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Bulk Truck Simulation Project

BY DALTON BEASLEY, DYSON BEASLEY, RYAN WALTMAN, WILLIAM VILLASANA

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Outline

  • Background
  • Time Study & Process Outline
  • Input Analyzer
  • Simulation
  • Preliminary Results
  • Process Analyzer
  • Recommendations
  • Conclusion
  • Appendix

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Background Information

  • Company:
    • Imerys
    • French Multinational Mining Company 
    • Founded in 1884 in Paris
  • Location:
    • Marble Hill, GA
    • Mine founded in 1850 by Samuel Tate's Georgia Marble Company
      • Marble Hill was sold to Imerys in 1995
    • Been around for over 170 years
  • Description
    • Marble Hill has the world's purest marble in the world
    • Imerys mines the marble and then manufactures their own products at the site

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Site Visuals

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Time Study & Process Outline

  1. Elements:
    1. Truck driver checks in at the scale house 
    2. Driver gets the loading information
    3. Driver travels to lead out area 
    4. Driver waits on other trucks 
    5. Driver waits for instructions on how to go under the chute
    6. Driver travel time to go under the chute
    7. Loader sets up safety equipment
    8. Truck gets loaded
    9. Loader gets a sample
    10. Loader removes safety equipment
    11. Truck travels back to scale house
    12. Scale house does a quality test and prints a BOL out
  • 3 Bulk truck loaders per shift

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  • 3 Scale house operators per shift 

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  • Data samples came from 1st shift 

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Input Analyzer

  • 11 Expressions Calculated
    • 1 Arrival Schedule Expression
    • 6 Process Expressions
    • 1 Waiting Expression
    • 3 Route Expressions
  • Types of Expressions
    • 3 Normal Distributions
    • 1 Poisson Distribution
    • 1 Erlang Distribution
    • 3 Beta Distributions
    • 1 Lognormal Distribution
    • 1 Triangular Distribution
    • 1 Weibull Distribution

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Input Analyzer

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Simulation

  • One Entity – Bulktrucks
    • Arrive based on Schedule with Expression
  • 2 Resources – Loaders & Operators
    • Loaders share 4 processes
    • Operators share 2 processes
  • Data Points of Interest
    • Resource Utilization
    • Total Average Wait Time

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Simulation (Arrival Dept.)

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Simulation (Loading Dept.)

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Simulation (Testing & Departure Dept.)

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Simulation (Variables & Visual Sim.)

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Preliminary Results

  • Number of Bulktrucks Out: 69
  • Total Average Time for Bulktrucks: 61.13 Minutes
    • Value Added: 21.7 Minutes
    • Non-Value Added: 22.24 Minutes
    • Wait Time: 13.24 Minutes
  • Loader Scheduled Utilization: 0.03 * 27 = 81%
    • Constant “27” used for Loaders
  • Operator Scheduled Utilization: 0.02 * 36.5 = 73%
    • Constant “36.5” used for Operators

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Process Analyzer 

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Recommendations

  • We recommend for Imerys to have 3 Loaders and 2 Scale House Operators 
  • Another alternative recommendation if they want to save more money is to have 2 Loaders and 2 Scale House Operators
  • Having 3 Loaders and 2 Scale House Operators is more optimal, but 2 loaders and 2 Scale House Operators are better if the company needs to save money
  • Continue having just 2 loaders might be an overload for workers, could potentially lead to problems

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Conclusions

  • We learned how to use Arena to help a company with a real-world situation 
  • We found two alternatives for the company to better organize their loading department
  • We now know how to use simulations for our future careers

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Appendix

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Input Analyzer�Arrival Times Raw Data

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Input Analyzer�Driving Loading Information Raw Data

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Input Analyzer�Route to Scalehouse Raw Data

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Input Analyzer�Waiting on Trucks Raw Data

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Input Analyzer�Truck under Shoot Raw Data

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Input Analyzer�Safety Equipment Raw Data

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Input Analyzer�Loading Bulktruck Raw Data

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Input Analyzer�Loading Sample Raw Data

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Input Analyzer�Remove Safety Equipment Raw Data

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Input Analyzer�Route back to Scalehouse Raw Data

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Input Analyzer�Quality Test Raw Data

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Entire Simulation

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Process Analyzer