WSC 2008

WSC 2008 Final Abstracts

Case Studies Track

Tuesday 8:30:00 AM 10:00:00 AM
Transport System Analysis

Chair: Cathal Heavey (University of Limerick)

Simulation in the Nuclear Industry
Shane Kite (Saker Solutions Ltd) and Colin Gardiner and Sean McCann (Sellafield Ltd)

This paper presents the use of simulation in planning Nuclear Decommissioning projects. Using a Flexsim simulation model of the Sellafield Magnox decanning facility decommissioning as an example, the presentation will highlight the use of simulation in the nuclear environment, the complexity of such models and the approach undertaken as well as identifying some of the benefits achieved as a result of the simulation project. The presentation will be given by Shane Kite, Managing Director of Saker Solutions Ltd and was created in conjunction with Colin Gardiner Head of Operations Research, Sellafield Ltd and Sean McCann, Project Leader Sellafield OR Group.

Simulation of Passenger Screening for Pandemic Influenza at U.S. Airport Ports of Entry
Robert Brigantic and George Muller (Pacific Northwest National Laboratory)

We present a stochastic discrete event simulation that was developed to model the screening of international airline passengers arriving at U.S. airport ports of entry for pandemic influenza. The simulation begins with the generation of international aircraft arrival patterns to the United States. Based on assumed prevalence rates in their origin countries, passengers are randomly assigned to one of three infected states in the simulation – not infected, infected with pandemic influenza, infected with other respiratory illness. Passengers then pass through various screening layers and ultimately exit the system. We track the declared outcome of each passenger over time as they exit the screening process, with a special emphasis on false negatives as they pose the most significant threat to our nation as they will exit the system and unknowingly further spread the pandemic virus throughout the United States. Extensions to DoD environment will also be discussed.

Throughput Capacity Verification of Automated Parking Systems
Marcelo Zottolo, Kathryn Peacock, Eric Lammers, and Edward Williams (PMC)

This presentation discusses modeling challenges, approach, and findings for the throughput capacity verification of a parking system. This system consists of a totally automated four-story parking structure located next to a train station. Demand variations through the day for parking and retrieving cars are verified using simulation and equipment constraints are identified.

Tuesday 10:30:00 AM 12:00:00 PM
Lean and Costing Applications

Chair: Feargal Timon (CIM Ireland Ltd)

A Six Sigma DMADV Project: The 787 LCF Scheduling Tool
Roberto F. Lu and Cliff J. Kirkham (The Boeing Company)

The Boeing 787 program revolutionized many aspects of commercial airplane production. One of the unique aspects of its global production system is that the major 787 structure components are transported via a small fleet of freighter airplanes. These freighter airplanes, called the Large Cargo Freighter (LCF), fly among five production sites to transport the 787 components forward and return their respective carrying tools back to their original sites. Simulating and optimizing LCF logistics related factors is an art as much as a science. This presentation depicts a Six Sigma approach combined with simulation modeling to improving existing tools and methods of the 787 LCF logistics. It is often difficult to start and conclude a LEAN Six Sigma project using simulation modeling. This presentation aims to share the valuable lessons learned through the practice of LEAN Six Sigma using simulation modeling.

Discrete Event Simulation Aids New Lean Production System at
Paul Babin and Gozde Agirbas (

Abstract: is employing several new Lean Production System concepts in its new expansion plant start-up. Building on several successful Discrete Event Simulations using ProModel, the company employed a new model to simulate the material flow in the new plant design. This case study illustrates how simulations can be used effectively to plan, analyze and communicate new concepts prior to deploying them in production.

JTRS Executable Architecture
Joseph Stuart Hurvitz (The MITRE Corporation)

Assessing the benefit of improved battlefield communication is a constant discussion within the DoD. Related to this discussion are questions of “what” and “how much” to procure in an environment of fiscal constraint. This paper describes a methodology that quantifies the benefit of battlefield communication technologies and utilizes the results in a warfighter cost/benefits study. To quantify the value of communication technologies, discrete event simulation is used to expand upon the static DoD Architecture Framework products developed for the Joint Staff Capabilities Integration & Development System process. The ARENA simulation package is employed to produce executable architecture of various military missions. Results quantify communication effectiveness into five warfighter metrics: Speed of Command, Situational Awareness, Footprint, Transformational Impact, and Interoperability. The metrics constitute the benefit portion of a portfolio analysis study to help decision makers determine which communication technologies should be developed and integrated onto military platforms.

