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Figure 3-2.Digital manufacturing tool

This day of age, simulation models and technology are used in single projects

that target the tactical or decision making support. Many of these models are designed to

plan equipment purchases or to evaluate planned changes of material flow control. [3]

A manufacturing system is made up of entities; input and outputs, activities,

resources and controls. ( Harrel and Tumay 1995 ).It encompasses processes but also

includes the resources and controls for carrying them out, as shown in figure below.[4]

Figure 3-3.A manufacturing system

Manufacturing system designs involves a number of interrelated subjects

including tooling, strategy, material handling systems, system size, process flow

configuration, flexibility needed for future engineering changes or capacity adjustment

and space strategy .The production process design is a critical area, since any decision

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will affect the system behavior for a long time to come, and/or be very costly to change

once the system is up and running.[5]

Simulation studies include resource utilization, line productivity and

manufacturing costs helps to identify the most suitable manufacturing line type within a

factory.[6]There are many way and avenues simulation can be utilized. In the

manufacturing system life cycle the following steps can be found; concept creation,

layout planning, production simulation, software development, operator training and

potentially operational use of the simulation model in decision support for managers.

Simulation models can shorten the sales cycle of a production system. The usage

or application of simulation in manufacturing is as follows,[7]

Layout and concert creation ( 3D , animation)- Visualization , communication- Cell, lines , factories

Production simulation ( data , analysis , reports )- Control principle, routing ,buffer sizes ,capacity , utilization ,

Software development ( emulation , system integration ) Training of operators ( emulation , VR ) Operational use of simulation ( Data , speed integration )

Simulation also can be used for layout planning and concept creation. With the

use of 3D visualization tools are needed to improve communication in concurrent

engineering teams. In this step the facility floor space needs and production principle

is verified. Logistic solutions can be evaluated too. Quick simulation or modelling is

really beneficial here.

In the case of software development, simulation models can emulate the real

system. The real programs that will be used in the real system can be tested with the

real data if available. The virtual system, simulation model replaces in this case the

planned system before anything is built to the factory floor. One of the main

requirements here is validated simulation model and integration of software.

For the case of training purposes of operators, the emulation and simulation

model is a great tool for training the operators; the system parameters can be studied

with the simulation model. The software training with the real data can be done and

this speeds up the ramp-up phase. If the control software has been integrated with the

simulation model. The operators have the same user interface as in the real life and

the simulation gives a holistic view to the manufacturing system.

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While some models are used to plan and design, other models are used in the

day-to-day operation of manufacturing facilities .These enhancement provides the

chance to evaluate the capacity of the system for new orders , unforeseen events suchas equipment downtime , and changes in operations.

Operations are equipped with schedules that manufacturers can use to run their

facilities. Planning and scheduling systems to validate plans and confirm schedules

can be complemented by the use of simulation. The augmented task of planners and

schedulers can be simulated to run the operation with better efficiency.

Some of the operational uses of simulation models are [Thomson, 1993]:

Emulation of real time control systems Real time display Real time forecasting Scheduling