WITH OPERATORS
Tutorial 2
THROUGHPUT ESTIMATION & STAYTIME – WITHOUT OPERATORS
Tutorial 2
Flexsim Simulation Result & Observations
Inference :
1. As per the Simulation Tested for 4320 min, For the Case 1-With Operators involved in Transportation, the
throughput is around 796 Nos and the stay time in the Buffer is 150 min, which indicates that parts stayed in the
Buffer/Storage for longer Duration before process. It is due to that operator's availability which is causing the
delay in Transportation to machines. So apparently parts get accumulated in the storage increasing the over all
stay time in the buffer.

2. For the Case 2 – Without Operators Involved in Transportation, the throughput is around 859 Nos and the stay
time in the Buffer is 2.69 min, which indicates that parts stayed in the Buffer/Storage is very less time which is
due to the operator related transportation is eliminated. So that parts moved from Buffer to Machines very fast.

3. The Important observation is by removing the transport constraints in the system, the Throughput increases
marginally good and stay time / Waiting time drastically came down and improved the efficiency.

4. Even though throughput improvement is marginal between the case 1 and case 2, if stay time is high, then there
will be High WIP Inventory cost, and more space is required for storage. Hence Based on the observations, the
efficient Material Handling systems is always recommended to improve the productivity.
Tutorial 3
LINE LAYOUT VS U LAYOUT
Tutorial 3
Flexsim Simulation Result & Observations (For 7320 min)
Layout Throughput Distance Travelled meters / Hour

L Layout 42 318.33
U Layout 44 28.64
Inference :
1. In the Line layout Configuration, Throughput is 42 and Distance travelled by operator is 318 meters per hour.
Since the Forging and Heat Treatment Machines are arranged in the straight line. The operator must travel long
distance to operate both the machines. Doing this will results increase in Operator Fatigue and Efficiency drops.

2. In the U Layout Configuration, throughput is 44. Since the distance between the machines are nearer, the
distance travelled by the operator is very less 28.6 meters per hour. Due to the shorter distance arrangement in
the U layout configuration, the idle time between the operations will drastically come down.

3. So U layout reduces the unnecessary movement of the operator, i.e. Eliminates one of the critical Muda (Motion
Waste) from the system to improve efficiency.
Tutorial 4
RESOURCE CAPACITY VALIDATION
Tutorial 4
Flexsim Simulation Result & Observations
Parameter Value

Throughput 84

Inference :
1. For the Simulation period of 1000 minutes, conveyor sorting system processed 84 parts through the entire
system.
2. Four different parts are sent from Machine to conveyors after processing. Then it gets sorted to corresponding
conveyors.
3. Even though the machine capacity is (1000/2) = 500 parts, the conveyor length and speed influence the Overall
throughput. Also, as per theoretical approach, based on the arrival time the desired output could be
approx.(1000/5 min) = 200 Parts.
4. Hence the Bottleneck should be lies with the conveyor side. Therefore by increasing the speed of the conveyor
or reducing the length of the conveyor, through put can be improved.
5. The Overall System Capacity is based on the machine capacity and Conveyor travel time.
Tutorial 5
LINE BALANCING
Tutorial 5
LINE BALANCING
Tutorial 5
LINE BALANCING
Tutorial 5
Flexsim Simulation Result & Observations
Parameter Normal Condition Peak Season Peak Season (After Bottleneck Eliminated)

Throughput 862 1006 1011

2. Condition 2 : During Peak season, the input to the source increased by 15% by reducing the arrival time by
15%. The Throughput of the System is 1006 and the machine utilization of the Tester machine is crossed its
Limit. i.e. Over utilized to > 90% Which is resulted as the Bottleneck of the System.

3. Condition 3 : Here to manage the bottleneck, i.e. By increasing the capacity of Tester machine, the
Utilization drops to 71% and the throughput also Improved to manage peak season demand.

4. We can also add one more Tester also for this problem. Depends on the Factory Manager Decision.
Tutorial 6
INVENTORY CONTROL
Tutorial 6
INVENTORY CONTROL
Tutorial 6
Flexsim Simulation Result & Observations
Parameter

No of Forklift Trips for 1000 Units Throughput 1049

Inference :
1. Simulation Run for the Throughput of 1000 units, Result shows that 1049 Forklift trips happened between
Storage 1 and Storage 2 until the 1000 units of Throughput.

2. Checked and verified the Input Control Conditions of the Forklift. i.e., Forklift will start only when storage 2
capacity goes below 10 and stops when it's reaching its maximum capacity 50.

3. As per the Observation, Storage 2 is always ensured with minimum of 10 parts, so that flow to the
Machine is continuous and not disturbed.

4. If we need to reduce the forklift trips as well as maintain flow, then We might need to increase the lift
capacity of the forklift >10 and another option. We might need to increase the storage 2 capacity should
be increased more than 50.
Tutorial 7
EQUIPMENT PERFORMANCE VALIDATION
Tutorial 7
Flexsim Simulation Result & Observations
Queue 1 Queue 2 Queue 3 Queue 4
WIP
203 215 198 215

Inference :
1. For the Simulation period of 4320 minutes, the Tilted tray conveyor sorting system processed 4 different
parts (198 -215) Nos and observed the balanced distribution to respective Buffer effectively.
2. This Simulation results creates path for 2 critical observations according to me, although the conveyor
system distribution is perfect. We need to ensure the downstream process flow should be smooth and
continuous.
3. If downstream process after conveyor sorting is not continuous, then the parts will get accumulated in the
Queue and over a period of time there might be congestion due to WIP accumulation.
4. To avoid this, either Parts arrival time needs to be adjusted or conveyor speed to be slower down in line
with the withdrawn Kanban provided by the downstream process in the pull system.
5. Hence as per the simulation, sorting is perfect but need to ensure the flow.
Tutorial 8
BATCH PRODUCTION VS SINGLEPIECE PRODUCTION
Tutorial 8
Flexsim Simulation Result & Observations
Parameter Batch Production Single Piece Production

Throughput 430 399

Inference :
1. Two production approaches were analyzed Batch Production (4 cakes at a time) vs Single Piece Production
(one cake at a time) and the simulation was run for 4320 minutes, and the throughput of both systems was
compared.
2. In Batch production 4 cakes are processed together in one cycle. Got higher throughput 430. Batch production
reduces idle time of the oven with the effective Utilization of the space. Drawback is Oven needs to wait until a 4
cakes form a batch. So, it increases WIP.
3. In Single Piece production, Cakes are produced one by one and throughput obtained is 399 which is lower. In
this approach better flow and no waiting for batch formation, so Lower WIP.
4. If the Owner is interested in Lean Implementation, based on the simulation results, he should choose Single
Piece production. Even though throughput is marginally less. Due to less Inventory, Quality of the product can
be ensured.