Date 5-Dec-23 Due date: 13-Dec-23

ASSIGNMENT-II ON EC4125 & ME4105 INDUSTRIAL ENGINEERING COURSE

(Marks-7.5)
Question-1: Scheduling of jobs in a flow shop for two machines using Johnson’s
method of optimization:

General Brief Description:

Consider a scheduling problem which represents an instance of 𝐹2 ||𝐶𝑚𝑎𝑥 problem. Find
optimal value of makespan using Johnson’s rule. The rule is applicable for an n-number
of jobs to be processed on 2-machines in the same order and the processing time for
each of the job on each machine is given.
Statement of the problem:
1) A flow shop contains 𝒏 jobs simultaneously available at time zero and these are
supposed to be processed by two machines arranged in series with unlimited
storage space between them.
2) The processing times of all jobs are known with certainty.
3) One of the objectives, and the most important one from manufacturing
perspective, is the time-span required to complete the set of jobs, which is also
known as the Makespan.
Objective:
1) It is required to sequence the 𝒏 jobs on the two machines so as to minimize
makespan (𝐶𝑚𝑎𝑥 ).
2) This problem is solved by Johnson’s non-preemptive rule for optimizing of the
Makespan in the two machine static flow shop problem.
3) Calculate the optimum schedule by Johnson’s method;
4) Hence, calculate the directed graph and the corresponding value of makespan,
𝐶𝑚𝑎𝑥 .
Algorithm for the program:
Let,
𝑝1𝑗 : processing time of job j on machine 1.

𝑝2𝑗 : processing time of job j on machine 2.

The data consisting of the number of jobs and the set 𝑝1𝑗 and 𝑝2𝑗 is given.

Step 1: Form set-I containing all the jobs with 𝑝1𝑗 < 𝑝2𝑗

Step 2: Form set-II containing all the jobs with 𝑝1𝑗 > 𝑝2𝑗

The jobs with 𝑝1𝑗 = 𝑝2𝑗 may be put in either set.

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 Step 3: Form the sequence as follows:
a) The jobs in set-I go first in the sequence and they go in increasing order of 𝑝1𝑗
Shortest Processing Time (SPT).
b) The jobs in set-II follow in decreasing order of 𝑝2𝑗 Longest Processing Time
(LPT). Ties are broken arbitrarily.
This type of schedule is referred to as SPT(1)-LPT(2) schedule.
The sequence hence formed is known as the Johnson’s Optimal Sequence. The
directed graph of this sequence gives the value of Makespan 𝐶𝑚𝑎𝑥 .

Question-1: (Scheduling of two machines in flow shop)

A flow shop contains two machines which process the jobs in a fixed sequence. There
are 7-jobs to be processed on the 2-machines. The process times of the 7-jobs are
given in the table below. In this table 𝑝1𝑗 & 𝑝2𝑗 indicate the process time of the 𝑗 𝑡ℎ job on
Machine-1 and Machine-2 respectively. Work out optimum schedule of processing the
jobs in Machine-1 first and then Machine-2 for the optimum Makespan using
Johnson’s Method.
Processing times of 7-Jobs on 2-Machines
Job (j) J1 J2 J3 J4 J5 J6 J7
p1j 12 3 10 5 7 11 1
p2j 11 4 9 6 7 10 2

Calculate the following:

(i) The Leading Set-1, Trailing Set-2 and the Tie-Set;
(ii) Order the entries, 𝑝1𝑗 , of Leading Set-1 and Tie-Set as per the SPT rule;

(iii) Order the entries, 𝑝2𝑗 , of Trailing Set-2 as per the LPT rule;

(iv) Form the Optimally Scheduled set;

(v) Hence work out the Directed Graph and state the value of the optimum Makespan
𝐶𝑚𝑎𝑥 ;
(vi) Work out the Gantt Chart indicating the Makespan and idle time of the Machine-2.
(vii) Hence calculate the Idle-Time of Machine-2.

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 (Marks-7.5)
Question-2: (Inventory - Economic order quantity with Multiple Item inventory)

a) The following conditions have to be observed for the inventory of an item:

Parameter Item-1 Item-2 Unit
Demand, D 14,000 18,000 items/year
Order cost, Co 1000 1000 Rs/order
Item cost, C 80 100 Rs/item
Carrying cost percentage, i 20.00% 20.00%

Hence calculate the following:

Quantity
(i) The economic order quantity, 𝑄; in stock
(ii) The total variable cost of item, 𝑇𝐶 Q

(iii) Cycle time, 𝑇 Q

-D
t
2𝐷 𝐶0
The economic order quantity is stated as 𝑄 = √ (Q-Dt)
𝐶𝑐

The variable cost of item is stated as, 𝑇𝐶 = √2𝐷 𝐶0 𝐶𝑐 t

T Time
Q
D
b) In a situation of inventory there are multiple items to be
ordered. The criteria for optimization of cost involves the cost for all items while
satisfying the constraint of maintain the total number of orders as a fixed quantity
which is given and in the second case maintaining the total cost as a fixed value.

If there is a constraint on the multiple items that may be ordered in other words
the number of orders per year is constrained. The particulars of the items are
given in the table below:
Parameter Item-1 Item-2 Unit
Annual demand, Di 14,000 18,000 Nos.
Cost of each item, Ci 80 100 Rs./item
Order cost, Co 1000 Rs./order
Carrying cost as percent of item cost, i% 20 % of item cost
Total number of orders, N 15 Nos.

