The objective of this study is to develop an integrated simulation model in a large complex casting system to assess existing system status and to introduce a set of optimizing alternatives. To achieve the above objective, visual SLAM and A WESIM, one of the most advanced simulation language in the world and a design of experiment methodology were utilized. The detailed conceptual models in fonnats of schematic diagrams, process flow charts and logical charts and collected data related to processes, operations, maintenance, repairs and quality control allowed creation of the infrastructure and development of the integrated simulation model. The integrated simulation model was verified and val idated by structured analysis and t-test. Furthermore, the structures and findings of the simulation model was verified and accredited by both industrial engineering department and production engineers and managers of the casting system. An important feature of this study is integration of design of experiments with the simulation model. Moreover, a unique design of experiment is introduced to identify the impacts of various alternatives on production level.
Consequently, integration of the simulation model and design of experiments developed a set of optimizing alternatives for various situations. The unique features of this study are four folds. First, the integrated approach allows modeling of all processes, operations, repairs, maintenance and quality control activities. Second, managers and decision-makers can easily use the rule base of the simulation to assess various alternatives. Third, optimum
. conditions for various production setting and tilt: required upgrading methods and alter mechanisms are introduced though integration of simulation and design of experiments. Finally, the simulation model is verified, validated and accredited and is composed of all local and global processes of the casting system. Therefore, it may by used for strategic planning and system's capacity development and consequently may result in billions of Dollars of profitability, presently, the integrated simulation model is being implemented at the casting system.
)