Simulation is one of the most powerful analysis tools available to those responsible for the

design and operation of complex processes or systems. In an increasingly competitive world,

simulation has become a very powerful tool for the planning, design, and control of systems. No
longer regarded as the approach of “last resort” it is today viewed as an indispensable problem-
solving methodology for engineers, designers, and managers [7].

This article presents some important features of the ARENA 3.0 software. This would help the
beginner to understand the basic concepts necessary for building a simple model. This in turn
could provide a springboard for building up complex real world models.

A Simple Simulation Model

Let us consider a simple simulation model. Suppose we have a single-channel queuing (waiting
line) system, such as a checkout counter in a drugstore. The time between the arrival of
customers is uniformly distributed from 1 to 10 minutes. This is obtained by means of a spinner
dial (such as those used in some board games). The time required to service a customer be
uniformly distributed between 1 to 6 minutes. A single die can be used to generate service times.
The system has two random variables and if a large number of readings need to be generated, a
computer is needed for generating the random variables and for doing the bookkeeping. To
simulate real-world systems adequately, we must also be able to generate behavioral
characteristics that are realistic. For example, the time between arrivals and the service times
generated must allow for something other than uniform distribution rounded to the nearest whole
number [7].

Distribution Selection

To test the compatibility of a set of observed frequencies with some theoretical frequency, we
must first identify the theoretical distribution we wish to try. If we are dealing with a discrete
variable, we record the frequency occurring within which each individual value occurs. If the
variable is continuous, we break the range of values into equal interval or class. The relative
frequency in each interval is then the observed frequency count in each class divided by the total
number of data points [7].

After we have obtained a relative frequency distribution, selecting the possible probability
distribution from which it may be derived becomes a matter of judge and experience [7].

Some examples of continuous distributions are uniform, triangular, negative exponential, Erlang,
gamma, Weibull, normal, lognormal, and beta. Some examples of discrete distributions are
discrete uniform, binomial, geometric, and Poisson [7].

Goodness-of-Fit Test

Once we have selected a distribution (based on visual inspection and theoretical grounds), we
then need to assess the quality of our fit. This can be done by using formal statistical tests or by
employing a simple graphical method in which an overlay of the theoretical distribution is
displayed on a histogram of the data and a visual assessment is made to determine the quality of
the fit. A goodness-of-fit test attempts to measure and evaluate the deviation of the sample
distribution from the theoretical. Examples of these tests include both the Chi-Square (x^2) and
the Kolmogrov-Smirnov tests [7].

Basic Modeling Concepts

IN ARENA3.0 environment, the word "entity" is a generic term used to denote any person,
object, or thing- whose movement through the system causes change in the state of the system.
Every entity possesses some unique characteristics referred to as attributes . For example in a
factory a job may have attributes specifying the part number, due date, and priority of the job.
The term variables, refers to the set of changeable values characterizing the components of the
system as a whole. Example of a variable is TNOW. It specifies the current value of the
simulated time [8].

In the ARENA3.0 modeling framework, there is a fundamental distinction between the Model
and the Experiment. The model is a functional description of the system’s components and their
interactions. The experiment defines the experimental conditions under which the model is
exercised to generate specific output data. An ARENA3.0 simulation program generates both a
model and corresponding experiments [8].

Processes are modeled in SIMAN by using a block diagram. A block diagram is a flow graph
depicting the process through which the entities in the system move. The block diagram is
constructed as a sequence of blocks, the shapes and names of which indicate their general
function. The experimental section of the program consists of elements which, are specified
interactively in the Arena modeling environment [8].

Blocks
The following section describes in brief the different blocks used by the simulation team.

CREATE: It is one of the several mechanisms by which an entity (product) can enter into the
model. It is typically used to model arrival processes in which entities sequentially enter the
model according to a specified pattern. The operands of Create block are Batch size indicating
the number of entities arriving simultaneously in the model, Offset time specifying the time
between the start of simulation and the arrival of the first entity, Interval specifying the delay
between the arrivals at successive points after the first. The Maximum Batches operand specifies
the maximum number of arrival points [8].

