Module-4

CO-4
Analyse various production activity control
techniques in operation environments
• Production activity control: Shop floor control
concepts, Techniques
• Performance measures, Gantt chart
• Finite loading systems, Priority sequencing rules
• General shop scheduling
• Static, Deterministic shop - Dynamic,
Probabilistic shop
Scheduling
Machines, manpower and facility are the commonly used resources
in production/service activities
Scheduling these resources lead to increased efficiency, utilization,
and ultimately profitability for organizations
Scheduling is defined as allocation of limited resources to jobs over
time to perform a number of tasks
The scheduling problems are often approached in two steps:
sequencing and scheduling
 Performance Measures

• Flow time: The amount of time a job spends in the service or

manufacturing system. Also referred to as throughput time or time
spent in the system, including service.
• Makespan: The total amount of time required to complete a
group of jobs.
• Tardiness: The amount of time by which a job missed its due date
or the percentage of total jobs processed over some period of
time that missed their due dates.
• Work-in-process (WIP) inventory: Any job that is waiting in line,
moving from one operation to the next, being delayed, being
processed, or residing in a semi-finished state.
• Total inventory: The sum of scheduled receipts and on-hand
inventories.
• Utilization: The percentage of work time that is productively spent
by an employee or machine.
Scheduling
• Scheduling: The allocation of resources over time to accomplish
specific tasks
• Demand scheduling: A type of scheduling whereby customers are
assigned to a definite time for order fulfillment
• Workforce scheduling: A type of scheduling that determines when
employees work
• Operations scheduling: A type of scheduling in which jobs are
assigned to workstations or employees are assigned to jobs for
specified time periods.
 Gantt chart
Used as a tool to monitor the progress of work and to view the
load on workstations.
The chart takes two basic forms:
Job or activity progress chart
Workstation chart
The Gantt progress chart graphically displays the current status of
Gantt
each job or activity relative to its scheduled completion date.
The Gantt workstation chart shows the load on the workstations Charts
and the nonproductive time.
Gantt
Charts
 SEQUENCING
Determining the order in which jobs at a work center will be
processed

Priority rules
Simple heuristics used to select the order in which jobs will be
processed
✔ The set of jobs is known, no new jobs arrive after
processing begins and no jobs are cancelled SEQUENCING
✔ Set up time is independent of processing sequence
✔ Set up time is deterministic
✔ Processing time are deterministic rater than variable
✔ There will ne no interruptions in processing such as
machine breakdowns, accidents or worker illness
 PRIORITY RULES
FCFS
Jobs are processed in the order in which they arrive at a machine or
work center
SPT
Jobs are processed according to processing time machine or work
center, shortest job first
EDD
Jobs are processed according to due date, earliest due date first
CR
jobs are processed according to smallest ratio of time remaining until
due date to processing time remaining
S/O
Jobs are processed according to average slack time(time until due
date minus remaining time to process).
Compute by dividing slack time by number of remaining operations
including the current one
Rush
Emergency or preferred customers first
Single machine scheduling
Flow shop scheduling
Job shop scheduling

Classification
 Single machine scheduling

A set of single operation jobs is available for processing at that

time
Set up time of each job is independent of its position in the jobs
sequence. So the set up time is of each job can be included in its
processing time
Job descriptors are known in advance
One machine is continuously available and is never kept idle
when is waiting
Each job is processed till its completion without break.
 Single machine scheduling
Processing time (tj)
It is the time required to process job j. The corresponding time t j will
normally include both actual processing time and set up time.
Ready Time(rj)
It is the time at which job j is available for processing. The ready time
of a job is the difference between the arrival time of that job and the
time at which that job is taken for processing
Due date(dj)
It is the time at which the job j is to be completed
Completion time (Cj)
It is the time at which of j is completed in sequence. Performance
measures for evaluating schedules are usually function of job
completion time.
 Single machine scheduling

Flow time(Fj)
It is the amount of time job j spend in the system.
Fj=Cj-rj
Lateness(Lj)
It is the amount of time by which the completion time of job j differs
from the due date.
Lj=Cj-dj
Postive lateness is a measure of poor service
Tardiness(Tj)
It is the lateness of job j if it fails to meet its due date or zero
otherwise
Tj=max{0,Cj-dj}
Single machine scheduling
Measures of performance
SPT Rules for Minimize mean flow time

Shortest processing time (SPT)sequencing means the

sequencing the jobs in increasing order of processing time.

