Introduction to OTM; Managing the Overview DAO2703 Transformation Process
Process Types; Operations Recognizing
Technologies; Process Flows the Plant Aggregate Production Planning Planning for the Plant; Inventory Material Operations Requirements PP&C Cycle Management Scheduling Planning
JIT Systems Theory of Improving
Constraints the Plant Strategic Operations Strategic Supply Chain Management Considerations
Prof Hum Sin Hoon
Lecture: Outline
• Scheduling for High, Mid and Low-Volume
Operations • Sequencing in Low-Volume Operations • Sequencing Priority Rules: FCFS; SPT; EDD; CR; S/O; & Johnson’s Rule • Scheduling Service Operations; Assignment Model
Prof Hum Sin Hoon
Scheduling for High, Mid and Low-Volume Operations
Operations Scheduling • Time to use equipment & time to perform activities • The order/sequence for processing jobs • Can yield Cost Savings & increase Productivity
Prof Hum Sin Hoon
Scheduling for High, Mid and Low-Volume Operations
Scheduling Context • Scheduling constrained by higher level decisions: ‒ plant capacity ‒ equipment selection ‒ the PP&C Cycle • aggregate plan, master schedule & material requirements plan
Prof Hum Sin Hoon
Scheduling for High, Mid and Low-Volume Operations High-Volume Operations • Flow-shops: as in assembly lines ‒ product follows same sequence through standardized equipment and activities ‒ high volume, limited variety of products • Flow Scheduling: adjust rate of output (cycle time) by balancing the line (assembly line balancing)
Prof Hum Sin Hoon
Scheduling for High, Mid and Low-Volume Operations Mid-Volume Operations • Batch-shops: ‒ mid-volume & mid-variety ‒ between Flow-shops and Job-shops • Intermittent Scheduling: ‒ schedule to produce batches intermittently ‒ batch size determined as in Economic Production Quantity (EPQ) Model (see Week 6 Lecture)
Prof Hum Sin Hoon
Scheduling for High, Mid and Low-Volume Operations Low-Volume Operations • Job-shops: low volume but large variety of jobs • Difficult to schedule because of: ‒ variety of processing tasks, times, sequences & materials • Job-shop Scheduling involves: ‒ Loading - assign jobs to processing workstations (MRP: planned-order releases (jobs) are loaded onto workstations; load report) ‒ Sequencing – decide the order in which jobs will be processed at workstation Prof Hum Sin Hoon Sequencing in Low-Volume Operations • Some objectives: ‒ Meet due dates (Minimize lateness) ‒ Minimize lead time (Minimize Makespan) ‒ Minimize setup time/cost ‒ Minimize work-in-process inventory
• Use Sequencing Priority Rules:
‒ Simple heuristics
Prof Hum Sin Hoon
Sequencing Priority Rules
• Some Priority Rules:
• First-come, first-served (FCFS) • Shortest processing time (SPT) • Earliest due date (EDD) • Smallest Critical Ratio (CR) • Ratio of time remaining till DD (due date) to processing time remaining • Smallest Slack per operation (S/O) • (Time remaining till DD – Remaining processing time)/(no of remaining operations) • Rush (emergency)
Prof Hum Sin Hoon
Sequencing Priority Rules
• Priority Rules: Assumptions
• Set of jobs to be sequenced is known; no new jobs arrive and no jobs are canceled • Processing times are deterministic • Setup times are deterministic • Setup time is independent of processing sequence • No interruptions in processing (machine breakdowns; accidents)
Prof Hum Sin Hoon
Sequencing Priority Rules
• Priority Rules: Common Performance Metrics
• Job flow time • Time from when a job arrives until it is completed; includes waiting time • Job lateness • Time by which the job completion time exceeds the job due date • Makespan • Time to complete a group of jobs from start of first job to completion of last job • Average number of jobs • Average number of jobs (WIP inventory) of a group of jobs that are in the shop (= [Total Flowtime] / [Makespan])
Prof Hum Sin Hoon
Sequencing Priority Rules Example: FCFS Rule Suppose you have the four Jobs (in order Processing Due Date jobs to the right arrive for of arrival) Time (days) (days hence) A 4 5 processing on one machine. B 7 10 What is the FCFS schedule? C 3 6 D 1 4 Do all the jobs get done on time?
