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OR- UNIT -5

Or unit 5 notes

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mr.inayat01
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| OPERATIONS RESEARCH \-4-T INTRODUCTION Sequencing is the selection of an appropriate order in which a number of can be assigned to a finite number of service facilities (machines or e: the output in terms of time, cost or profit, jobs (operations) ‘quipments) 50 as to optimize One of the common problems in production processes is allocation of jobs on machines so as to have optimum utilization, The assignment or sequencing provides a single procedure for optimum loading of faciliti Consider a problem of a machinist who has to perform three operations namely milling, drilling and tapping on a finite number of different jobs (say five jobs) and the time required to perform these operations (in minutes) for each job is known. Itis also given that, each job frst goes for milling, then for drilling and finally for tapping, The problem of the machinist is to decide which job should be processed first, which to process next, and so on ie,, the sequence in which the jobs should be performed so as to minimize the total time required to process al the jobs. This may be considered as an example of five-jobs and three machines sequencing problem. 4.2 GENERAL SEQUENCING PROBLEM A general sequencing problem may be described as : Let there be 1 different jobs (1,2,3,.....m) each of which has to be processed, one at a time on each of m machines (My, My, My,.....) The order of the machines in which each job should be performed is given (for ‘example, each job is processed on machines in the order M,, M,, My,....).In other words, a job is assigned to machine M, first and after it has been completely processed on machine M,, itis assigned to machine M,. If the machine M, is not free at that moment for processing the same job, then the job has to wait in a waiting line for its turn on machine M,, ie, passing is not allowed. The general sequencing problem, therefore is to find the sequence out of (n!)" possible sequences which minimize the total elapsed time between the start of the job on the first machine and the completion of the last job on the last machine. In practice, if n =3and m=3, the total possible sequences will be 3!)° =216. Theoretically, it may be possible to find optimum sequence but it will require a large computational time. The sequencing technique provides the procedure to find out the optimum sequence for processing the jobs. ASSUMPTIONS UNDERLYING THE SEQUENCING PROBLEMS UN\* \ ‘Aotations ty = processing time (time required) for job i on machine j. T =Total elapsed time for processing all jobs including idle time, if any Ij =Idle time on machine j from the end of job (~1)to the start of the job i, SY 4, Number of machines. The number of machines refer to the number of service facilities through which a job must pass before it is assumed to be completed. Processing order. It refers to the order/sequence in which the given machines are required for completing the jobs. . Processing time. Processing time is the time required by a job on each machine. 4. Idle time on a machine. It is the time for which a machine does not have a job to process, ie, idle time is the time from the end of job (i~1)to the start of the job ion a machine. Total elapsed time. It is the time interval between the start of the first job and completion of the last job including the idle time if any in a particular order by the given set of machines. 6. No passing rule. It refers to the rule of main the order in which jobs are to be processed on a given set of machines. For example, if n jobs are to be processed through three machines M,, M, and Mg, then this rule states that each job will go to machine M, first, then to M, and finally to My. To explain the procedure of sequencing, let us consider four different cases, namely : 1. Two machines and 1 jobs. In the system there are only two machines M, and M, and there are n jobs. Each job is to be processed on M, and then M, i, the order of the machines is M,, My 2. n jobs and three machines. In this system n jobs are to be processed on three machines M,,.M;,M;- 3. jobs to be assigned to ‘mn! machines. » 4. Two jobs to be assigned to m machines. PROCESSING n JOBS THROUGH TWO MACHINES mang Pred suggested by Johnson for determining the optimum sequence for njobs on 2 s follows : Nap ro jobs along with their processing times in a tabular form as shown on next Scanned with CamScanner ~~ | OPERATIONS RESEARCH Procering tne Jobs Number on machine | 1 2 3 ome ” M fa Sn hy Nn M, ty Sa by hn Step 2 the columns for processing, Himes on machine Jing, Hime in each column, i, find out an M, and M, and find the mum (1, 1, )for all j Step SM the smalle job on M, and if it corresponds to 1 in the seq processing, time corresponds to machine M4, the ine M,, then sig te job a dat jg the job a the ast job Sep 4 iv a tie in selecting the minimum of all the processing, times, then three ions may arise as follows + imum among, all processing times is same for the machine, ie, min (hy