FMC Simulation with Simio RPS

This project involves the use of Simio RPS with a flexible manufacturing cell. The project will demonstrate the use of Simio for traditional design-oriented analysis as well as the use of Simio RPS' advanced risk-base planning and schedule functionality.

The following pages each include a YouTube video with the content. Alternatively, you can view the video playlist directly on YouTube

The embedded videos were recorded at 1280x720 resolution. If your computer does not support this resolution, you should use the video playlist on YouTube so that you can better control the video size.

V1 - Introduction


This video gives an overview of the project and describes the flexible manufacturing cell that we'll be using in the example.

V2 - Static Capacity Analysis

Static Capacity Analysis

This video focuses on the development of a static capacity model for our FMC. We will use the capacity model to do some preliminary system analysis and, later, to verify our Simio models.

V3 - Initial Simio Model Part 1

Initial Simio Model Part 1

This video is the first of two videos that illustrate the initial Simio model development. Modeling is shown in detail in a step-by-step fashion.

V4 - Initial Simio Model Part 2

Initial Simio Model Part 2

This video is the second part of the initial Simio model development. Modeling is shown in detail in a step-by-step fashion.

V5 - Model Verification

Model Verification

Verification involves ensuring that the model works as we think that it does.

V6 - Experimentation Part 1

Experimentation Part 1

Using the model to determine the number of operators requried and to determine the system capacity given the current product mix.

V7 - Optimization and OptQuest

Optimization and OptQuest with the Simio Model

Demonstrates the use of the OptQuest add-in to maximize the system throughput by setting the number of operators and the part interarrival time.

Note:: There is an error in this video -- the stability expression should be greater than the threshold, not less than as is shown in the constraint (around 2:50 of the video). In other words, the ratio of the departure rate to the arrival rate should be greater than the threshold value (of, say 99%) to ensure that what arrives, departs, while accommodating some level of WIP.

V8 - RPS Model Part 1

RPS Model Part 1

Introduces the ideas of Simio RPS and describes the requried model modifications. Adds worker schedules, and orders table, and binds the orders table to an external data source.

V9 - RPS Model Part 2

RPS Model Part 2

Adds the Ship Date state to the Orders table and sets a corresponding Ship Date target to evaluate performance. Also incorporates the WIP table and associated process so that the system starts in a non empty-and-idle state.

When discussing "WIP" in the video, I inadvertently used both of the terms "work in process" and "work in progress". These terms are interchangeable in our context, but sorry for the confusion! Also, when working with the setup times (around time 14:10 of the video), I have the setup time units in "minutes" where the units should be "hours".

V10 - RPS Model Part 3

RPS Model Part 3

Turns on Resource Logging for the workstations and the operator and illustrates the Create Plan feature of Simio RPS. Goes through the various views of the work plan.

V11 - RPS Model Part 4

RPS Model Part 4

Demonstrates the Analyze Risk feature and goes through three basic changes to the system to try to improve the on-time performance (adds and operator, orders the workstation queues by order due date, and adds an overtime shift).