Answer: FCFS Schedule
Jobs (in order Processing Due Date Flow Time of arrival) Time (days) (days hence) (days) A 4 5 4 B 7 10 11 No, Jobs B, C, and D C 3 6 14 are going to be late. D 1 4 15
Prof Hum Sin Hoon
Sequencing Priority Rules Example: SPT Rule Suppose you have the four Jobs (in order Processing Due Date jobs to the right arrive for of arrival) Time (days) (days hence) A 4 5 processing on one machine. B 7 10 What is the SPT schedule? C 3 6 D 1 4 Do all the jobs get done on time?
Answer: SPT Schedule
Jobs (in order Processing Due Date Flow Time of arrival) Time (days) (days hence) (days) D 1 4 1 C 3 6 4 No, Jobs A and B are A 4 5 8 going to be late. B 7 10 15
Prof Hum Sin Hoon
Sequencing Priority Rules Example: EDD Rule Suppose you have the four Jobs (in order Processing Due Date jobs to the right arrive for of arrival) Time (days) (days hence) A 4 5 processing on one machine. B 7 10 What is the EDD schedule? C 3 6 D 1 4 Do all the jobs get done on time?
Answer: EDD Schedule
Jobs (in order Processing Due Date Flow Time of arrival) Time (days) (days hence) (days) D 1 4 1 A 4 5 5 No, Jobs C and B are C 3 6 8 going to be late. B 7 10 15
Prof Hum Sin Hoon
Sequencing Priority Rules Example: CR Rule Answer: CR Schedule Suppose you have the four Jobs (in order Processing Due Date jobs to the right arrive for of arrival) Time (days) (days hence) A 4 5 processing on one machine. B 7 10 What is the CR schedule? C 3 6 D 1 4 Do all the jobs get done on time?
In order to do this schedule the CR’s have be calculated for each job: CR(A)=(5/4)=1.25 CR(B)=(10/7)=1.43 This is a Static application of CR CR(C)=(6/3)=2.00 rule; see basic text (page 708) CR(D)=(4/1)=4.00 for Dynamic application version No, Jobs B, C and D The CR schedule is A-B-C-D (same as the FCFS schedule) are going to be late.
SPT (1+4+8+15=28)/4 = 7* (3+5)/4 = 2 28/15 = 1.87* EDD (1+5+8+15=29)/4 = 7.25 (2+5)/4 = 1.75 29/15 = 1.93 CR (static) 11 (days) 5 (days) 2.93 * SPT minimizes Avg Flow Time and Avg Number of Jobs Prof Hum Sin Hoon Sequencing Priority Rules Example: S/O Rule (basic text: page 710)
Prof Hum Sin Hoon
Sequencing Priority Rules Johnson’s Rule: Two Work Center Sequencing • Technique for minimizing completion time (Makespan) for a group of jobs to be processed on two workstations; also minimizes total idle time • Several conditions must be satisfied – Job times must be known and constant – Job times must be independent of sequence – Jobs must follow same two-step sequence – Job must be completed at first workstation before moving to second
Prof Hum Sin Hoon
Sequencing Priority Rules Johnson’s Rule: Optimal Sequence 1. Select job with the shortest time ▪ if shortest time is at first workstation, schedule that job first; ▪ if the time is at the second workstation, schedule the job last; ▪ break ties arbitrarily. 2. Eliminate the job from further consideration 3. Repeat above steps, working toward the center of the sequence, until all jobs are scheduled
Prof Hum Sin Hoon
Sequencing Priority Rules Johnson’s Rule: Example First, select the job with the smallest time in either stage Suppose you have the following four jobs with time Job D has the smallest time in the first stage. Place Job D as requirements in two stages of early as possible in the unfilled job sequence below production. What is the job Drop D out, select the next smallest time (1.25 of Job A at sequence using Johnson’s stage 2), and place it 4th in the job sequence Rule? Drop A out, select the next smallest time; there is a tie in two Time in Hours stages for two different jobs. In this case, place the job with Jobs Stage 1 Stage 2 the smallest time in the first stage as early as possible in the A 1.50 1.25 unfilled job sequence B 2.00 3.00 C 2.50 2.00 Then place the job with the smallest time in the second D 1.00 2.00 stage as late as possible in the unfilled sequence Job Sequence 1 2 3 4 Job Assigned D B C A
Prof Hum Sin Hoon
Scheduling Service Operations Service Scheduling: Challenges • Cannot store or inventory services • Customer service demand is random • Scheduling service operations involves – Customers (managing their random arrivals) – Workforce (scheduling workers to meet peak?) – Equipment (capacity available; deal with bottlenecks?)