QUEUE: It provides waiting space for the entities whose movements through the model have
been suspended based on the system’s status. An example is a work piece Waiting in turn to be
processed on a busy machine. The operands of queue block are Queue ID indicating the name of
the queue, Capacity of the queue and the Balk label which is used to direct the entity to an
alternative block other than the seize block [8].

SEIZE: It is used in conjunction with the queue block and is used to model the status delays.
When a resource becomes idle the entity from the previous queue block enters the seize block
and seizes the resource. The state of the resource now changes from idle to busy. The operands
of seize block include priority for the allocation of entities waiting for the same resource. Priority
is given to those entities, which have been waiting the longest. The Resource ID indicating the
resource requested by the waiting entity and the number of units of the resource requested by the
entity [8].

DELAY: Once an entity has been allocated the necessary resources, it typically engages in time-
consuming activities, such as setup, machining, inspection etc. In ARENA3.0, delays such as
these can be modeled by using the DELAY block. The operands of the delay block are the
duration of the delay and the storage ID, which provides statistics on the number of entities
residing in one or more DELAY blocks [8].

RELEASE: When an activity that requires resources has been completed, the entity possessing
the resources typically releases them so that they can be allocated to entities either currently
waiting or yet to arrive at QUEUE-SEIZE blocks. Operands of seize block are Resource ID
indicating the resource just released and the Quantity of entities to release simultaneously [8].

COUNT: It is used to count the number of occurrences of some event, e.g., work-pieces entering
the system, exiting the system or sent through rework. The operands of the Count block include
the Counter ID (name of the counter) and the Counter increment for which, a default value of
one is assumed [8].

DISPOSE: It provides a mechanism for modeling the departure of entities from the system. The
dispose block has a single entry point, no operands, and no exit points. All entities entering the
dispose block are terminated from the model [8].

GROUP: It is commonly used to group a set of entities having a particular set characteristics. A
representative entity is created and it moves through the model and behaves, as though, it is a
single entity. The most important operand of group block is the quantity to group. This is
commonly used to simulate a manufacturing scenario in which a set of parts corresponding to a
particular product need to be grouped before they can be assembled by the machine [8].

SPLIT: The entities, which had been grouped, need to be split or de-grouped before they are
disposed. The split block is used for the same. The departing entities have the original attribute
values they had when the entity set was formed [8].

ASSIGN: Whenever attributes and variables are used in a model they need to be assigned values
during model execution. This is made possible by means of the assign block. The operand of the
block is Variable or Attribute = Value. Each time an entity passes through the ASSIGN block,
the value on the right hand side of the equals sign is copied on to the variable or attribute on the
left hand side of the equation. Example when the entities pass through the CREATE block they
can be assigned a job type of 1,2,3 with a certain probability of the entity belonging to each type
[8].

BRANCH: This is used to direct the entities to different sections of the model depending upon
the condition of true or false. The operands of the branch block are the following:
 a. Maximum Number of Branches (it is usually 1).
b. With (indicates the probability and the label to which the entity needs to be directed).
c. Else (indicates the label to which the entity needs to be directed if the else condition
becomes true).
d. Always (whatever the condition the entity needs to be sent to a specific label).

As described earlier, experiment defines the experimental conditions under which the model is
exercised to generate specific output data. The length of the simulation run, the number of
replications of the simulation, the characteristics of resources and queues, etc all come under
experimental conditions. Using special data records called elements the experiment is developed.
It is generally preferable to enter the experiment before entering the model. By first defining the
objects such as resources in the experiment, the drop down list can then be selected when
entering the model graphically [8].

Elements
The following section describes in brief the various elements used by the simulation team in
developing the project.

