Industrial Engineering Commons^™

Combining Activity-Based Costing With The Simulation Of A Cellular Manufacturing System, Paul Savory, Robert Williams, Rodney Rassmuseun

Department of Industrial and Management Systems Engineering: Faculty Publications

Discrete-event simulation is one of the most effective techniques for analyzing a manufacturing system. Unfortunately, little attention is given to using simulation models to estimate the economic impact of a proposed system configuration. This paper defines how activity-based costing (ABC) concepts can be incorporated into a discrete-event simulation model. Special emphasis is on demonstrating how decision making can be aided by having the simulation create a detailed “Bill of Activity” describing costs associated with manufacturing a part. The integration of ABC and simulation is illustrated by evaluating the impact of a proposed manufacturing cell configuration. The additional costing information aids …

A Web-Based Interface For Storing And Executing Simulation Model, Ashu Guru, Paul Savory, Robert Williams

Department of Industrial and Management Systems Engineering: Faculty Publications

The dominance of the Internet in the development ofinformation and communication technology has madeWeb-based distributed solutions increasingly attractive.Apart from providing other services, the World Wide Webis being looked upon as an environment for hostingmodeling and simulation applications. SIMAN is asimulation language that allows users to simulate discreteand continuous systems. In this research, a web-basedinterface or toolkit has been developed for storing andexecuting SIMAN simulation models over the Internet.This toolkit consists of a World Wide Web interface toSIMAN and a web-accessible database for storing usermodels. It provides users an easy-to-use environment fordeveloping text-based simulation models using the SIMANsimulation language. It also …

Introduction To Industrial Engineering: Team Tower, Paul Savory

Department of Industrial and Management Systems Engineering: Instructional Materials

Classroom exercise for IMSE 150 at the University of Nebraska-Lincoln. This goal is to introduce freshman industrial engineering students to various aspects of industrial engineering and being an engineer. One of the key areas of Industrial Engineering is quality control. Quality control is concerned with testing and inspecting a product to confirm that it meets production and customer specifications. To understand some of the basics of quality control, let’s consider the production of M&M candies.

Introduction To Industrial Engineering: Group Resume, Paul Savory

Department of Industrial and Management Systems Engineering: Instructional Materials

Classroom exercise for IMSE 150 at the University of Nebraska-Lincoln. This goal is to introduce freshman industrial engineering students to various aspects of industrial engineering and being an engineer. This ice-breaking exercise has students work in groups to create a group resume to get to know each other better.

Introduction To Industrial Engineering: Bad Human Factor Designs, Paul Savory

Department of Industrial and Management Systems Engineering: Instructional Materials

Classroom exercise for IMSE 150 at the University of Nebraska-Lincoln. This goal is to introduce freshman industrial engineering students to various aspects of industrial engineering and being an engineer. Ergonomics or human factors does not only encompass product design, but safety, and product use. A simple definition is “to make the work place safe and less stressful on the worker.” Human factors or ergonomics impacts all aspects of our lives. Let's consider each of the following examples of bad human factor designs.

Introduction To Industrial Engineering: Theme Park Design And Layout, Paul Savory

Department of Industrial and Management Systems Engineering: Instructional Materials

Classroom exercise for IMSE 150 at the University of Nebraska-Lincoln. This goal is to introduce freshman industrial engineering students to various aspects of industrial engineering and being an engineer. Plant layout and design is one of the key areas of industrial engineering. There are numerous issues that must be accounted for. A subset include: machine utilization, queueing space, and flow of materials. To provide students with an introduction to plant layout and design, let's consider designing a theme park. As we will see, many of the concepts will be the same.

Introduction To Industrial Engineering: Interpretation Of Visual Displays, Paul Savory

Department of Industrial and Management Systems Engineering: Instructional Materials

Classroom exercise for IMSE 150 at the University of Nebraska-Lincoln. This goal is to introduce freshman industrial engineering students to various aspects of industrial engineering and being an engineer. The area of human factors or ergonomics focuses on human beings and their interaction with products, equipment, facilities, producers, and environments used in work and everyday life. The emphasis is on human beings and how the design of things influences people. One small area of ergonomics is concerned with how humans interpret visual displays. For an introduction to this area, let's consider the visual interpretation of static displays (i.e., information that …

Introduction To Industrial Engineering: Manufacturing Variability, Paul Savory

Department of Industrial and Management Systems Engineering: Instructional Materials

Classroom exercise for IMSE 150 at the University of Nebraska-Lincoln. This goal is to introduce freshman industrial engineering students to various aspects of industrial engineering and being an engineer. This fun and interactive penny manufacturing game highlights the impact of variability, capacity, and overtime.

