Chapter 5.aggregate Planning and Scheduling
Chapter 5.aggregate Planning and Scheduling
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Aggregate Planning
Meaning
➢ Aggregate planning is the process of developing, analyzing,
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Planning Horizon
Aggregate planning: Intermediate-range capacity
planning, usually covering 3 to 12 months. The
goal of aggregate planning is to achieve a
production plan that will effectively utilize the
organization’s resources to satisfy expected
demand.
Long range
Intermediate
range
Short
range
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Aggregate Planning Outputs
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The Planning Process
Top
executives Intermediate-range plans
(3 to 12 months)
Sales planning
Production planning and budgeting
Operations Setting employment, inventory,
managers subcontracting levels
Analyzing operating plans
Short-range plans
(up to 3 months)
Job assignments
Operations Ordering
managers, Job scheduling
supervisors, Dispatching
foremen Overtime
Part-time help
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Operations Scheduling
schedule to follow and ensure for accurate delivery times while also
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Loading, Sequencing and Scheduling
➢ Sequencing
➢ Scheduling
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Loading, Sequencing and Scheduling
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What is Scheduling?
Scheduling can be defined as “ prescribing of when and where each operation
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Definition of Scheduling
The three jobs consist of A,B, and C operations respectively; and there are
four machines - one machine of each type. We designate them as M1, M2, M3,
and M4 based on their categories.
The operations for job A are designated as A1, A2, A3, and A4. The operations
of job B are designated as B1, B2, and B3 and B4. Similarly the four
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operations of job C are designated as C1, C2, C3, and C4.
Scheduling Example (continued)
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Scheduling Example - Data
Operation Machine Processing Time
The table on right hand side (RHS) gives the Job
Number Number (Days)
data for this example.
A A1 M1 5
B2 M3 6
The operations of all jobs have to follow their
B3 M4 8
processing sequences. For example operation
A3 of job A can not be processed before
C C1 M1 4
operation A2.
C2 M2 6
C3 M3 8
The processing time for each operation is
also given in this table. C4 M4 2
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Scheduling Example – Objective Function
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Objectives of Operations Scheduling
The Objectives of Operations Scheduling include the
following:
Optimizing the Efficiency of Labor
Utilizing Equipment to the Fullest Extent
Increasing Profit and Output
Service Level Improvement
Manufacturing time Reduction
Production Cost Minimization
Worker Cost Minimization
Inventory Minimization
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Functions of Operations Scheduling
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The role of scheduling
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Forward and Backward Scheduling
Due
Now Date 24
Forward Scheduling
Forward scheduling is a done if no product is available
on the material availability date calculated by backward
scheduling. The system does an availability check to
determine the first possible date when the product will be
available. This new material availability date forms the
starting point for scheduling the remaining activities. The
loading time, pick/pack time, transit time, and
transportation lead time is added to the new material
availability date to calculate the confirmed delivery date.
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Forward Scheduling
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Forward Scheduling
Due Date
Now 27
Backward Scheduling
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Scheduling Criteria
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Principles of Scheduling
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Principles of Scheduling (Continued)
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Loading Jobs : Techniques
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Gantt Charts
➢ Gantt charts are visual aids that are useful in loading and scheduling. The
name is derived from Henry Gantt, who developed them in the late 1800s. The
chart show the use of resources, such as work centers and labor. It also shows
today’s job schedule by employee.
➢ When used in loading, Gantt charts show the loading and idle times of several
departments, machines, or facilities. They display the relative workloads in the system so
that the manager knows what adjustments are appropriate. If a work center becomes
over loaded, employees from a low-load center can be transferred temporarily to
increase the work force. Or if waiting jobs can be processed at different work centers,
some jobs at high load centers cane be transferred to low load centers.
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Gantt Charts
➢ Gantt charts are widely used in business to describe all kinds of projects
according to the rules of project management. They are usually created by
computer applications. Different Gantt applications have different features and
capabilities.