For the case of Multiple Items calculate the following:

(i) The Lagrange multiplier, 𝜆;
(ii) The order quantity of item-1 & 2, 𝑄1 & 𝑄2 ;
(iii) The orders of items-1 & 2, 𝑁1 & 𝑁2 (as real numbers);
(iv) Hence the total number of orders 𝑁;

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 𝑖 2
The Lagrange multiplier is stated as: 𝜆 = 2𝑁2 (∑𝑛𝑗=1 √𝐷𝑗 𝐶𝑗 ) − 𝐶𝑜

2𝐷
The order quantity is stated as: 𝑄𝑘 = √ 𝑖𝐶 𝑘 (𝐶𝑜 + 𝜆); ∀ (1 ≤ 𝑘 ≤ 𝑛)
𝑘

𝐷
And the number of items (a real variable) is stated as: 𝑁𝑘 = 𝑄𝑘
𝑘

c) There is a constraint on the total value of the cost, B, of the multiple items that
may be ordered in a year then calculate the order quantities. The particulars of
the items are as given below:

Parameter Item-1 Item-2 Unit

Annual demand, Di 14,000 18,000 Nos.
Cost of each item, Ci 80 100 Rs./item
Order cost, Co 1000 Rs./order
Carrying cost as percent of item cost, i% 20 % of item cost
Total value of order, B 8000 Rs./year

For the case of Multiple Items calculate the following:

(i) The Lagrange multiplier, 𝜆;
(ii) The order quantity of item-1 & 2, 𝑄1 & 𝑄2 ;
(iii) The total variable costs of items-1 & 2, 𝑇𝐶1 & 𝑇𝐶2;
(iv) Hence the total value of the orders 𝐵;

𝐶𝑜 2
The Lagrange multiplier is stated as: 𝜆 = ∑𝑛
2 ( 𝑗=1 √𝐷𝑗 𝐶𝑗 ) − 𝑖
2𝐵

𝑘 𝑜2𝐷 𝐶
The order quantity is stated as: 𝑄𝑘 = √(𝑖+𝜆)𝐶 ; ∀ (1 ≤ 𝑘 ≤ 𝑛)
𝑘

𝑄𝑘 𝐶𝑘
And the total variable cost for kth-item is stated as: 𝑇𝐶𝑘 = and the total
2
𝑄𝑘 𝐶𝑘
cost of the multiple items order is 𝐵 = ∑2𝑘=1
2

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 (Marks-7.5)
Question-3: (Cellular Manufacturing – Rank order clustering)
A manufacturing system was originally laid out for facilitating mass production with
Functional Manufacturing. A change in the business strategy requires a Cellular
Manufacturing system to be implemented which requires machines to be clustered.
There are in total 6-Machines and 7-Part Families being produced in the manufacturing
unit. Earlier the four machines were laid out to assist the Functional Manufacturing and
are denoted as machines M1 to M6. The part-families being manufactured are denoted
as P1 to P5. The layout of the machines and parts are denoted conventionally by an
incidence matrix given below:
Incidence Matrix
Part Families
P1 P2 P3 P4 P5 P6 P7
M1 1 1 1
M2 1 1 1
Machines

M3 1 1 1 1
M4 1 1 1
M5 1 1 1 1
M6 1 1 1

The incidence matrix is a binary matrix and the entries of the matrix are unity where
the parts visit the machine, as shown above. Therefore, the part-P1 visits the machine
M2, hence the entry in the corresponding cell of M2-P1 is 1. If the part does not visit a
particular machine then the entry is a blank.
Use the Rank Order Clustering method to cluster the incidence matrix which will be
suitable for Cellular Manufacturing. Hence calculate the following:
(i) Work out the weights for ordering the Machines using the 2’s exponents;
(ii) Reorder the machines by sorting the weights in descending order;
(iii) Next work out the weights for the Part Families adopting the same method;
(iv) Reorder the Part Families by sorting the weights;
(v) Hence work out the Cellular Manufacturing layout;
(vi) Indicate which machines are going to be part of which cell and which Part
Families will be manufactured in those cells.
(vii) Explain in one sentence, which type of manufacturing system is more suitable
for handling products having more variety.

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 (Marks-7.5)
Question-4: ( Assembly Line Balancing)
A product being assembled in an industry consists of 13 tasks as shown in the figure
given below. The time required for each task is given in the table and the precedence
condition is shown in the network given in figure.

Task Number 1 2 3 4 5 6 7 8 9 10 11 12 13
Task Time 4 3 4 6 2 5 2 7 9 4 7 5 3
Precedence-1 1 2 1 4 1 6 3 8 8 10 8 9
Precedence-2 5 11
Precedence-3 7 12
3 4
9
2 3 9

4 5 2 7 3
4 7
1 6 7 8 10 11 13

4 5 12
5
6 2
Cycle Time = 13

Assembly line network

Calculate the following:
(i) What will be the time required to assemble the product when one robot is
doing all the tasks?
(ii) What will be the time required to assemble the product when 13-Robots are
working at 13 stations to assemble the product?
(iii) Is it possible to achieve a cycle time of 13? If yes then work out the line
balancing strategy for T=13, using shortest processing time heuristic rule;
(iv) For the assembly line calculate the line efficiency and smoothness index.
(v) Discuss the drawbacks when line is not properly balanced.
∑ 𝑡
𝑖 𝑖
𝐿𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝑁×𝑇 ; Smoothness index = ∑𝑛𝑖=1(𝑇 − 𝑡𝑖 𝑋𝑖 )2

(END OF ASSIGNMENT-II)