Mechanical

Engineering

Day 9
Hungarian Method
Simulation in manufacturing

A Vocational Degree programme developed by MCAST and Fraunhofer IAO.

Hungarian method
The historical development:
• The Hungarian method is a combinatorial optimization algorithm
which solves the assignment problem in polynomial time.
• It was developed and published by Harold Kuhn in 1955, who gave
the name "Hungarian method" because the algorithm was largely
based on the earlier works of two Hungarian mathematicians: Dénes
Kőnig and Jenő Egerváry.

Description of the problem:

C is a m x n matrix representing the costs of each of m workers to
perform any of n jobs. The assignment problem is to assign jobs to
workers so as to minimize the total cost. Since each worker can
perform only one job and each job can be assigned to only one
worker the assignments constitute an independent set of the matrix C.

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Assignment problem

c11
W1 WP1
c12
c13

c21
c22
W2 WP2
c23

c31 c32

W3 WP3
c33

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Mathematical model:
• The Hungarian method solves minimization/maximization
assignment problems with m workers and n jobs.

m n
F ( x )    cij  xij  min / max
i 1 j 1

• Examples:
− Processing time (F(x)  min)
− Total cost (F(x)  min)
− Transport distance (F(x)  min)
− Profit (F(x)  max)

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Model limitations:
• worker can perform one and only one job; for each worker
(row) i
m
 xij  1 j  1,2,...,n
i 1

• each job can be assigned to only one worker; for each job
(column) j
n
 xij 1 i  1,2,...,n
j 1

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Facts:
• An assignment problem seeks to minimize the total
cost/processing time assignment of m workers to m
workplaces, given that the cost of worker i performing job
on workplace j is cij.
• It assumes all workers are assigned and each job is
performed.

• Special considerations can include:

– number of workers does not equal the number of jobs — add
dummy workers/jobs with 0 assignment costs as needed
– maximization objective — create an opportunity loss matrix
subtracting all profits for each job from the maximum profit for that
job before beginning the Hungarian method

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Step 1: Finding zeros
Step 1.1 For each row, subtract the minimum number in that row
from all numbers in that row.
Step 1.2 For each column, subtract the minimum number in that
column from all numbers in that column.

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Step 2: Finding circled (independent) zeros
Step 2.1 Examine rows: Find a row with only one unmarked zero and
circle it. Cross other zeros in related column (If row have two
or more unlined zeroes skip that row)
Step 2.2 Examine columns: Find a column with only one unmarked
zero and circle it. Cross other unmarked zeros in related row.
(If column have two or more unmarked zeroes skip that
column)
Step 2.3 Repeat steps 2.1. and 2.2. until all zeros are marked (circled
or crossed).

In case when all rows/columns have two or more unmarked zeroes the
procedure can not be continued. The next step is to circle an arbitrary
zero (in row/column with lower number of zeros if possible) and
continue with steps 2.1 and 2.2 until all zeros are marked.

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Step 3: Finding lines to cover rows/columns
Step 3.1 Mark all columns without circled zeros with *.

Step 3.2 Mark all rows with crossed zeros in marked columns with *.

Step 3.3 Mark all unmarked columns with circled zeros in previously
marked rows with **.

Step 3.4 Repeat steps 3.2 and 3.3 until all possible rows and columns
are marked according this rules. Increase number of * sings in
every iteration.

Step 3.5 Draw lines to cover over marked rows and unmarked
columns.

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Step 4: Finding zeros in next iterations
Step 4.1 Find minimum uncovered value in matrix
Step 4.2 Subtract the minimum value from all uncovered values, and
add minimum value to values on intersections of lines to
cover.
Step 4.3 Repeat steps 1 to 4.1

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Checking the algorithm:
• Number of lines to cover must be equal to number of
independent (circled) zeros.
• Independent zeros must not be in intersection of cover
lines.
• All zeros must be covered with lines to cover.
• If number of independent zeros equals m, the independent
zeros provides the optimal assignment.
• If number of independent zeros is less then m, algorithm
should be repeated.

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Example 1 (minimization objective):
It is necessary to assign 5 workers to 5 workplaces so that the total
processing time is minimal. Each worker can be assigned to each
position. Data matrix shows the duration of the processing time of
every worker at every workplace in time units.