Introduction To Industrial Engineering: Ethical Choices, Paul Savory

Department of Industrial and Management Systems Engineering: Instructional Materials

Classroom exercise for IMSE 150 at the University of Nebraska-Lincoln. This goal is to introduce freshman industrial engineering students to various aspects of industrial engineering and being an engineer. All industrial engineering, product designers, and managers must at some point in their career face an issue that requires some amount of ethical or moral judgment. Consider the following scenarios and discuss with your group members what each of you would do.

Simulation Modeling Presentations: The Life Cycle, Edward Yellig, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

A typical large scale simulation modeling project spans many months and encompasses activities such as problem definition, data collection, model development, experimentation, and scenario analysis. During the life cycle of a simulation project, numerous presentations are made to many different types of audiences. The purpose of these presentations will vary from seeking project approval, requesting information, discussing simulation model features, verifying the model, validating the model, presenting the experimental results, and offering model conclusions. This paper will discuss presentation techniques we used during a year-long simulation-modeling project. We will highlight techniques used for defining the purpose of each presentation, identifying …

Road Rescue Implements A Continuous Process Improvement Framework, John Olson, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

Continuous improvement programs traditionally focus on making small incremental improvements to a system. Unfortunately, their success can be limited due to the rapid changing environment within which most small companies operate. Improvement efforts should be flexible enough to capitalize on incremental and radical changes to a system. This paper presents a case analysis of how Road Rescue, an ambulance manufacturer, uses a continuous improvement framework to capitalize on both radical and incremental improvement opportunities. Results include a 10% increase in throughput, reduced cycle time of 44%, increased customer satisfaction, and higher quality.

Cracking The Shell To Student Learning: An Innovative Instructional Approach, John R. Olson, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

Management and Industrial Engineering courses is motivating students to learn and apply the quantitative and managerial aspects of the material. The aim of our educational methodology is to not only teach and reinforce the core principles of the disciplines, but to have students develop a set of skills that will make them competitive in the classroom and the workforce. Teaching is why a university exists. As a result, the objective of our instructional approach is to attract and retain dedicated students to the fields of Operations Management and Industrial Engineering and to keep those students competitive and in focus with …

Using Simulation To Derive Activity-Based Costing Estimates, Paul Savory, Robert Williams

Department of Industrial and Management Systems Engineering: Faculty Publications

This presentation showcases integrating activity based costing into the development of a SIMAN simulation of a manufacturing system.

A Multithreaded Scheduler For A High-Speed Simulator, Gene Saghi, Kirk Reinholtz, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

The Cassini spacecraft is on its journey to Saturn to perform a close-up study of the Saturnian system; its rings, moons, magneto-sphere, and the planet itself. Sequences of commands will be sent to the spacecraft by ground personnel to control every aspect of the mission. To validate and verify these command sequences, a bit-level, high-speed simulator (HSS) has been developed. To maximize performance, the HSS is implemented with multiple threads and runs on a multiprocessor system. A key component of the HSS is the scheduler, which controls the execution of the simulator. The general framework of the scheduler can be …

An Aggregation Procedure For Simulating Manufacturing Flow Line Models, Paul Savory, Gerald Mackulak

Department of Industrial and Management Systems Engineering: Faculty Publications

We develop a formal method for specifying an aggregate discrete-event simulation model of a production flow line manufacturing system. The methodology operates by aggregating production stations or resources of a flow line. Determining the specifications for representing the aggregated resources in a simulation model is the focus of our presentation. We test the methodology for a set of flow lines with exponentially distributed arrival and service times. Comparisons between analytical and simulation results indicate the aggregation approach is quite accurate for estimating average part cycle time.