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Dispatching-Scheduling Techniques
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Gantt Chart
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Gantt Chart
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Gantt Chart
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Gantt Chart
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Gantt Chart
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Gantt Chart
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Gantt Chart
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Gantt Chart
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Gantt Chart – C halved
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B4 F4
10
0
5 12
STAR FINIS
A2 C3 E3 G2
T H
10
2
7
D5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 Days
B
T
A C
S D
K
S E
G
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Assignment Method
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Assignment Method
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.
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Assignment Example
JOB A B C
X $11 $14 $ 6
Y $ 8 $10 $11
Z $ 9 $12 $ 7
Give the job assignment which will minimize the total cost.
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Assignment Example
Solution : Table 1
Machine Row
A B C min cost
Job
X $11 $14 $ 6 =6
Y $ 8 $10 $11 =8
Z $ 9 $12 $ 7 =7
Step 1a – Rows: The minimum cost in row X,Y and Z is $ 6,$8 and $ 7 respectively. Subtract
these elements from all elements in their respective row. The reduce cost matrix is :
Machine
A B C
Job
X $ 5 $ 8 $ 0
Y $ 0 $ 2 $ 3
Z $ 2 $ 5 $ 0 58
Assignment Example
Step 1b – column : The minimum elements in column A,B and C is $ 0,$ 2 and $ 0
respectively. Subtract these elements from all elements in their respective columns.
The reduced cost matrix is :
Machine
A B C
Job
X $ 5 $ 6 $ 0
Y $ 0 $ 0 $ 3
Z $ 2 $ 3 $ 0
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Assignment Example
Step 2 - Lines : Draw the minimum number of line to cover all zeros. We find
only two lines are needed to cover all the zeros, the solution is not optimal
Machine
A B C
Job
X $ 5 $ 6 $ 0
Y $ 0 $ 0 $ 3
Z $ 2 $ 3 $ 0
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Assignment Example
Step 3 – Subtraction : Select the smallest Machine
number among uncovered elements.Here A B C
it is 2. Subtract this elements from all the Job
X $ 5 $ 6 $ 0
elements uncrossed by the line and add it
Y $ 0 $ 0 $ 3
to elements at intersection point of drawn Z $ 2 $ 3 $ 0
line. The cost in the matrix which is
crossed by the line drawn should remain Smallest uncovered number
as it is. The next reduced cost matrix will
be as follows.
Machine
A B C
Job
X $ 3 $ 4 $ 0
Y $ 0 $ 0 $ 5
Z $ 0 $ 1 $ 0 61
Assignment Example
Step 3 – Lines :Because
three lines are needed, the Machine
solution is optimal and
A B C
assignments can be made.
Job
X $ 3 $ 4 $ 0
Y $ 0 $ 0 $ 5
Z $ 0 $ 1 $ 0
Machine Machine
A B C A B C
Job Job
X $11 $14 $ 6 Z $3 $ 4 $0
Y $ 8 $10 $11 Y $ 0 $ 0 $ 5
Z $ 9 $12 $ 7 Z $ 0 $ 1 $ 0
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Priority Rules
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Simple Sequencing Rules
PROCESSING DUE
JOB TIME DATE
A 2 7
B 8 16
C 4 4
D 10 17
E 5 15
F 12 18
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Simple Sequencing Rules: FCFS
▪ Sequence: A-B-C-D-E-F
Job Processing Flow DUE TARDINESS
SEQUENCE TIME TIME DATE Flow – dd
(0 if negative)
A 2 2 7 0
B 8 10 16 0
C 4 14 4 10
D 10 24 17 7
E 5 29 15 14
F 12 41 18 23
41 120 54
▪ Sequence: A-C-E-B-D-F
Job Processing Flow DUE TARDINESS