W1 W2 W3 W4 W5
WP1 22 17 25 23 6
WP2 2 9 7 5 2
WP3 38 33 38 23 22
WP4 15 24 14 4 12
WP5 33 33 24 32 23

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Solution:

Step 1.1

W1 W2 W3 W4 W5 ui
WP1 22 17 25 23 6 6
WP2 2 9 7 5 2 2
WP3 38 33 38 23 22 22
WP4 15 24 14 4 12 4
WP5 33 33 24 32 23 23

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Step 1.2

W1 W2 W3 W4 W5
WP1 16 11 19 17 0
WP2 0 7 5 3 0
WP3 16 11 16 1 0
WP4 11 20 10 0 8
WP5 10 10 1 9 0
vj 0 7 1 0 0

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 W1 W2 W3 W4 W5
WP1 16 4 18 17 0
WP2 0 0 4 3 0
WP3 16 4 15 1 0
WP4 11 13 9 0 8
WP5 10 3 0 9 0

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Step 2

W1 W2 W3 W4 W5
WP1 16 4 18 17 0
WP2 0 0 4 3 0
WP3 16 4 15 1 0
WP4 11 13 9 0 8
WP5 10 3 0 9 0

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Step 3.1 and 3.2
*
W1 W2 W3 W4 W5
WP1 16 4 18 17 0
WP2 0 0 4 3 0 *
WP3 16 4 15 1 0
WP4 11 13 9 0 8
WP5 10 3 0 9 0

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Step 3.3 and 3.4 *
* *
W1 W2 W3 W4 W5
WP1 16 4 18 17 0
WP2 0 0 4 3 0 *
WP3 16 4 15 1 0
WP4 11 13 9 0 8
WP5 10 3 0 9 0

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Step 3.5 *
* *
W1 W2 W3 W4 W5
WP1 16 4 18 17 0
WP2 0 0 4 3 0 *
WP3 16 4 15 1 0
WP4 11 13 9 0 8
WP5 10 3 0 9 0

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Step 4.1 *
* *
W1 W2 W3 W4 W5
WP1 16 4 18 17 0
WP2 0 0 4 3 0 *
WP3 16 4 15 1 0
WP4 11 13 9 0 8
WP5 10 3 0 9 0

min = 3

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Step 4.2

W1 W2 W3 W4 W5
WP1 13 1 18 17 0
WP2 0 0 7 6 3
WP3 13 1 15 1 0
WP4 8 10 9 0 8
WP5 7 0 0 9 0

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 *
Step 1 to step 4.1 * *
* * *
W1 W2 W3 W4 W5
WP1 13 1 18 17 0
WP2 0 0 7 6 3 **
WP3 13 1 15 1 0
WP4 8 10 9 0 8
WP5 7 0 0 9 0 *

min = 1

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Step 4.2

W1 W2 W3 W4 W5
WP1 12 0 17 17 0
WP2 0 0 7 7 4
WP3 12 0 14 1 0
WP4 7 9 8 0 8
WP5 7 0 0 10 1

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Step 1 and step 2

W1 W2 W3 W4 W5
WP1 12 0 17 17 0
WP2 0 0 7 7 4
WP3 12 0 14 1 0
WP4 7 9 8 0 8
WP5 7 0 0 10 1

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Solution:

W1 W2 W3 W4 W5

WP1 17/1
WP2 2/1
WP3 22/1
WP4 4/1
WP5 24/1

F x   c12  x12  c21  x21  c35  x35  c44  x44  c53  x53  17  2  22  4  24  69

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Example 2 (maximization objective):
The company opened four workplaces and five candidates applied.
Verification of their expertise has been made, and the number of
points each candidate won at each workplace is shown in the matrix.
It is necessary to determine the arrangement of workers to
workplaces so that overall efficiency is maximized.