olay) hy © by then process the Ath job first and rth job Las (ii) the tie for th imum occurs among, processing, times f,, on machine M, only, then select the job corresponding, to the sinallest job subscript first (iii) IC the tie for the then select the job imum occurs among, processing times f,, on machine My. responding, to the largest job subscript last. ep 5 Cross off the jobs already assigned and repeat steps 1 through 4 assigning, the remaining, jobs next to first or next to last, until all the jobs have been assig Zep © Calculate the idle time for machines M, and My (i) Idle time for machine M, = (Total elapsed time) = (Time when the last job in a sequence finishes on machine M,) (ii) dle time for machine M, = Time at which the first job in a sequence finishes on machine M, +)’ (Time when the jth job in a sequence starts on machine i M,) ~ (Time when (j = 1th job in a sequence starts on m lapsed time to process all jobs through two machines is gj Step? The total n by Total elapsed time = Time when the ith job in a sequence finishes on machine M: "Myst De by fr i where, M,, © Time required for processing, jth job on machine M, hy © Time for which machine M, remains idle after processing, () - Uth i0® and before starting work in jth job, Example 1 ~ Five jobs are performed first on machine M, and then on machine My. Time in hours taker by each job on each machine is given below ; Scanned with CamScanner 177 SEQUENCING PROBLEMS Machines Jobe | A B c D Ee | M, 5 1 9 3 10 | Determtine the optimum sequence of jobs and the minimum time elapse. Solution. It is the case of two machines and five jobs, the order of machines is Ma M, “The smallest processing time between the two machines is 1 which corresponds to job B on racine 1. Thus the job B will be processed first as shown below PLT TI th 4 jobs and their processing “After the job B has been set for processing first, we are left wi times are as given below ? Jobs > A c D E 3 10 Machines + M 5 M 2 7 time in this reduced problem is 2 which corresponds to job A om rule, job A will be processed in the last. Thus the current partial 8 4 The minimum processing machine 2, therefore according to assignment becomes B rt tl.) The set of processing times now gets reduced to Ce, Lo | Machines 4 a _ c D E M 9 3 10 My spe, 1 [4] Scanned with CamScanner | 7 OPERATIONS RESEARCH ‘The set of proce ing time is now reduced to Jobs Machines 4 c E M, 9 10 M, 7 4 The minimum processing time in this reduced problem is 4 which corresponds to job E on machine M,. Hence we assign job E at last but one place (last place already assigned to job 4) B D E A Now, there is only one empty place in the sequence and one job Cis left to be assigned, sojob Cis assigned to third place as shown B D c E A This completes the sequencing plan to give the order of processing as BoD+C+E>A imum elapsed time can be done in tabular form : Calculation of mii Table 1 Machine M, ‘Machine M, Sequence 190 | rime | Ps | Ti | nine in| Penne | Tine |e B 0 1 lari 6 7 Pa D 1 3 4 7 8 15 s c 4 9 13 15 7 2 - E 13 10 2B 23 4 a 1 A B 5 28 2% |: 2 a oe is 30 Thus, the minimum processing time to complete all jobs by proposed sequen time units, It is also observed that the total idle time for machine M, is 3 time units. the" repeated then machine M, will remain idle for 2 time units, because processing, iN" Vie can start only when the processing of last job of previous cycle is completed it. f"~ units. Scanned with CamScanner 179 SEQUENCING ProaLEns Example 2 ‘gi jabs are to be processed on fax machines A and then on machine B. Time in hi machine B. Time in hours taken by each job on each machine is given below : Jobs Machine A Machine B Determine the optimum sequence of jobs that minimtzes the total elapsed time to complete the ‘And compute the minimum time, Solution. The smallest proces ‘A and for job 2 on machine B. Henve, the job 3 will be processed first assign first i position (0 job 3. $i assign last postion t0 job 2 as shown under : 3 2 ‘| sing time between the two machines is 2 for job 3 on machine Similarly, by rule, jobs and their processing times are as given below : Jobs 4 5 6 10 R 6 1" 10 7 Now, we are left with 4 Machine A Machine B ‘The smallest processing time between the two machines is 3 for job number 1 on machine 3. Hence the job 1 will be processed last but one. [ 3 Now, we have to assign remaining 3 jobs with their pr ocessing time as under Jobs 4 Machine A aa D ; Machine B A 0 ; is 6 for job number six on Now the smalte i machi nt he Smullet processing time between the two machi . assign job 6 on 2nd position as shown under btef PT pte) Scanned with CamScanner 180 OPERATIONS RESEARCH ‘The only two jobs are two be assigned with their processing time as shown under Jobs 4 5 Machine A 10 2 Machine B un 10 The smallest processing time is 10 for ob 4 on machine A and for job 5 on machine B. Hence, finally assign job 4 on 3rd position from the beginning and job 5 on 3rd position from last as shown below : 3]/o6{4 ]5]1] 2 ‘The sequencing plan to give the order of processing is as follows : 39694959192 Table 2 Calculation of minimum elapsed time Machine A Machine B Sequence dle OF 5005 | rime in | Processing | Time | rime in Processing | Time time 3 0 2 2 2 5 7 2 6 2 6 8 8 7 15 1 4 8 10 18 4s, 18 n 29 3 5 18 2 30 4. 