The MAST simulation environment analyzing low frequency inventory systems

Many of today's manufacturing facilities incorporate the latest manufacturing technology including machine tools, fixturing devices, tooling, communication networks, computer software and operators. The integration of these islands of automation into one system is a technology within itself requiring “state of the art” tools to ensure proper compatibility between and among components. When this integration is treated as a technology separate from the technology of individual components, specially developed design tools are necessary to explore these unique characteristics. One such tool combining the desirable characteristics of minimal data input, high flexibility in simulating various system configurations and output results directed at specific characteristics of integrated manufacturing is the MAST Simulation Environment, Release 2. The complete MAST environment is comprised of four integrated software programs: SPAR, MAST, BEAM and BOAT. Each of the four programs performs specific tasks needed in the design cycle for a manufacturing system. As an integrated whole, these four programs combine to form a design/analysis environment uniquely suited for the study of manufacturing systems. The SPAR module allows input of part production and process plan for all part types to be run in the FMS. From this input, the number of stations, transporters and pallets can be determined. These results can be adjusted using a “full screen” editor until a feasible system configuration is reached. SPAR will then automatically generate data for the MAST simulation language. With the SPAR generated date, MAST will simulate each part motion, transporter movement, station status and the actions of tools and operators. Upon completion of the simulation, performance statistics can be printed, graphically displayed, or the activity which took place in the simulation can be animated. A detailed schedule of parts and their operations is recorded for each work station. This can be displayed graphically in the form of a Gantt Chart or representative part traces can be taken. These traces show the elapsed time comparative parts incur during their process through the manufacturing facility. The third program is BEAM which “plays back” the simulation activity with graphical displays of part production, station utilization and transporter utilization. Finally, BOAT (Best Over All Tool) provides an expert system shell which assists the user with problem formulation by remembering steps which have been taken and suggesting the next step. It also provides expert analysis of results based upon the Manufacturing Integration Model (MIM). MIM is a theoretical result relating system flexibility, inventory and throughput.