Q.1 Single
Find the optimal sequence which will minimize the mean machine
flow time and also obtain the minimum flow time scheduling
Job(j) 1 2 3 4 5

P.Time(tj 15 4 5 14 8
)
 SPT Rules for Minimize mean flow time

Job(j) 2 3 5 4 1

P.Time(tj 4 5 8 14 15
) Single
machine
JOB sequence that minimize mean flow time is 2-3-5-4-1 scheduling
Job(j) 2 3 5 4 1
P.Time (tj) 4 5 8 14 15

C.Time(Cj)(Fj) 4 9 17 31 46
Mean flow time

Single
machine
scheduling
 Weighted Mean flow time

Each job is assigned a weight Wj

WSPT rule
Sequencing of jobs in increasing
order of weighted processing
time is known as weighted
Single
shortest processing time
machine
Q.1 scheduling
Determine the sequence which will minimize the weighted mean flow
time .Also find the weighted mean flow time
Job(j) 1 2 3 4 5
P.Time(tj) 15 4 5 14 8
Weight(Wj) 1 2 1 2 3
Weighted Mean flow time
Job(j) 1 2 3 4 5
P.Time(tj) 15 4 5 14 8
Weight(wj) 1 2 1 2 3
tj/wj 15 2 5 7 2.67

Optimal sequence which minimize the weighted mean flow time is Single
2-5-3-4-1 machine
Job(j) 2 5 3 4 1 scheduling

tj 4 8 5 14 15
Cf(Fj) 4 12 17 31 46
wj 2 3 1 2 1
Fj x wj 8 36 17 62 46
ED Rule to minimize Maximum Lateness

Lj=Cj-dj
The maximum job lateness and maximum job tardiness are
minimized by EED Sequencing
EDD rule
Sequencing of jobs
in increasing order Single
of due date machine
scheduling
Determine the sequence which will minimize the maximum lateness
(L max). Also determine the L max with respect too optimal sequence
Job(j) 1 2 3 4 5 6
P.Time(tj) 10 8 8 7 12 15
Due date(dj) 15 10 12 11 18 25
EDD sequence is
2-4-3-1-5-6

Job(j) 2 4 3 1 5 6
P.Time(tj) 8 7 8 10 12 15
C.Time(cj) 8 15 23 33 45 60
Due date 10 11 12 15 18 25 Single
Lateness -2 4 11 18 27 35 machine
scheduling

Optimized value of Lj=35

There are n jobs, each requires processing on m machines
The order in which the machines are required to process a job
is called process sequence of that job
The process sequence of all the jobs are the same
But the processing time for various jobs on a machine may
Flow shop
differ.
Scheduling
If an operation is absent in a job, then the processing time of
the operation of that job is assumed as zero.
 Two machines, many jobs

All Jobs follow same sequence – Johnson’s Rule

 JOHNSON’S RULE

Johnson’s rule: A procedure that minimizes makespan when scheduling a

group of jobs on two workstations.
Find the shortest processing time among the jobs not yet scheduled.
If two or more jobs are tied, choose one job arbitrarily
If the shortest processing time is on workstation 1, schedule the
corresponding job as early as possible. If the shortest processing time
is on workstation 2, schedule the corresponding job as late as
possible
Eliminate the last job scheduled from further consideration. Repeat
steps 1 and 2 until all jobs have been scheduled
Johnson’s Rule at the Morris Machine Co.
Time (hr)
Motor Workstation 1 Workstation 2
M1 12 22
M2 4 5
M3 5 3
M4 15 16
M5 10 8

Eliminate
Eliminate
Eliminate
Eliminate M5
M2 M3
M1 from
and
from
from consideration.
the only job
consideration. The
remaining
The next
next to shortest
be
shortest time
time is
Shortest time isconsideration.
3 hours The next
at workstation shortest
2, so time is
M5 isat
M2
scheduled
M1 at at Workstation
isjob
M4.
workstation
workstation 1,schedule
#1,last.
#2, so
so so schedule
schedule M2
M1 next
M5 first.
next.to last.
schedule M3

Sequence = M2 M1 M4 M5 M3
 Example 16.5
Johnson’s Rule at the Morris Machine Co.

The schedule minimizes the idle time of workstation 2

and gives the fastest repair time for all five motors.
No other sequence will produce a lower makespan.
Gantt Chart for the Morris Machine Company Repair Schedule
Workstation

1 M2 M1 M4 M5 M3 Idle—available
(4) (12) (15) (10) (5) for further work

2 Idle M2
(5) Idle M1
(22)
M4
(16)
M5
(8)
M3
(3)

0 5 10 15 20 25 30 35 40 45 50 55 60 65
Day
• Consider the following 2 machine and 6 jobs
flow shop scheduling problem. Using Johnsons
algorithm, obtain the optimal sequence which
will minimize the makespan

Job i Machine 1 Machine 2

1 5 4
2 2 3
3 13 14
4 10 1
5 8 9
6 12 11
Optimal sequence is 2-5-3-6-1-4
 Makespan

Makespan for this schedule is 53

 Gantt chart

Makespan for this schedule is 53

Extension of Johnsons Rule
Extension of Johnsons Rule

Hypothetical Problem
Consider the following 3 machines and 5 jobs flow shop problem. Check
whether Johnsons Rule can be extended to this problem. If so, What is the
optimal schedule and the corresponding makespan
Scheduling in low volume systems with many variations in
requirements
Each job has m different operations. Some of the jobs are having
less than m operations
Process sequence of jobs are no the same. Hence flow of each
Job shop
job in job scheduling is not unidirectional
Scheduling
The process sequence of all the jobs are the same
But the processing time for various jobs on a machine may differ
If an operation is absent in a job, then the processing time of the
operation of that job is assumed as zero