Tuesday 1:30:00 PM 3:00:00 PM
Models to Support Operations

Chair: Paul Babin (

Implementation of Core Manufacturing Simulation Data in Aerospace Industry
Roberto Lu (The Boeing Company), Swee Leong (National Institute of Standards and Technology), Nils Bengtsson (Production Modeling Corporation Europe AB), Björn Johansson (Chalmers University of Technology), Frank Riddick, Tina Lee, Guodong Shao, and Charles McLean (National Institute of Standards and Technology) and Al Salour, Laurance N. Hazlehurst, and Sidney Ly (The Boeing Company)

This presentation will describe how Boeing implements the Core Manufacturing Simulation Data (CMSD) information model. The presentation will include visualization of manufacturing data for parts and tooling visibility in manufacturing industry. Simulation analyses are prepared by extracting and formatting data from real world production databases. This includes automatic data processing, automatic curve fitting for distribution functions, automatic CMSD file generation, and finally data is automatically fed to simulations.

Flexible Simulations for Manufacturing
Christopher Milligan (Visual8 Corp.) and Doug Meiser (The Kroger Co.)

The Kroger Co. is one of the largest retailers in the United States. Its manufacturing division produces 43% of corporate brand units sold in its stores. Kroger’s 15 dairies operate at near-full capacity and produce all varieties of fluid milk, orange juice, cultured products such as yogurt and cottage cheese, novelty treats and non-carbonated beverages. Kroger and Visual8 Corp. have created a Flexible Dairy Cooler Simulator which is used in the analysis of production schedules, cooler layouts, picking methods, staffing levels, and shipping schedules at each dairy. The tool offers the flexibility to represent, through a drag-and-drop interface, the layout of any current or future Kroger Dairy. This presentation will demonstrate how this tool is being used to help Kroger streamline operations while improving customer service levels, and explore the tactical value of day-to-day use of a standardized simulation tool in the manufacturing environment.

Simulation as an Integral Part of the Decision Making Processes in a Service Industry: Eircom’s Field Technicians.
Feargal J. Timon (CIM Ireland Ltd)

Eircom is Irelands main supplier of Telecommunication networks. Fault arrival in these networks is unpredictable, however the pattern of fault arrivals is predictable. A key decision involves the planning of staff levels in order to meet potential peak demand (which can be excessive); as planning to meet average demand leads to very poor service levels. The model is used find an agreed balance between Service Level and “Productivity”. The model also provides a collaborative and transparent decision making methodology for Eircom. The main groups involved are customer service, field management, and the field workforce. The model helps in analysing these conflicting requirements and bringing the three groups together to reach a decision. The Model is used to plan staffing levels, overtimes rules, field force mobility and boundaries, and to cost Regulatory Body demands on service levels.

Tuesday 3:30:00 PM 5:00:00 PM
Design and Reliability Applications

Chair: Roberto Lu (The Boeing Company)

The Use of Discrete Event Simulation for Designing Robustness into Ground Combat Vehicles
Tommy E. White (Oakland University)

Robust parameter design methodology will lead to products and process that are insensitive to the effects of noise variables. Finding the optimal setting for design factors depends on the noise variables used in the simulation representative of the real world operating environment and product in the field see the same noise variables. This paper show how basics robust parameter design and simulation can help influence the design of a Ground Combat Vehicle.

Asset Reliability Modeling and Simulation
Ted Tower (Kimberly Clark Corporation)

Traditionally in manufacturing discrete event simulation, delay occurrence and duration are represented by static distributions. For many problems and industries, this assumption may be appropriate, rendering them essentially independent. The manufacturing of soft, disposable consumer products, however, may involve the assembly of multi-component products with flexible materials that pose significant challenges to process reliability and thus make the independence assumption invalid. In fact, these non-linear interactions between coupled-delays can result in substantial financial opportunities from seemingly minor contributors. We describe an Asset Reliability Modeling and Simulation (ARMS) framework developed at Kimberly-Clark that uses discrete event simulation and dynamic reliability modeling of assets' process event databases. Models are essentially built "on the fly" and survival simulations are validated against asset process history. Analytics and reports provide a means for identifying the biggest, overall improvement opportunities in performance metrics including production, delays, uptime, and waste.

Case Study for Usage Modeling in the Automotive Industry
Arai Monteforte (ReliaSoft Co.)