PROJECT: It is used to describe the simulation project used by ARENA3.0 in labeling the
SIMAN summary report. The program automatically generates this report at the end of each
replication if it is defined under the experimental conditions. The operands of the element
include Project Title, Analyst Name, Date, Summary Report (yes/ no). Maximum of 24
characters can be entered in the first two fields [8].

QUEUES: It defines the information of the model’s queues. The operands of the queue element
are Number (need not be defined), Name of the queue, Ranking Criterion . The following
criterion are used:

a. FIFO (First-in, First-out): Entities wait in the queue in the order in which they arrive.
b. LIFO (Last-in, First-out): Entities are ranked in the reverse order of their entry into the
queue.
c. LVF (Attribute ID): The queue is ordered by increasing values of the specified attribute
with ties broken by the FIFO rule.
d. HVF (Attribute ID): Queue is ordered by the decreasing values of the specified attribute
with ties broken by the FIFO rule [8].

RESOURCES: It defines the information about the model’s resources. The operands include
Number (need not be defined), Name of the resource, Capacity, which defines the number of
identical and interchangeable units that initially exist for the resource. It defaults to 1 [8].

COUNTERS: This element provides descriptive information of the counters included in the
model section. The operands included in the element are Number (need not be defined), Name of
the counter, Limit. The last operand specifies a certain value which when exceeded causes the
program to terminate [8].
REPLICATE: It defines the Number of Replications for which the simulation is to be run, the
Beginning Time of the first replication and the Replication Length, which defines the duration of
each simulation replication [8].

ATTRIBUTES: and VARIABLES: These elements provide general information about the
symbolic names and properties of the attributes and variables. The operands of the elements
include Number (optional), Name (index), Initial Values. The second operand is used to specify
an array with certain index values. Each element in the array has a unique index value, which is
stored in a common array name. The third variable is used to initialize a variable to a certain
value [8].

STATIONS: It defines the information of the stations used in the model. The operands include
Number (optional), Name of the station [8].

SETS: It defines a group of similar elements that may be referenced by a common name and set
index. The elements that make up the set are referred to as the members of the set. Typical sets
would contain groups of resources, queues, stations, pictures, counters, tallies, expressions, etc.
The operands of the element are Number (optional), Name of the Set and the Members of the set.
The last operand can be referenced by the set name. The function used by the Simulation team in
building the manufacturing model was MemIdx (Setname, Member Name). This function returns
the index number of a specific member in the set. The member name was the first station at
which the entity entered the model [8].

SCHEDULES: This is used to change the capacity of the resource over time. The resource
follows a time dependent schedule as specified in the element. For example, the resource is idle
for the first 30 minutes of the simulation run. During this period it has a capacity of 0. During the
next 30 minutes of the run the resource can have a capacity of 1. The operands of the element
include Identifier, which is fed into the resource block following the schedule and Resource
Capacity and the Capacity Duration, which specifies the capacity of the resource during a
certain time period [8].

SEQUENCES: It defines the sequence in which an entity visits the stations. The operands
include Number (optional), Name of the sequence, Station ID and the Assignments (duration of
delay, assignment of picture or job type, etc.) at each station [8].

Arena3.0 Verification Tools Used by the Simulation Team

a. RUN CONTROLLER: It allows the user to step through the execution of the model by
exercising complete control from the keyboard or the mouse. The entity can be moved
through one or more blocks, its value can be examined by using simple commands. The
execution can also be suspended at critical points or when specified variables reach
defined values. The run controller also provides access to a model’s source statements,
which can be listed during execution [8].
b. ANIMATION: Successful verification depends on one’s ability to comprehend the
complex interactions among the many components within a model. Of all the techniques
available to help in the verification process, animation is without a doubt the single, most
 powerful aid available. Only animation can present a dynamically moving picture of the
many interactions taking place within the simulation. The animation displays the same
information for all model components simultaneously [8].

