A Simulation Model for Factory Productivity Momtoring

TABLE OF CONTENTS

DECLARATION

APPROVAL

DEDICATION

ACKNOWLEDGEMENT

TABLE OF CONTENTS

ABSTRACT

CHAPTER ONE 1

INTRODUCTION 1

1.1 Background ofthe study 1

1.2 Case study description 2

1.3 Problem Statement 2

1.4 Project Objectives 3

1.4.1 General Objective 3

1.4.2 Specific Objectives 3

1.5 Justification ofthe study 3

1.6 Project scope 3

CHAPTER TWO 4

LITERATURE REViEW 4

2.1 Introduction 4

2.2 Simulation Models 4

2.3 Applications of Simulation Models 4

2.4 Characteristics of simulation models 5

2.5 Model types and their comparisons 6

2.6 Classification of Simulation Models 6

2.7 Discrete Event Simulation Model 7

2.8 Productivity 8

2.9 Productivity monitoring 8

2.10 Conclusion 9

CHAPTER THREE 10

METHODOLOGY 10

V

3.1 Overview. 10

3.2 System study 10

3.2.1 Reading 10

3.2.2 Interviews

3.2.3 Questionnaires 10

3.2.4 Observation

3.3 Analysis 11

Figure 1. Process map 12

3.4 Development ofthe Model 13

3.4.1 Determining model requirements 13

3.5 Testing and validation 13

ChAPTER FOUR 14

SYSTEM DESIGN AND IMPLEMENTATION 14

4.1 Model Design 14

Table 2. Production resources, their types and unit ofmeasure 14

The simulation process 14

4.2 Implementation 20

CHAPTER FIVE 21

FINDINGS, CONCLUSIONS AN]) RECOMMENDATIONS 21

5.1 Discussion 21

5.2 Conclusion 21

5.3 Recommendations 21

REFERENCES 22

APPENDICES 23

APPENDIX A 23

Questionnaire 23

APPENDIX B 25

Sample System Codes 25

ABSTRACT

This project is about a productivity simulation system for a factory. It is a real timesystem, which has been designed to monitor productivity by capturing information on all the resources that are used in producing a unit quantity of a product. The resources in this project are people, water, furnace oil and electricity. The value of these resources for aspecific period oftime is divided by the quantity of product processed or produced in the same period to evaluate the unit cost of production in that period and hence the productivity of the factory can be monitored on an hourly basis. The simulation model isthus made to be an integral process in a processing factory rather than a system that checks performance after a process is complete.The system therefore works well when there is a system in place that captures all the resources that go into the manufacturing process accurately and on a regular basis.