An Integrated Approach To Simulation And Activity-Based Costing For Evaluating Alternative Manufacturing Cell Designs, Robert Williams, Paul Savory, Rodney Rasmussen

Department of Industrial and Management Systems Engineering: Faculty Publications

One effective technique for improving manufacturing efficiency involves the application of group technology part families and manufacturing cells. Selection of the best or optimum configuration of the manufacturing cell relies on the experience and judgment of the cell designer. This paper describes how activity-based costing (ABC) concepts can be integrated into a discrete-event simulation model and be used to evaluate manufacturing cell configurations. The output of the combined ABC simulation model provides a detailed “Bill of Activity” which allows the cell designer to consider costs as a critical factor in the cell design problem. Alternative cell configurations studied in this …

Selecting For Random Drug Testing At Union Pacific Railroad, Jennifer Meyer, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

Many industries have recently implemented programs to detect and deter the use of recreational drugs in the workplace. The transportation industry has received careful government attention, particularly where the safety of the public may be seriously affected by employees who use drugs. Following federal guidelines, Union Pacific Railroad first implemented a random drug-testing plan in 1990. Because the assigned jobs, shifts, and work locations of many railroad employees change frequently, defining the selection population was particularly challenging. In its continuing efforts to validate and improve this plan, Union Pacific Railroad sought an external evaluation to determine the fairness of its …

Simulating Queue Scheduling Policies For A Spacecraft Simulator, Paul Savory, Gene Saghi

Department of Industrial and Management Systems Engineering: Faculty Publications

The mission of the Cassini spacecraft is a unique opportunity to gain insights into major scientific questions about Saturn, the creation of the solar system, and the conditions that led to life on Earth. In preparation for the launch, NASA's Jet Propulsion Laboratory developed a software simulator to emulate the hardware data-control system of the spacecraft. Its primary use is to validate and verify commands that will be transmitted to the spacecraft. To improve the performance of the simulator, we used the SIMAN simulation language to model numerous queue-scheduling policies. Implementation of the simulation results combined with a software-code redesign …

Cycle Time Estimation For Simulating A Tandem Queueing Systems Using Aggregation Techniques, Paul Savory, Gerald Mackulak

Department of Industrial and Management Systems Engineering: Faculty Publications

One approach to simulating a single-server tandem queuing system is to explicitly model each of the production stages. In this paper, we apply queueing theory, a recursive algorithm, and composite random number sampling to develop an equivalent aggregate representation consisting of only a single production stage. Preliminary test results indicate that the aggregation works well for estimating the mean and variability of the total cycle time.

Using Mathematica To Aid Simulation Analysis, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

As computer power has increased, so has the capability of software developers to write programs that assist people with time-consuming tasks. Mathematica is such a program. The objective of this paper is to demonstrate how Mathematica, a symbolic programming environment, can be used to aid simulation analysis. In addition to a general discussion of Mathematica’s uses, advantages, and disadvantages, several examples will be presented. The examples include using Mathematica for distribution fitting, queueing analysis, random number generation, and creating a surface plot for optimization.

Issues In Developing An Undergraduate Simulation Course, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

Experience in developing an undergraduate simulation course is described. The course introduces the philosophies, principles, and methodologies for discrete-event simulation modeling. Strategy in choosing the course simulation software is discussed, plus important areas of teaching emphasis are highlighted.

Simulation Project Characteristics In Industrial Settings, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

In a survey of practitioners of discrete-event simulation from industry and research institutes who "build models for money," we asked about project goals, user backgrounds and training, organizational types and activities, software and hardware choices, modeling team composition, and effort allocation within a modeling project. We found that (1) only about half of the practitioners have three or more years experience, (2) many academics feel strongly affiliated with their industry clients rather than with their university employers, (3) shop-floor supervisors rarely lead simulation projects, even though their knowledge of the system may be unparalleled, (4)simulation models are generally described as …

Extending Simulation’S Advantages To Novice Model Builders: Intellisim Tutorial, Paul Savory, Gerald Mackulak, Jeff Cochran

Department of Industrial and Management Systems Engineering: Faculty Publications

The potential benefits that discrete-event simulation offers are impeded by the high level of expertise necessary to successfully conduct a sound simulation study. As a solution, this paper introduces IntelliSIM, an intelligent simulation environment. Using this environment makes simulation more accessible to users by reducing the need for extensive experience or training. One of IntelliSIM’s key features for accomplishing this is a tutorial and training module that quickly acquaints a novice simulation user with IntelliSIM’s features and the process of performing a simulation study. This paper discusses this tutorial by explaining how IntelliSIM develops a simulation model, thus illustrating how …