This article has provided a brief insight as to how the simulation team has used the ARENA3.0
simulation tool to develop the models. This would enable the beginner to know the various
blocks and elements used by the team and serve as a guide for understanding the manufacturing
processes. We suggest that those people who do not have any exposure to simulation read this
article before the presentation by the simulation team [8].

Back to Table of Contents

 B. Computer Manufacturing Model [LR]

The computer manufacturing model differs from the automobile model with regards to detail,
layout, and input data. Less detailed than the automobile manufacturing model in terms of
specifying individual operations in the assembly stage, the computer manufacturing model
simulates five main stages in assembling and testing computers. These processes are:

1. Assembly
2. Electrical testing
3. Software loading
4. Final testing and inspection
5. Packaging

Rather than having a single flow line as in the automobile model, the layout of the computer
model consists of two repetitive parallel lines, each line consisting of the five main stages as
shown in the following figure:
Parallel Lines in Computer Manufacturing Model
Each line is analagous to a work cell in that material flows continuously through each stage with
minimal in-process inventories. A complete product is manufactured at each cell, which uses
equipment for each stage of the production process.

As described in the Manufacturing Team's web site, a typical manufacturing plant consists of
four main components:

 Receiving
 Production Processing
 Packaging, and
 Shipping

These components are incorporated in the computer manufacturing model in the following
manner:

Receiving
Orders of varying sizes arrive in intervals and are processed as first-in-first-out. For
simplification, all requested computers in a particular order have the same configuration. The
configuration consists of processor type, number of boards, and monitor type. The model
specifies three types of processors, two types of boards, and two types of monitors. These
attributes are probalistically assigned to each order with 12 configurations possible. Orders are
sent to the least busy line but wait to be filled until the assembly stage is free. The model
assumes that all raw materials for the assembly stage are readily available and are sufficient to
fill each order. The logic for order processing in Arena is shown below.

Order Processing Logic in Computer Manufacturing Model

Production Processing and Packaging
As mentioned previously, the production layout consists of two repetitive parallel lines. Orders
are fed to each line, which consists of five stages. The processing times for each stage are:
assembly - 12 minutes, electrical wiring test - 5 minutes, load software - 15 minutes, final test
and inspection - 5 minutes, and packaging - 5 minutes. The utilization rate of the assembly stage
is driven by the nature of the orders arriving: the size of each order and the time between orders.
Queue formations and potential bottlenecks may occur at the assembly and loading software
stages, where the processing times are high. These problems may be addressed by increasing the
capacity of the resources, such as adding a third assembly stage or loading software for multiple
computers at a time. Packaging involves selecting the appropriate monitor for the order and
sending the packages to the shipping area.

Shipping
Although the computer model does not specifically simulate shipping activities, the model is
flexible enough to have this component included at a later date. One consideration may involve
combining packaging and shipping activities into one area.
The input data for the computer manufacturing model was not obtained from actual existing data
from any particular computer manufacturer. Instead educated guesses were made for order sizes
and processing times. Although one of the tenets in developing any simulation model involves
obtaining actual data, this requirement was lifted in order to show a simple manufacturing model
that utilizes parallel manunfacturing cells, and how the sizes, arrival, and number of orders affect
assembly utilization rates.

Back to Table of Contents

 C. Automobile Manufacturing Model [AB]

The automobile is perhaps the most important invention second only to electricity in the 20th
century. It has changed life of man in a way unimaginable before its invention. "The world
travels on wheels" is the buzzword of the 20th century. The manufacturing of these automobiles
is both a fascinating and challenging task. The simulation team has simulated the manufacturing
process of wagons, sedans and convertibles in a Toyota car plant.

