Manufacturing Management - Lecture 4 - Operations Scheduling
Manufacturing Management - Lecture 4 - Operations Scheduling
Manufacturing Management
Operations Scheduling
Steven Nahmais (2015), Production and operations analysis, Chapter 9
Learning Objectives
When you complete this chapter you should be able to:
1. Explain the relationship between short-term scheduling,
capacity planning, aggregate planning, and a master
schedule
2. Draw Gantt loading and scheduling charts
3. Apply the assignment method for loading jobs
4. Name and describe each of the priority sequencing rules
5. Use Johnson’s rule
6. Define finite capacity scheduling
7. List the steps in the theory of constraints
8. Use the cyclical scheduling technique
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Strategic Importance of Short-
Term Scheduling
Effective and efficient scheduling can be a
competitive advantage
Faster movement of goods through a facility
means better use of assets and lower costs
Additional capacity resulting from faster
throughput improves customer service
through faster delivery
Good schedules result in more reliable
deliveries
Scheduling Issues
Scheduling deals with the timing of
operations
The task is the allocation and
prioritization of demand
Significant issues are
The type of scheduling, forward or
backward
The criteria for priorities
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Hierarchy of Production Decisions
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Forward and Backward
Scheduling
Backward scheduling begins with the due
date and schedules the final operation first
Schedule is produced by working backwards
though the processes
Resources may not be available to accomplish
the schedule
Due
Now Date
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Scheduling Process-Focused
Facilities
1. Schedule incoming orders without violating
capacity constraints
2. Check availability of tools and materials
before releasing an order
3. Establish due dates for each job and check
progress
4. Check work in progress
5. Provide feedback
6. Provide work efficiency statistics and
monitor times
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Scheduling Problems in
Operations
• Job Shop Scheduling.
• Personnel Scheduling
• Facilities Scheduling
• Vehicle Scheduling and Routing
• Project Management
• Dynamic versus Static Scheduling
Operations Scheduling
• Specifies when labor, equipment, and facilities are needed to
produce a product or provide a service.
• Scheduling is the allocation of resources over time to perform a
collection of tasks
• It is the last stage of planning before production occurs
• Resources
– Workers, Machines, Tools
• Tasks
– Operations that bring some physical changes to material in
order to eventually manufacture products
– Setups such as walking to reach the workplace, obtaining and
returning tools, setting the required jigs and fixtures,
positioning and inspecting material, cleaning etc.
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Terminology
• Flow shop: n jobs processed through m machines in the same sequence .
Shop design in which machines are arranged in series
Input parts
Finished Products
A Pure Flow Shop
Finished Products
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Terminology
• Job shop: the sequencing of jobs through machines
– A job shop does not have the same restriction on workflow as a flow
shop. In a job shop, jobs can be processed on machines in any order
– Usual job shop contains m machines and n jobs to be processed
– Each job requires m operations (one on each machine) in a specific order,
but the order can be different for each job
– Real job shops might not require to use all m machines and yet may have
to visit some machines more than once
– Workflow is not unidirectional in a job shop
Input parts
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Terminology
• Parallel processing vs. sequential processing: parallel
processing means that the machines are identical
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Objectives in Scheduling
• Conformance to prescribed deadlines
– Meet customer due dates, minimize job lateness, minimize
maximum lateness, minimize number of tardy jobs
• Response time or lead time
– Minimize mean completion time, minimize average time in
the system
• Efficient utilization of resources
– Maximize machine or labor utilization, minimize idle time,
maximize throughput, minimize the length of time the shop
is open
• Costs
– Minimize work-in-process inventory, minimize overtime
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Loading
Process of assigning work to limited resources
Perform work with most efficient resources
Many times an operation can be performed by
various persons, machines, or work centers but with
varying efficiencies. If there is enough capacity,
each worker should be assigned to the task that he or
she performs best, and each job to the machine that
can process it most efficiently.
Use assignment method of linear programming to
determine allocation
Assignment Method
1. Perform row reductions by
subtracting the minimum 4. Matrix Modification : modify
value in each row from all matrix by subtracting the
other row values minimum uncrossed value
2. Perform column reductions from all uncrossed values, and
by subtracting minimum adding it to all cells where two
value in each column from all lines intersect
other column values ‾ other values in matrix remain
3. Line Test : Cross out all zeros unchanged
in matrix, using the minimum 5. Repeat steps 3 and 4 until
number of horizontal and optimum solution is reached
vertical lines. If the number of
lines equals the number of
rows in matrix, then optimum
solution has been found.
