Production Scheduling PDF

Scheduling
 When and in what sequence the work will be done

 Involves deciding
- when the work will start
- in certain duration of time how much work will be
completed
 It is time phase of loading (Assignment of tasks or
work to a facility)
Factors affecting scheduling
 External factors:
-Customer demand
-Customer delivery date
-Stock of goods already available with dealers and stockiest
 Internal factors
- Stock of finished goods with firm
- Time interval to process finished goods from raw material
- Availability of material quantity and specification
- Availability of equipment (no. of m/c, capacity)
- Availability of manpower (no. and kind of skills)
Master Production Schedule
 Resembles a central office which
possesses information about all the
orders in hand
 MPS is weekly breakdown of the
production requirement
 As orders are received, they are
marked on master schedule
depending on their delivery dates
 MPS is updated continuously
 It shows the work ahead, yet to be
completed
Advantages of MPS Limitations of MPS
 Simple and easy to  Provides only overall
understand picture
 Can be kept current  Does not give detained
 Low cost to make and information
maintain
 A certain % of weekly
capacity can be allocated for
rush orders
Applications
 In big firm for purpose of loading of entire plant
 In R&D organisations
 Overall planning in foundries, computer centres and repair
shops
Operation Scheduling
 Most important in Job shop production as batch size is very small,
Machines and workers are versatile (can perform different operations
Activities in Operation Scheduling

 Assigning job orders to different machines
 Deciding sequence of processing on different machines (priority rule)
 Planning the route of movement of material during processing
 Issuing dispatch list to various work centers containing info. about
-Work centers a customer order should be processed at,
-The customer order to be processed first,
-Time of processing it should take.
 Tracking progress of various scheduled jobs, revising the schedule in
case of delays.
Problems due to lack of proper scheduling
 Delay in meeting due dates of orders
 High Work-In-Process (WIP) inventory
 High average completion time of job
 No information on the current status of a job
 Low utilization of workers and work stations
 High overall setup time for machines.
 High cost of production/operation
Types of Operation scheduling
 Forward Scheduling
-As early as possible approach to be used for assigning customer orders
-as soon as a work center is free to process a job, they should be assigned
the job.
 Backward scheduling
- Based on As late as possible approach with condition that the jobs get
ready by their due dates
- thus process planning starts with assigning the job to last workstation in
the sequence
- can be useful in case there is some delay in availability of resources
General
machine/m
an loading
Sequencing rules: ‘n’ jobs on one machine
These are required to decide about the sequence of the
jobs on work station
 First Come First Serve (FCFS): Jobs are processed in their sequence
of arrival
 Last Come First Serve (LCFS):
 Due date method: Job with closest due date done first
 Shortest Time of Processing (STP)rule: Jobs with shortest
processing time done first
 Priority based service
 Random method
Sequencing rule contd..
 Critical ratio rule (CR): Jobs with the smallest CR are run first
 CR = time remaining / work remaining

due date of job ‘i’ - today’s date
CRi=
remaining processing time of job ‘i’
• With each passing minute the CR for jobs changes

