A conceptual framework for the generation of simulation models from process plans and resource configuration

Although simulation is a popular tool for modelling and analysing modern manufacturing systems, to model shop floor control systems (SFCSs) in simulation requires quite costly efforts, since they are responsible for resolving various decision problems, such as deadlock, part dispatching, and resource conflict. The objective of the paper is to address a conceptual framework necessary to generate a WITNESS simulation model automatically from graph-based process plans and resource configurations. A graph-based process plan is used to capture part operations, their related resource requirements, and their temporal precedence relationships. A WITNESS simulation model is a graphical representation of shop floor resources with the part flow logic embedded within each resource element. To generate a WITNESS model, a process plan is automatically converted into a machine-centred part routeing graph (MCPRG) and then a transport-tending part routeing graph (TTPRG). The MCPRG implies part flows among machines, in which a node represents a machine and an edge represents a part route. The TTPRG implies part flows among machines and material handling devices, in which a node represents either machine or material handler, and an edge represents a part route. From the TTPRG, the part's input and output rules for each resource can be automatically extracted and plugged into the WITNESS model. The approach proposed in the paper enables manufacturers to generate a simulation model rapidly and effectively for performance measurement, such as bottleneck identification, work in progress, throughput times, dynamic resource utilization, and deadlock, of the SFCSs.