SEQUENCE TIME TIME DATE Flow – dd
(0 if negative)
A 2 2 7 0
C 4 6 4 2
E 5 11 15 0
B 8 19 16 3
D 10 29 17 12
F 12 41 18 23
41 108 40
▪ Sequence: C-A-E-B-D-F
Job Processing Flow DUE TARDINESS
SEQUENCE TIME TIME DATE Flow – dd
(0 if negative)
C 4 4 4 0
A 2 6 7 0
E 5 11 15 0
B 8 19 16 3
D 10 29 17 12
F 12 41 18 23
41 110 38
A 2 7 (7-0)/2 =3.5
B 8 16 (16-0)8 =2.0
C 4 4 (4-0)/4 =1.0
D 10 17 (17-0)/10=1.7
E 5 15 (15-0)/5=3.0
F 12 18 (18-0)/12=1.5
A 2 7 (7-4)/2 =1.5
B 8 16 (16-4)8 =1.5
C - - -
D 10 17 (17-4)/10=1.3
E 5 15 (15-4)/5=2.2
F 12 18 (18-4)/12=1.17
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Sequencing Rules: Critical Ratio
A 2 7 (7-16)/2 =-4.5
B 8 16 (16-16)8 =0.0
C - - -
D 10 17 (17-16)/10=0.1
E 5 15 (15-16)/5=-0.2
F - - -
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Sequencing Rules: Critical Ratio
A - - -
B 8 16 (16-18)8 =-0.25
C - - -
D 10 17 (17-18)/10=-0.1
E 5 15 (15-18)/5=-0.6
F - - -
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Sequencing Rules: Critical Ratio
A - - -
B 8 16 (16-23)8 =-0.88
C - - -
D 10 17 (17-23)/10=-0.6
E - - -
F - - -
▪ Sequence: C-F-A-E-B-D
Job Processing Flow DUE TARDINESS
SEQUENCE TIME TIME DATE Flow – dd
(0 if negative)
C 4 4 4 0
F 12 16 18 0
A 2 18 7 11
E 5 23 15 8
B 8 31 16 15
D 10 41 17 24
41 133 58
Average
Average Average Number of
Flow Time Tardiness Jobs at the
Rule (days) (days) Work Center
FCFS 20.00 9.00 2.93
SPT 18.00 6.67 2.63
EDD 18.33 6.33 2.68
CR 22.17 9.67 3.24
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Two Work Center Sequencing
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Johnson’s Rule Conditions
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Sequencing Jobs Through Two Serial Process
Johnson’s Rule
List time required to process each job at each machine. Set up a one-
dimensional matrix to represent desired sequence with # of slots
equal to # of jobs.
If smallest time occurs on machine 2, put the job as near to the end of
the sequence as possible.
Repeat steps 2-4 until all slots in matrix are filled and all jobs are
sequenced. 79
Johnson Rule
Example
Each of five jobs needs to go through work center A and B. Find the
optimum sequence of jobs using Johnson's rule.
Seq: 2, , , , 80
Johnson Example
Seq: 2, , , ,1
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Johnson Example
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Johnson Example
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Johnson Example
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Job Sequencing on Two Machine
Johnson’s Rule
Example 2 : 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
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Job Sequencing on Two Machines
Johnson’s Rule
Example 2 : Solution
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
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Job Sequencing on Two Machines
Example-3 -Johnson’s Rule
Question :Solve the following sequencing problem using Johnson’s rule method and find out :
a. Total run time
b. Total idle time
c. Draw a chart showing runtime and idle time.
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Job Sequencing on Two Machines
Example-2 -Johnson’s Rule
Solve the following sequencing problem using Johnson’s rule method and find out :
a. Total run time
b. Total idle time
c. Draw a chart showing runtime and idle time.
Work
Station
I d le--available
1 B A D E C f o r f urther work
2 Idle B I d le A D E C
0 5 10 15 20 25 30 35 40 45 50 55 60 65
Hour
Makespan = 65 hours
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THANK YOU
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