WP1 WP2 WP3 WP4

W1 5 5 4 1
W2 4 6 4 1
W3 8 6 7 6
W4 2 4 4 4
W5 6 10 9 4

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Solution:

1. addition of dummy workplace with 0 points for all workers:

WP1 WP2 WP3 WP4 WP5

W1 5 5 4 1 0
W2 4 6 4 1 0
W3 8 6 7 6 0
W4 2 4 4 4 0
W5 6 10 9 4 0

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2. Selection of the maximum number of points for every job
(workplace):

WP1 WP2 WP3 WP4 WP5

W1 5 5 4 1 0
W2 4 6 4 1 0
W3 8 6 7 6 0
W4 2 4 4 4 0
W5 6 10 9 4 0

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3. Creation of an opportunity loss matrix subtracting all points for
each job from the maximum points for that job:

WP1 WP2 WP3 WP4 WP5

W1 3 5 5 5 0
W2 4 4 5 5 0
W3 0 4 2 0 0
W4 6 6 5 2 0
W5 2 0 0 2 0

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 * *
* * * *
WP1 WP2 WP3 WP4 WP5
W1 3 5 5 5 0
W2 4 4 5 5 0
W3 0 4 2 0 0 *
W4 6 6 5 2 0
W5 2 0 0 2 0 *

min = 2

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 WP1 WP2 WP3 WP4 WP5
W1 1 3 3 3 0
W2 2 2 3 3 0
W3 0 4 2 0 2
W4 4 4 3 0 0
W5 2 0 0 2 2

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 *
* *
WP1 WP2 WP3 WP4 WP5
W1 1 3 3 3 0
W2 2 2 3 3 0
W3 0 4 2 0 2
W4 4 4 3 0 0
W5 2 0 0 2 2 *

min = 2

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 WP1 WP2 WP3 WP4 WP5
W1 1 1 1 3 0
W2 2 0 1 3 0
W3 0 2 0 0 2
W4 4 2 1 0 0
W5 4 0 0 4 4

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 WP1 WP2 WP3 WP4 WP5
W1 1 1 1 3 0
W2 2 0 1 3 0
W3 0 2 0 0 2
W4 4 2 1 0 0
W5 4 0 0 4 4

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Solution:

WP1 WP2 WP3 WP4 WP5

W1 0/1
W2 6/1
W3 8/1
W4 4/1
W5 9/1

F x   c15  x15  c22  x22  c31  x31  c44  x44  c53  x53  0  6  8  4  9  27

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Simulation in manufacturing
Definition of simulation:
• Simulation is the model that imitates operation of a real
world system over time.
• Can in principle be done by hand, but usually done on
computer.
• Each simulation model must be customized to target
system.
• Assumptions/approximations about how system works is
often done while developing model.

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Application areas:
• Designing and analyzing manufacturing systems.
– Material Flow Systems
• Assembly lines and Transfer lines
• Flow shops and Job shops
• Flexible Manufacturing Systems and Group Technology
– Supporting Components
• Setup and sequencing
• Handling systems
• Warehousing
• Designing and analyzing transportation and logistics.
• Evaluating designs for service organizations such as.
equipment repair, ship service, call centres, hospitals.
• Reengineering of business processes.
• Determining ordering policies for an inventory system.

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• Types of Simulation
– Static/ Dynamic
– Stochastic/Deterministic
– Discrete Event/Continuous
• Simulating Random Behaviour
– Random Number Generation
– Random Variant Generation
– Probability Expressions and Distributions
• If model structure is simple enough, mathematical
methods could be use to get exact information on
questions of interest. It is analytical solution.
• For complex models, it might not be obvious what the
events are.
• Possibility of combining events to simplify model.

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• More complex systems require models that are also
complex
– Must be studied via simulation — evaluate model numerically and
collect data to estimate model characteristics
– But now have better modeling software … more general, flexible, but
still (relatively) easy to use
– Can consume a lot of computer time
• But now have faster, bigger, cheaper hardware to allow for much better
studies than just a few years ago … this trend will continue
• However, simulation will also continue to push the envelope on computing
power in that we ask more and more of our simulation models
• Example: Manufacturing company considering extending its
plant
– Build it and see if it works out?
– Simulate current, expanded operations — could also investigate
many other issues along the way, quickly and cheaply
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• System: A collection of entities (people, parts, messages,
machines, servers, …) that act and interact together
toward some end In practice, depends on objectives of
study.
• State of a system: Collection of variables and their values
necessary to describe the system at that time.
• Simulation clock: Variable that keeps the current value of
simulated time in the model. Usually there is no relation
between simulated time and real time needed to run a
model on a computer.