Ascertaining Important Features For Industrial Simulation Environments, Gerald Mackulak, Jeffery Cichran, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

Recent years have witnessed the development and commercial release of multiple simulation tools, environments, and intelligent simulators. Each release seems to contain additional advanced features designed to simplify simulation use and increase the productivity of model builders. But to date, no one has addressed feature definition from the viewpoint of a simulation practitioner. This paper discusses our efforts to identify and prioritize simulation features deemed most desirable from the practitioner viewpoint. A series of three questionnaires were developed and administered to a group of qualified simulation practitioners. With results that are of interest to simulation users, researchers, and simulation software …

The Science Of Simulation Modeling, Paul Savory, Gerald Mackulak

Department of Industrial and Management Systems Engineering: Faculty Publications

Many people refer to simulation model building as an “intuitive art”. This implies that modeling can only be done by a select group of highly trained creative people and thus isolates many from considering simulation as a usable tool. Model building is a science that is learned through education, training and experience. In this paper, we discuss the role of science in performing a simulation study. We illustrate the teaching of the science of simulation by discussing the simulation curriculum at Arizona State University.

A Robust Aggregation Approach To Simplification Of Manufacturing Flow Line Models, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

One of the more difficult tasks facing a modeler in developing a simulation model of a discrete part manufacturing system is deciding at what level of abstraction to represent the resources of the system. For example, questions about plant capacity can be modeled with a simple model, whereas questions regarding the efficiency of different part scheduling rules can only be answered with a more detailed model. In developing a simulation model, most of the actual features of the system under study must be ignored and an abstraction must be developed. If done correctly, this idealization provides a useful approximation of …

A Robust Aggregation Approach To Simplification Of Manufacturing Flow Line Models, Paul Savory

Department of Industrial and Management Systems Engineering: Presentations

One of the more difficult tasks facing a modeler in developing a simulation model of a discrete part manufacturing system is deciding at what level of abstraction to represent the resources of the system. For example, questions about plant capacity can be modeled with a simple model, whereas questions regarding the efficiency of different part scheduling rules can only be answered with a more detailed model. In developing a simulation model, most of the actual features of the system under study must be ignored and an abstraction must be developed. If done correctly, this idealization provides a useful approximation of …

Introduction To Intellisim 2.0, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

IntelliSIM is a prototype for a new generation of knowledge-based simulation tool that has been developed by the Systems Simulation Laboratory at Arizona State University. This tool is a computer environment that allows non-simulation trained modelers to predict the performance of a manufacturing system for which the necessary data is available. The system provides predictive data on such items as throughput time, queue levels, equipment utilization, reactions to machine failures, etc. With IntelliSIM, the benefits of discrete-event simulation can be exploited without requiring the high level of expertise necessary to successfully conduct a sound simulation study. The approach offered with …

Introduction To Intellisim 1.0, Paul Savory

Department of Industrial and Management Systems Engineering: Faculty Publications

IntelliSIM is a prototype for a new generation of knowledge-based simulation tool that has been developed by the Systems Simulation Laboratory at Arizona State University. This tool is a computer environment that allows non-simulation trained modelers to predict the performance of a manufacturing system for which the necessary data is available. The system provides predictive data on such items as throughput time, queue levels, equipment utilization, reactions to machine failures, etc. With IntelliSIM, the benefits of discrete-event simulation can be exploited without requiring the high level of expertise necessary to successfully conduct a sound simulation study. The approach offered with …

Material Handling In A Flexible Manufacturing Systems Processing Part Families, Paul Savory, Gerald Mackulak, Jeff Cochran

Department of Industrial and Management Systems Engineering: Faculty Publications

The objective of this simulation study is to analyze the system performance of a six machine flexible manufacturing system cell in which a material handling system is to be incorporated. The analysis focuses on determining the production potential of the cell by grouping common parts into "families". To accomplish this, computer simulation models are developed using the SIMAN simulation language.

Initially the manufacturing cell is modeled with no material handling system to get an upper bound estimate of production output. We next explore the impact that an automatic guided vehicle (AGV) has on system performance of the manufacturing system cell. …