• Task with shorter remaining time and longest processing
time will get priority
• A job with negative CR (due date already gone) should be
given prioity
Performance measures
 Completion time
 Epoch at which the job is completed
 Makespan
 Completion time of the last job processed
 Lateness and tardiness
 Lateness of job j
 = (completion time of job j)-(due date of job j)
- if it is positive it is tardiness
-if it is negative it is earliness (0 tardiness)
 5 jobs labelled as 1,2 ,3 4 and 5 are to be processed in a
machining centre
 Sequence the jobs by FCFS, STP, Due date method and
Critical ratio methods and compare the results
Job no. Processing time Due date
1 11 61
2 29 45
3 31 31
4 1 33
5 2 32
Sequencing ‘n’ jobs on 2 machines
Johnson’s method
 Johnson's rule is a method of scheduling jobs in two work
centers.
 Its primary objective is to find an optimal sequence of jobs to
reduce makespan (the total amount of time it takes to complete all jobs).
 It also reduces the amount of idle time between the two work
centers.
 The method minimizes the makespan in the case of two work
centers.
 Furthermore, the method finds the shortest makespan in the
case of three work centers if additional constraints are met
Johnson rule contd..
The technique requires several preconditions:
 The time for each job must be constant.
 Job times must be mutually exclusive of the job sequence.
 All jobs must be processed in the first work center before
going through the second work center.
 All jobs are equally prioritized.
https://en.wikipedia.org/wiki/Johnson%27s_rule
Johnson's rule is as follows:
 List the jobs and their times at each work center.
 Select the job with the shortest activity time.
 If that activity time is for the first work center, then
schedule the job first. If that activity time is for the
second work center then schedule the job last.
 Eliminate the shortest job from further consideration.
 Repeat steps 2 and 3, working towards the center of the
job schedule until all jobs have been scheduled.
Example: Each of five jobs needs to go through work center A
and B. Find the optimum sequence of jobs using Johnson's
rule.
Job times (hours)
Job Work center A Work center B
A 3.2 4.2
B 4.7 1.5
C 2.2 5.0
D 5.8 4.0
E 3.1 2.8
Solution
1. The smallest time is located in Job B (1.5 hours).
- Since the time is in Work Center B, schedule this job last.
- Eliminate Job B from further consideration.
? ? ? ? B
2. The next smallest time is located in Job C (2.2 hours).
- Since the time is in Work Center A, schedule this job first.
- Eliminate Job C from further consideration.
C ? ? ? B
3. The next smallest time after that is located in Job E (2.8 hours).
- Since the time is in Work Center B, schedule this job last.
- Eliminate Job E from further consideration.
C ? ? E B
4. The next smallest time after is located in Job A (3.2 hours).

-Since the time is in Work Center A, schedule this job first.
-Eliminate Job A from further consideration.
C A ? E B
5. The only job left to consider is Job D.
C A D E B
So, the jobs must be processed in the order C → A → D → E → B, and must be
processed in the same order on both work centers.
Assignment Method: ‘n’ products on ‘m’ machine
One machine does on job only
1. Perform row reductions
 Subtract minimum value in each row from all other row values
2. Perform column reductions
 Subtract minimum value in each column from all other column
values
3. Line Test
 Cross out all zeros in matrix using minimum number of
horizontal & vertical lines.
 If number of lines equals number of rows in matrix, optimum
solution has been found, stop.
4. Matrix Modification
 Subtract minimum uncrossed value from all uncrossed values &
add it to all cells where two lines intersect. Go to Step 3.
Assignment
Cooker
Example
Food 1 2 3 4
Beans 10 5 6 10
Peaches 6 2 4 6
Tomatoes 7 6 5 6
Corn 9 5 4 10
Row reduction Column reduction Line Test

5 0 1 5 3 0 1 4 3 0 1 4
4 0 2 4 2 0 2 3 2 0 2 3
2 1 0 1 0 1 0 0 0 1 0 0
5 1 0 6 3 1 0 5 3 1 0 5
Number lines <> number of rows so modify matrix

Assignment Example
Modify matrix Line Test
1 0 1 2 1 0 1 2 # lines = # rows
0 0 2 1 0 0 2 1 so at optimal solution
0 3 2 0 0 3 2 0
1 1 0 3 1 1 0 3
Cooker Cooker
Food 1 2 3 4
Beans 1 0 1 2 Food 1 2 3 4
Peaches 0 0 2 1 Beans 10 5 6 10
Tom 0 3 2 0 Peaches 6 2 4 6
Corn 1 1 0 3 Tomatoes 7 6 5 6
Corn 9 5 4 10
l
Orders completed in 6 hours
Total number of hours = 21

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Scheduling

 When and in what sequence the work will be done

Activities in Operation Scheduling

 CR = time remaining / work remaining

• With each passing minute the CR for jobs changes

4. The next smallest time after is located in Job A (3.2 hours).

5. The only job left to consider is Job D.

Row reduction Column reduction Line Test

Number lines <> number of rows so modify matrix

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