Stress, strength and their interference are essential components of reliability. To estimate product reliability, reliability engineers require an understanding of product stress. Such estimates are more meaningful if stress relates directly to product use. Because often usage data is stable and varies little over time, obtaining representative mathematical models for stress and usage is feasible. Applying discrete event simulation along with usage and stress distributions can then simplify traditional modeling approaches (which required second-by-second data sets for every use element), thus reducing cost and time to acquire information. Developing modules that replicate conditions based on factors such as geographic location, time, etc. gives companies more flexibility in usage models to better support new global markets and product applications. ReliaSoft shares an example developed for a customer of an application of usage modeling, using ReliaSoft's RENO simulation software, to drive requirements, product development and reliability estimates for the global automotive market.

Wednesday 8:30:00 AM 10:00:00 AM
Manufacturing Plant Analysis

Chair: Colin Eustace (Maunsell AECOM)

Productivity Evaluation of 56" Pipe Production Unit
Soheil Mardani (Simaron Pardaz Co.), Mohammad Alkatheer (Ahwaz Pipe & Mills) and Alireza Kabirian (Iowa State University)

Simulation is not only used for future forecasting, it is also used to analyze the past. Ahwaz Pipe Mills is producing wide variety of diameter sizes (12” to 56”) all capable of meeting a large diversity of customer requirements for Gas/Oil and water in past 30 years The basic process of pipe production is not complex. The steel sheets pass several press and welding machines to form a pipe. Due to the necessary buffers and inspection stages it becomes complex. One of the most important challenges at the plants are the downtimes of the equipment which requires the production system to be dynamic. According this uncertainty measuring the amount of time that the whole production line is idle is almost an impossible job. Applying simulation techniques at APM has been done with two main goals: Increase productivity and to use production resources more effectively & analyzing past production operations.

3D Simulation Supports Business Improvements in Small Medium Enterprises
Colm Higgins, Rory Collins, and Tom Egar (Northern Ireland Technology Centre)

Challenged by the need to become more competitive Small and Medium Enterprises (SME's) are faced a plethora of business improvement tools and techniques. Some changes are easier to comprehend but other more wide-scale changes required can require a leap of faith. Funding Agencies are also driven by targets to help companies and may push changes which may not be entirely appropriate for the SME. Invest Northern Ireland (INI) recognized the challenges in helping implement change for their client SME's and sought the help of the Northern Ireland Technology Centre (NITC). INI has "3D Factory Simulation Service" to assist client companies to see how they might implement change using the virtual environment, before major funds are committed. This paper aims discuss how the NITC helps to deliver this service; the methodology deployed, the challenges faced, the direct benefits attained by the companies as well as some affiliated bonus' not first apparent.

Wednesday 10:30:00 AM 12:00:00 PM
Mining and Plant Applications

Chair: Paul Young (Dublin City University)

Simulation of Queensland Coal Rail Operations
Colin Murray Eustace (Maunsell AECOM)

Queensland is Australia's biggest coal export state, accounting for almost 50% of global traded coking coal and 10% of global traded thermal coal. Significant increases in throughput are required in response to global demand. Coal rail systems provide common infrastructure for a large number of independently operated mines and multiple domestic and export coal terminals. Coal train movements are typically unscheduled, driven by varying mine demand and are complex due to yard and port constraints. The unique complications and unscheduled nature of the rail operations make the challenge of simulating the operations beyond most commercially available rail simulation software, which are generally timetable driven with some localized conflict resolution. This case study describes the development of a simulation model capable of capturing the complexities of the coal rail system and the use of the model as a tool to support decision making for infrastructure upgrades and operational changes.

Design & Evaluation of Engine Assembly Line Layouts
Soheil Mardani (Simaron Pardaz Co.), Pouyan Jalili (Ipco) and Alireza Kabirian (Iowa State University)

IPCO is power train supplier for IranKhodro which is the largest car manufacturing company in the MiddleEast. Recently has done a lot of effort to optimize energy consumption, decrease environment pollution and use alternative fuel in the world. Thus IPCO started research, design and production gas fuel engine instead of petrol one for automobiles in C and D class. Following market research the annual target rate settled 200,000 engines. To design the layout in limited area (3800 m2) & also analyze specification of the production & material handling equipment, considering all of the constraint, resources and facilities, simulation model get developed in Enterprise Dynamics. The length of conveyors, cycle time of equipments, optimized number of required pallets & etc. get specified for 2 types of F shape & L shape of layout. Initial inspection shows that the optimum annual production rate will be 185000 units which is less than target.

Simulation of Sublevel Caving Operation - Simulation Applied to Mining
Marco Alessandro Corsaro (Anglo American)

The feasibility of proposed mining method at a South African diamond mine is tested via simulation. The simulation objective is to test mining production schedules, suggested fleet size and ore transportation system (truck loop vs. ramp). The model indicated the best mining method to be employed.