MSE 495

Industrial Engineering
Please remember to write your PIN on all Assignments you submit
Posted: January 22, 2024 Due: Monday, February 5, 2024, in class

Assignment number 2
(Chapters 3, 4, and 5)

First, we review Johnson’s algorithm and then list the problems for this Assignment.

Steps for Johnson’s n-job 2-machine algorithm

Given a table of data as in the following:

Machine Numbers
Job Machine Machine
M1 M2
a 1 3
b 2 5
c 4 1
d 3 2
e 6 4

With the condition that there is a “Technological Processing Order” of M1 then M2

for all the jobs, the steps of Johnson’s algorithm are as follows.

- Sketch a schematic diagram (for the sake of visual representation and clarity)
as in the following Figure:

M1 M2

Job line-up (sequence) placeholders

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 - Glance over the processing time and pick the smallest value
- If it belongs to M1, schedule the corresponding job from the “head” of the
line-up; if it belongs to M2, schedule the corresponding job from the “end” of
the line-up.
- If a tie between the processing times exists (i.e., there are equal processing
times), break the tie arbitrarily. We showed several scenarios in the class
lecture.
- (Not part of the original algorithm: In breaking the tie, pick the option that
may provide an additional/secondary advantage. We discussed examples in
the class lecture.

Now The Problems

Problem 1. Review Chapter 3 with the intention of “learning for good”; the types
and differences between the characteristics of the manufacturing systems. As no
specific problem is given, no submission is required for this self-reading exercise
(i.e., this problem). You will have to review Lecture-Notes 4 and 5a to be able to
attempt problems 2, 3, and 4 of this assignment.

Problem 2. Using the diagrams on pages 36 and 37 of the lecture-notes, develop the
form code (first five digits) in the Opitz classification system for the part shown in
the following figure. Because you do not have the complete user guide for the Opitz
classification and coding system, use your judgment to guess the best digit values,
but briefly give your reason(s) for selecting a particular value for each digit of the
code (The unit for dimensions is inch. However, this is immaterial for developing
the form code.)

5.0

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Problem 3. Five jobs must be processed through a two-machine permutation job-
shop (5/2/P/Cmax). The processing times and a set of due dates for these jobs are
shown in the following table.

a. Determine the minimum makespan schedule. “Makespan” is another term

for the completion time or throughput time.
b. Using a Gantt chart, determine the completion time for each job. Then, by
setting up a table for the schedule and the values you have just determined,
find the lateness for each job and the average lateness for the set of jobs.
(Pages 42-43 of lecture-notes.)
c. By visually inspecting your table, tinker with the sequence/schedule you
have determined and try to find another sequence/schedule that results in
smaller maximum lateness. You may need to re-draw the Gantt chart for
this. (Note: We have negative lateness too. For example, a lateness of -2 is
greater than a lateness of -4.) Also, re-calculate the average lateness.
Machine Numbers
Job Machine 1 Machine 2 Due Date
J1 1 3 5
J2 2 5 12
J3 4 1 16
J4 3 2 20
J5 6 4 25

Problem 4. A set of 10 jobs must be processed through a two-machine job shop. The
technological orderings and processing times of the jobs are shown below. Use
Jackson's general shop algorithm (10/2/G/Cmax, double application of Johnson's two-
machine algorithm) to find a minimum makespan schedule. Construct a Gantt chart
of the schedule and determine the makespan for the set of jobs and the total idle time
for each machine, if any. (Note: The time after the last operation of a machine on a
set of jobs is not considered “idle time”.)
Machine Numbers Processing Times
Job Operation 1 Operation 2 Operation 1 Operation 2
J1 M1 M2 4 6
J2 M1 - 3
J3 M1 - 4
J4 M1 M2 5 2
J5 M2 M1 1 2
J6 M2 - 1
J7 M2 M1 7 8
J8 M2 - 3
J9 M2 M1 6 7
J10 M1 M2 2 4

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