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• System Variables
–Decision Variables (Input Factors)
–Response Variables (Output Variables)
–State Variables
• Entity: Objects that compose a simulation model
• Attributes: Entity characteristics
• Resources: A servicing entity
• Lists and list processing: Queues
• Activities and delays

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• Event: Instantaneous occurrence that may change the
state of the system
• Discrete-event simulation: Modelling of a system as it
evolves over time by a representation where the state
variables change instantaneously at separated points in
time
• Continuous simulation: Modelling of a system where state
variables change continuously as a function of time.
Typically, it represents solving sets of differential
equations numerically over time

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• Many systems are partly discrete, partly continuous
• Combined discrete-continuous simulation
– Continuous variables described by differential
equations
– Discrete events can occur that affect the
continuously-changing variables
– Most of discrete-event simulation software can do
combined discrete-continuous simulation

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Advantages of Simulation
• Time stretching/contraction capability
• Decision aid
• Great flexibility in modelling complex systems
• Cause-effect relations
• Easy to compare alternatives
• Exploration of possibilities
• Diagnosing of problems
• Visualization
• Preparing for change
• Cost effective investment
• Training aid capability
• Specification of requirements
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Disadvantages of Simulation
• Simulation models can be expensive to develop.
• Training is required.
• Interpretation of large amount of output results is required.
• Time consuming.

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Steps in Simulation Modelling:
• Problem formulation
• Statement of objectives
• Model conceptualization
• Model development
• Data collection
• Verification and validation
• Experimental design
• Experimentation
• Production runs and analysis
• Analysis of results
• Documentation/reporting
• Implementation

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Objectives:
• Performance analysis
• Capacity analysis
• Configuration comparisons
• Optimization
• Sensitivity analysis
• Visualization

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Manufacturing Simulators
• ProModel • SimSource
• Witness • Deneb
• Taylor II • Valisys (Tecnomatix)
• AutoMod • Open Virtual Factory
• Arena • EON
• ModSim and Simprocess • Simul8
• Delmia • EmPlant
• Ideas • Siemens

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I-DEAS: Visualization EDM machine tools
Groups of machine tools

Turning machine tools

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Visualization:
Layout planning with
transport ways

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Visualization:
Layout planning with
complex transport
ways

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Visualization:
Building and environment planning

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Visualization:
Building and environment planning

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Visualization:
Warehouses and transportation planning

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Delmia: Process simulation

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Delmia: Process simulation with conveyer transport

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Animation:
Assembly processes

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Animation:
Welding processes

Simulation Realization

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Animation:
Welding processes in
automotive industry
Realization
Simulation

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Animation:
Welding processes in
shipbuilding industry

Simulation Realization

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Case study:
Opel
factory

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Case study:
Opel
assembly line

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Case study:
Falcon
Assembly and welding

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DELMIA Digital Manufacturing Solutions Layout Planning
Time Measurement

Process Planning

Product Design Ergonomics

Robotics & PLC

Machining &
Production Quality Control
Factory Flow
Management Simulation

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Digitalization of process and resource

Process information
Process times
Assembly stages
Indirect labor
Space requirements
Part bins
Materials
Throughput
Equipment
…

The entire planning of Product, Process and Resources

can be optimized through what-if scenarios
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Case study: Automotive Processes DaimlerChrysler

Stamping BIW

Painting

Final Assembly

Powertrain
Machining
Powertrain
Assembly
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Stamping

Stamping BIW

Painting

Final Assembly

Powertrain
Machining Powertrain
Assembly

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BIW (Body in white)
BIW

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Painting

Stamping BIW

Painting

Final Assembly

Powertrain
Machining
Powertrain
Assembly

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Powertrain machining

Stamping BIW

Painting

Final Assembly

Powertrain
Machining
Powertrain
Assembly

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Design change impact

Tool Paths Inspection

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Final assembly

Stamping BIW

Painting

Final Assembly

Powertrain
Machining
Powertrain
Assembly

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Final assembly
Final
Assembly

Painted Body Car

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Final assembly

Process Definition Ergonomics

Time Analysis
3D Process
Detailing

Pre-Planning
Work instructions
Documentation
Line balancing
Line/cell detailing
Layout planning

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Digital Manufacturing in Aerospace

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