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CMPS User’s Manual

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    • Arena 10.0 (CPR 7) and FactoryTalk Activation Client Tool
    • Congestion Modeling Planning System
    1. Heijun-Ka (Model Mix)
    2. Vehicle Definition
    3. Station Definition
    4. Route Definition
    5. Production Area Definition
    6. Vehicle Routing
    7. Trigger Part Definition
    • Run Simulation Model
    • Without Animation
    • With Animation
      B.Simulation Results

      1. Vehicle Utilization
      2. Link/Aisle Way Use
      3. Average Delivery Time
      4. Total Number of Deliveries Completed


The primary purpose of Congestion Modeling Planning Software (CMPS) will be to determine if sufficient capacity is available (in terms of equipment) to satisfy the stated demand. The user can vary the following operating parameters to conduct “What-If” analysis:

  • Heijun-Ka (Model Mix) -The user can specify the model type to be produced and the corresponding daily production ratio. CMPS can accommodate up to 100 unique model types to be evaluated in each scenario.   Congestion Modeling Planning Software also allows the user to change the number of days to simulate, the number of shifts per day and the number of hours per shift.   The purpose of having the ability to change the number of days to simulate is to have the simulated system reach a steady-state pattern.   The number of days required to reach a steady-state condition can vary with differing process parameters.
  • The vehicle type to be used in the analysis – Congestion Modeling Planning Software allows the user to change the vehicle type, corresponding speed and quantity of vehicles by vehicle type to be evaluated in each scenario. There can be up to a maximum of ten (10) vehicles by vehicle type specified for each scenario.   Congestion Modeling Planning Software allows for a maximum of 200 vehicle types and vehicle speed.
  • Congestion Modeling Planning Software allows the user to specify all the stations used in a scenario.   A station is defined as a location where material is stored in a storage area or a line-side storage area.   It is very important to note that the station defined by the user must correspond to the Station # (column B).   Each station number is noted on the layout of the Body Weld operations included with this manual.   Congestion Modeling Planning Software can accommodate up to 4000 unique station.
  • The Route Definition allows the user to define all routes by name used in the simulation and the corresponding vehicle type assigned to each route.   A route is a user defined name that corresponds to a particular route a vehicle type would complete for specific line-side material deliveries.   The same vehicle type can be assigned to multiple routes. Congestion Modeling Planning Software can accommodate up to 2000 unique route descriptions.
  • Production Area Definition – this allows the user to specify the production areas to be used in the simulation along with the corresponding production rate (in seconds).   The production rate is used to specify the rate at which line-side material is consumed.   Congestion Modeling Planning Software can accommodate up to 200 unique production areas.
  • Vehicle Routing by Route Name – This allows the user to specify all the stops a vehicle type has to complete for a specific route.   Congestion Modeling Planning Software allows the user to specify up to 60 stops for any route.
  • The Trigger Part Definition – A vehicle route may include multiple stops for different part numbers at the same line side station or different line side storage areas.   However, for each route, there is a Trigger Part that when the quantity of this part (at the line side storage area), is less than or equal to the respective Kanban quantity, a material delivery request is created.   This request could include making material delivery of parts that are not the Trigger parts.   The purpose for this logic is to include all the potential additional stops the vehicle has to make for the respective Trigger Part request.   Congestion Modeling Planning Software has the capability to allow the user to change the following variables associated with each Trigger Part:
  • The model type associated with the Trigger Part
  • The respective part number
  • The respective part description
  • The production area assigned to the Trigger Part.   This is used to indicate the consumption rate of the Trigger Part
  • The assigned Pick-up/Drop-off station.   This is used to increment the quantity of parts at the respective station (by the quantity per delivery, once the vehicle stops at that station
  • The time the vehicle spends at the Pick-up/Drop-off station.   It should be noted that this time will be applied to all the stops the vehicle makes for its respective route.
  • The quantity of parts consumed per cycle (takt time) for the respective Trigger Part
  • The quantity of parts per delivery for the respective Trigger Part
  • The assigned storage location to retrieve the Trigger Part for delivery to the corresponding line side storage station
  • The assigned route for the respective Trigger Part
  • The corresponding Kanban quantity for the respective Trigger Part
  • The curing process time – Congestion Modeling Planning Software the capability to allow the user to change the curing time for each part number listed and for each dip cycle.

The user can run Congestion Modeling Planning Software with the specified parameters and view the results. All output time units in this system are in minutes. The results are divided into four (4) categories:

  1. Vehicle utilization, which includes wait time, blocked time, idle time and busy time for all conveyance vehicle types.
  2. Link/Aisle way use.
  3. Average delivery time by vehicle.
  4. The number of deliveries completed for the specified time period simulated by vehicle type.
  5. The scenario data contains all data input written to the model for the particular scenario.

Congestion Modeling Planning Software can be used as often as will be needed, based on the business/operating environment. This will allow the analyst to evaluate future business and operating scenarios to optimize the utilization and throughput of the conveyance processes.


CMPS will be a very powerful analysis tool. However, it will be important to note, that the analyst must have a thorough understanding of both the processes being analyzed and the statistics

The minimum requirements/recommendations for running the Arena software are as follows:

  • Arena software, version 10.0
  • Microsoft Windows 98, Windows ME, NT 4.0 (Service Pack 6a or later), Windows Server 2003, or Windows XP (Service Pack 1 or later).
  • Internet Explorer 5.01. (This does not need to be your active browser, but some of the IE components are necessary for Arena to work)
  • Adobe Acrobat Reader 5.0 or later to view documentation.
  • Hard drive with 75-250 MB free disk space (depending on the operating system and options installed)
  • 64 MB of RAM (recommended 128 MB of RAM or higher, depending on the operating system)
  • Minimum Pentium processor 300Mhz or higher

Note: The running and animation of Arena and some large simulation models can be calculation-intensive, so a faster processor with additional memory may result in significantly improved performance. In addition, a large monitor and a screen resolution of at least 1024 x 768 is recommended for improved animation viewing

  • Under Microsoft Windows NT, 2000, Server 2003, and XP, you must have Administrator privileges to install the software. To run Arena, you should be a Standard user (member of the Power Users Group) or better

Included with this manual is a CD containing the required files to run CMPS. Load the CD into the CD drive. If it does not start, browse to the “autorun.exe” file on the CD and double-click the file to start the installation. An autorun program should start and the following screen will appear. The installation program will examine your system and determine if there are any required system updates that need to be installed and installs them.