Make assignments where
zeros appear
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Assignment Example
Cooker
Food 1 2 3 4
Beans 10 5 6 10
Peaches 6 2 4 6
Tomatoes 7 6 5 6
Corn 9 5 4 10
Row reduction Column reduction Line Test
5 0 1 5 3 0 1 4 3 0 1 4
4 0 2 4 2 0 2 3 2 0 2 3
2 1 0 1 0 1 0 0 0 1 0 0
5 1 0 6 3 1 0 5 3 1 0 5
Assignment Example
Modify matrix Line Test
1 0 1 2 1 0 1 2
0 0 2 1 0 0 2 1 # lines = # rows
0 3 2 0 0 3 2 0 so at optimal solution
1 1 0 3 1 1 0 3
Cooker
Cooker
Food 1 2 3 4 Food 1 2 3 4
Beans 1 0 1 2 Beans 10 5 6 10
Peaches 0 0 2 1 Peaches 6 2 4 6
Tom 0 3 2 0 Tomatoes 7 6 5 6
Corn 1 1 0 3 Corn 9 5 4 10
Orders completed in 6 hours
Total number of hours = 21
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Priority Sequencing Rules
• When more than one job is assigned to a machine or activity, the operator needs to
know the order in which to process the jobs.
• Prioritize jobs that has been assigned to a resource
• If no order specified use first-come first-served (FCFS)
• Other Sequencing Rules
– FCFS - first-come, first-served: First Come First Served. Jobs processed in
the order they arrive to the shop. Viewed as a “fair” rule
– LCFS - last come, first served
– SPT - shortest processing time: Shortest Processing Time. Jobs with the
shortest processing time are scheduled first. Popular method to determine the
next homework assignment by many students
– LPT - longest processing time
– DDATE - earliest due date: Earliest Due Date. Jobs are sequenced according
to their due dates.
– SWPT: Shortest Weighted Processing Time. A weight is assigned to each job
based on the job’s value (holding cost) or on its cost of delay
– CUSTPR - highest customer priority
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Simple Sequencing Rules
PROCESSING DUE
JOB TIME DATE
A 5 10
B 10 15
C 2 5
D 8 12
E 6 8
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Simple Sequencing Rules: DDATE
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Simple Sequencing Rules: SPT
Best values
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FCFS Example PROCESSING DUE
Flowtime: The amount of time a
job spends from the moment it is JOB TIME DATE
ready for processing until its 1 7 8
completion, and includes any 2 1 12
waiting time prior to processing 3 5 6
Earliness: The amount of time a 4 2 4
job a early 5 6 18
Job j pj Dj Cj Fj Lj Ej Tj
1 7 8 7 7 -1 1 0
2 1 12 8 8 -4 4 0
3 5 6 13 13 7 0 7
4 2 4 15 15 11 0 11
5 6 18 21 21 3 0 3
Average 12.8 3.2 1 4.2
Max 21 11 4 11
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Job j pj Dj Cj Fj Lj Ej Tj
2 1 12 1 1 -11 11 0
4 2 4 3 3 -1 1 0
3 5 6 8 8 2 0 2
5 6 18 14 14 -4 4 0
1 7 8 21 21 13 0 13
Average 9.4 -0.2 3.2 3
Max 21 13 11 13
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EDD Example JOB
PROCESSING DUE
TIME DATE
1 7 8
Earliest Due Date 2 1 12
3 5 6
4 2 4
5 6 18
Job j pj Dj Cj Fj Lj Ej Tj
4 2 4 2 2 -2 2 0
3 5 6 7 7 1 0 1
1 7 8 14 14 6 0 6
2 1 12 15 15 3 0 3
5 6 18 21 21 3 0 3
Average 11.8 2.2 0.4 2.6
Max 21 6 2 6
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CR Example JOB
PROCESSING DUE
TIME DATE
1 7 8
Critical Ratio: 2 1 12
3 5 6
Due Date - Current Time 4 2 4
Processing time remaining until completion 5 6 18
Subtract Current Time
Job j pj Dj Cj Fj Lj Ej Tj
1 7 8 7 7 -1 1 0
4 2 4 9 9 5 0 5
3 5 6 14 14 8 0 8
2 1 12 15 15 3 0 3
5 6 18 21 21 3 0 3
Average 13.2 3.6 0.2 3.8
Max 21 8 1 8
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Comparing Methods
Method Fj Lj Ej Tj
FCFS Ave 12.8 3.2 1 4.2
Max 21 11 4 11
SPT Ave 9.4 -0.2 3.2 3
Max 21 13 11 13
SWPT Ave 9.8 0.2 4 4.2
Max 21 13 9 13
EDD Ave 11.8 2.2 0.4 2.6
Max 21 6 2 6
CR Ave 13.2 3.6 0.2 3.8
Max 21 8 1 8
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Example 7.1, con.