The following is the step by step procedure for the manufacturing of cars in the "Toyota
Production System":

1. The manufacturing process begins with the chassis assembly. The chassis is the skeleton
of the car. It is the part on which the car is built.
2. Axle and tires are fitted to the chassis assembly.
3. In the next stage, the engine is fitted to the chassis. The engine is the power-producing
component of the car. The power produced in the engine is use to propel the car. Engines
are mostly of the internal combustion type.
4. The gearbox is then fitted into the chassis. The gearbox is the component that is used to
change the speed supplied to the wheels.
5. The next stage involves the fitting of the radiator into the engine. The radiator helps in
cooling the engine, transmitting the excess heat to the surrounding by conduction.
6. The seats are then fitted to the car in the next stage.
7. The battery is then fitted and electrical connections are carried out. The electrical
connections connect the various components of the car to the battery.
8. The body of the car is then fitted on the chassis.
9. The windshield, doors, and wipers are fitted to the car along with the bonnet.
10. The finishing touches are carried out on the car.
11. The car is then sent for inspection and testing after which it is taken to the parking lot and
kept ready for shipping.

Below is a block diagram describing the manufacturing flow.

 U-Flow in Automobile Manufacturing

The student version of the model limited the number of blocks to be used. The challenge was to
use the limited number of blocks available without simplifying the process. For this purpose Sets
were used along with Attributes such as "Work time" and "Op time." Given below is a brief
explanation of attributes, variables, sets and counters used in the model.

Attributes

1. Worktime: If the job arriving at the workstation is a Hardtop or a Wagon it is delayed by

the duration given in the work time attribute of the delay block.
2. Optime (operation time): If the job arriving at the workstation is a Sedan it is delayed by
the duration given in the Op time attribute of the delay block.
3. Setindex: Corresponds to a specific workstation in the set of stations.
4. Timein (time in): Denotes the time at which a job arrived in the system.
5. Jobtype (type of job): Denotes that the type of job is a hardtop, wagon or sedan.

Sets

1. Queueset: Signifies all the queues along the main assembly line, which are sequentially
visited by the job.
2. Stationset: Corresponds to all the stations along the main assembly line, which are
sequentially attended by the job.
3. Resourceset: Denotes all the resources along the main assembly line, which are
sequentially attended by the job.

Counters

1. Wagons: Number of wagons produced

2. Hardtops: Number of hardtops produced
3. Sedans: Number of Sedans produced
4. Total cars: Total number of cars produced
Variables
Every job is delayed at the workstation for a specific duration. This is obtained by fitting the
historical data in the input analyzer. In the manufacturing model case the duration of the delay is
LOGNORMAL with a mean and standard deviation. Since there are three different types of jobs
with different delays, a variable array is defined with constants for the distribution. Each constant
in the array signifies a part of the operand for a specific job in the delay block. The following
three constants have been defined:

1. Mean
2. C
3. Std

Back to Table of Contents

 D. Transportation Model [AT]

For any organization having several manufacturing facilities, and a huge and spread market,
transportation remains an inevitable part of its total system. The transportation model developed
by the simulation team serves as a guideline to study how automobiles manufactured at a
particular facility are transported to various places.

Following is a brief procedure on how this transportation takes place:

1. At first all the cars are accumulated in a huge parking lot, which also serves as a loading
area for the trucks that carry these cars.
2. Once the specified number of cars is available, they are loaded on to the trucks as per the
capacity of the trucks.
3. These trucks then transport the vehicles to the specified destination, such as a dock,
where all these trucks are then handed over to a distributor.
4. At the dock, the vehicles are unloaded from the trucks, and then loaded onto a ship.
5. Once the ship is loaded to its capacity, it is then directed to its destination, which may be
other countries, or within the nation, but to different states.

The block diagram below, explains how the flow of the automobiles takes place once
manufactured, to the time they are delivered to their final destination.
 Transportation of Manufactured Cars

The attributes, variables, sequences, etc. that are used in the model are explained below:

Attributes: Time-In is the only attribute used in the model, which determines what time the car
entered the system, for how long it was in the system.
Schedules: This element describes the schedules for the resources, when they are available and
when they are not.
Counters: Counts the total number cars that are transported during the specified time.
Transporters: There are two types of transporters, Trucks and Ship, which are being used in this
model.