Prof Hum Sin Hoon
Scheduling Service Operations Service Scheduling: Examples • Demand Management: Appointment/Reservation systems – Control customer arrivals for service – Estimate demand for service • Capacity Management: Scheduling the workforce – Manages capacity for service – Cyclical scheduling: workers scheduled to work shifts with consecutive days off, on a repeating basis • Scheduling Multiple Resources – Coordinates use of more than one resource – Assignment Model: Assigning Workers to Machines [also useful in assigning Jobs to Machines (Loading)]
Prof Hum Sin Hoon
Scheduling Service Operations Assignment Model: Example (basic text page 702; Hungarian Method) Workers Row Workers A B C D Step 1 Min $8 6 2 4 2 6 4 0 2 1
6 7 11 10 6 0 1 5 4 2 Jobs 3 5 7 6 3 0 2 4 3 3
5 10 12 9 5 0 5 7 4 4
0 1 0 2 Column Min
Prof Hum Sin Hoon
Assignment Model: Example Workers Workers Step 2 A B C D 6 3 0 0 6 4 0 2 1
0 0 5 2 0 1 5 4 2 Jobs 0 1 4 1 0 2 4 3 3
0 4 7 2 0 5 7 4 4
0 1 0 2 Column Min
Prof Hum Sin Hoon
Assignment Model: Example Workers Step 3 A B C D 6 3 0 0 1
0 0 5 2 2 Jobs 0 1 4 1 3
4 0 4 7 2
Prof Hum Sin Hoon
Assignment Model: Example Workers Step 4 A B C D 7 3 0 0 1
1 0 5 2 2 Jobs 0 0 3 0 3
4 0 3 6 1
Prof Hum Sin Hoon
Assignment Model: Example Workers Steps 5 & 6 A B C D 7 3 0 0 1
1 0 5 2 2 Jobs 0 0 3 0 3
4 0 3 6 1 1-to-1 assignments Assignment 1-C 2-B 3-D 4-A at minimum Cost $2 $7 $6 $5 $20 Total cost
Prof Hum Sin Hoon
Assignment Model: • Hungarian Method • for making 1-to-1 assignments at minimum cost 1. Subtract smallest number in each row from every number in the row (row reduction); enter results in a new table 2. Subtract smallest number in each column from every number in the column (column reduction); enter results in new table 3. Test whether optimum assignment can be made: cover all zeros with minimum number of lines; if this is equal to number of rows, optimum is reached and make the assignment; otherwise, continue with next step 4. Subtract the smallest uncovered number from every uncovered number; add this number to the numbers at intersections of lines; leave other numbers as they are; enter results in new table 5. Repeat steps 3 and 4 until optimal assignment can be made 6. Make assignments; begin with rows or columns with only one zero; match only one row with one column; eliminate row and column after each match