Comparison of
Sequencing Rules
No one sequencing rule excels on all criteria
SPT does well on minimizing flow time and
number of jobs in the system
But SPT moves long jobs to the end which may
result in dissatisfied customers
FCFS does not do especially well (or poorly) on
any criteria but is perceived as fair by customers
EDD minimizes lateness
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Guidelines for selecting a sequencing rule
1. SPT is most useful when the shop is highly congested. SPT
tends to minimize mean flow time, mean number of jobs in the
system (and thus work-in-process inventory), and percent of jobs
tardy. By completing more jobs quickly, it theoretically satisfies
a greater number of customers than the other rules. However,
with SPT some long jobs may be completed very late, resulting
in a small number of very unsatisfied customers.
2. Use SLACK for periods of normal activity. When capacity is
not severely restrained, a SLACK oriented rule that takes into
account both due date and processing time will produce good
results.
3. Use DDATE when only small tardiness values can be
tolerated. DDATE tends to minimize mean tardiness and
maximum tardiness. Although more jobs will be tardy under
DDATE than SPT, the degree of tardiness will be much less.
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Deterministic Scheduling
with Multiple Machines
• For the case of m machines and n jobs, there are n! distinct
sequenced on each machine (permutations), so (n!)m is the total
number of possible schedules
• For m = 3 and n = 4, total number of possible schedules is
243=13,824
• The optimal solution for scheduling n jobs on two machines is
always a permutation schedule
– Assume flow shop: in each job operations have to be done on both
machines
– Permutation schedule = jobs are done in the same order on both
machines
– This is the basis for Johnson’s algorithm
Example
Metal Frame makes 4 different types of metal door frames.
Preparing the hinge upright is a two-step operation.
Jobs
1 5 4 3 2 14
2 2 5 2 6 15
Natural schedule: 1 2 3 4
Is it optimal? 1 2 3 4
7 14 16 22
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Deterministic Scheduling with Multiple
Machines: Johnson’s Rule
• Name Machine 1 = A, Machine 2 = B,
then ai = processing time for job i on A
and bi = processing time for job i on B
• Johnson’s Rule says that job i precedes job j in the optimal sequence
if
min ai , b j mina j , bi
Algorithm:
• Step 1: Record the values of ai and bj in two columns
• Step 2: Find the smallest remaining value in two columns. If this
value in column a, schedule this job in the first open position in the
sequence; if this value in column b, schedule this job in the last open
position in the sequence; Cross off each job as it is scheduled
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Johnson’s Rule Example
Machine Machine
Job Center 1 Center 2
A 6 8
B 11 6
C 7 3
D 9 7
E 5 10
D 9 7
E 5 10
C
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Johnson’s Rule Example
Machine Machine
Job Center 1 Center 2
A 6 8
B 11 6
D 9 7
E C
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B 11 6
D 9 7
E A C
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Johnson’s Rule Example
Machine Machine
Job Center 1 Center 2
D 9 7
E A B C
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E A D B C
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Johnson’s Rule Example
Machine Machine
Job Center 1 Center 2
E 5 10
A 6 8
D 9 7
B 11 6
C 7 3
E A D B C
Each triplet above shows the start, processing, and stopping times
of an operation.
Johnson’s rule guarantees that the above schedule gives the best
value (41) of makespan. Operations Scheduling
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Johnson’s Rule Example
Work Center 1 Work Center 2
Job (Drill Press) (Lathe)
A 5 2
B 3 6
C 8 4 B E D C A
D 10 7
E 7 12
WC
1 B E D C A
WC
2
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Johnson’s Rule Example
Work Center 1 Work Center 2
Job (Drill Press) (Lathe)
A 5 2
B 3 6
C 8 4 B E D C A
D 10 7
E 7 12
Time 0 3 10 20 28 33
WC
1 B E D C A
WC
2 B E D C A
Time 0 3 9 10 22 29 33 35
B E D C A
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Johnson’s schedule: 1 5 4 3 2 14
4–x–x–x 2 2 5 2 6 15
4–x–x–3
job A B
4–x–1–3 1 5 2
4–2–1–3 2 4 5
3 3 2
4 2 6
Natural schedule: 1 2 3 4
1 2 3 4
7 14 16 22
4 2 1 3
Johnson’s schedule:
4 2 1 3
Is it optimal? 7 14 17 22
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Results for Multiple Machines
• For three machines, a permutation schedule is still
optimal if we restrict attention to total flow time only
(not necessarily the case for average flow time).
• Under some circumstances, the two machine algorithm
can be used to solve the three machine case:
– Label the machines A, B and C
– min Ai maxBi , for i or min C i max Bi , for i
– Redefine Ai’= Ai + Bi and Bi’= Bi + Ci
Example 7.6
Machines
A B C
1 4 5 8
2 9 6 10
3 8 2 6
4 6 3 7
5 5 4 11
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References
• Presentation by McGraw-Hill/Irwin
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