30 10 40 1 1 30 5 35 3 43 - 2 35 3 38 43 2 45 - Thus the minimum processing time to complete all the jobs by the proposed sequence is 45 units. Scanned with CamScanner An THREE MACHINES AND n JOBS the three machines are M,, M; and M, and the ord h b fy he order of processis > My > M, (ict, M,M,My system). The sequence of jobs in his ayston car be “st ane of the following conditions is satisfied ; otherwise the algorithm fal e rithm fails : suppose machines is M, carried out if at le {9 Smallest processing time of any job on machine M, is greater than or equal t traximum processing time of any job on M,, it, process time of all jobs on Mf is nore than the corresponding, processing time of jobs on M,. 2 smallest processing time of any job on M, should be greater or equal to the (ii) Similarly, maximum process time of any job on M,. Tat least one of these conditions is satisfied, then for sequencing the processing times of each job for machines M, and M, and also for machines M, and M : processing time forjob 1 on My and M, =processng time of job 1 on M, > M. Ze + processing time of job1 on M,, wv Me And, processing time for job 1 on M, and M, = processing time of job 1 on Mp "5% Ma “+ processing time of job 1 on Ms. .quence the jobs by using the method used ie, Now, these two times for jobs can be used to se for n jobs and two machines. \ hme 6 1 minimizes the total elapsed time (in hours) required to complete the following Find the sequence that jobs on three machines My, Mz, My in the order M, —> My > My = Jobs | Machines B Cc D E M, 8 7 10 6 M, 3 2 5 (ey 4 M, 4 8 6 Zz 8 Solution. Verification of conditions : Minimum processing time on M, =6 hours Maximum processing time on M, =6 hours Scanned with CamScanner 188 OPERATIONS RESEARCH Therefore, minimum processing time on M, 2 maximum processing time on yy the conditions is satisfied. Adding the processing, tim Now, the sequencing of the M, and M, as one machine and M and M, as Jes M, and M, first and then M, and My, we get Jobs Machines |} A B M, and M, | 9 10 M, and M, | 7 10 u 13 2 another mach E B D c A i] The minimum elapsed time can be calculated as follows : jobs can be done by the method already described considering Table 6 * ‘Machine 1 Machine 2 Machine 3 | sea’ Fine | Process. | Time | tate | Time | Process: | Time | tale | Time | Proves | Tre te | Tre | Tag time | out | time | in| ing time | out | time | in | ing time | out | time | Ee. 20) 6 6] - [76 4 0} Ge pace) 621) 165|00) B | 6 8 wu] -|4] 2 | wf] 4] we] 8 | %| - | p |ul] w |al-}a} « |s%}s fay 7 |) 4 | c | 2 7 | a1} - | 31 5 | a] 1]a7] 6 |B] - | A [31 6 7 | Led 3 ao] 1 | 43 a [vid Example 7 Find the sequence that minimizes the total time in hours required to complete Minimum elapsed time is 47 hours. Se Task: _ Machines = — A B c D ro mie 3 8 c 4 9 8 mle 2 4 3 2 5 1 4 3 mic 3 6 7 5 n 5 6 2 What is the minimum elapsed time ? Scanned with CamScanner the following 5 1.89 SEQUENCING PROBLES. solution. Verification of conditions : Minimum processing time on M, =3 Maximum processing time on M; =5 Minimum processing time on M, =5 Now, minimum processing time on M, 2 maximum processing time on condition is satisfied. Adding the processing times for M, and M, and then for M, and M, we get Tasks Machines — > oD : F ie M,+M, 7 Ou 9 ° w 8620 MM, | 10 10 7 1% 6 5 Now, the sequencing of the jobs can be done by method already described. Considering ‘M, + M, as one machine and M, + M; as another machine, the optimum sequence is : [alole o 0 m “Table 7 Calculation of Elapsed Time Machine M, Process- | Time | Ide ing time | ‘ont | time 3 3 - 4 7 - 7 4 - 8 2 - 8 ww - 7 37 - 9 |] - The optimum sequence is an ASDSGSBSFSC5E id the minimum total elapsed time =59 hours. Scanned with CamScanner 1 OD OPERATIONS RESEARCH Example 8 We have five jobs, each of which must go through machines A, B and times (in hours) are given in the following table : Cin {he order AB p re sing Jobs Machines 1 2 3 4 5 mic A 8 10 6 7 i mic B 5 6 2 3 4 mle C 4 9 8 6 5 Determine the optimal sequence of jobs that minimizes the total elapsed time. Al fa ity for the machines A, Band C. lng Solution. Verification of condition : Minimum processing time on machine M, Maximum processing time on machine M, =6 Minimum processing time on machine _M, Since minimum M, 2 maximum M,, the required condition is satisfied Adding the processing times for M, and M, first and then M, and M, we get: Jobs Machines ~——————*0es 1 2 3 4 5 M,+M, 13 16 8 10 5 M;+M, 9 15 10 9 9 The optimum sequencing is as follows : 3 2 4 1 5 “Table 8 Calculation of Elapsed Time Machine 1 Machine 2 Je | time | Process- | Time | tate | Tame | Process | Time im _| ing time | ‘out _| time | in | ing time | ‘out 3 o 6 6 - 6 2 8 I 2 10 we | - | 16 6 2 } 4 16 7 23 - 23 3 26 | | | | 1] 3 8 3s] - | 31 5 3 ‘ Fis} uftel-jel . | « 5<51 hour \ Thus elapsed time (minimum) for sequence 3-42 +4717 « ~~ Scanned with CamScanner 191 SEQUENCING PROBL? pespinne test A book binder has o ‘ of Printing press, one binding machine and the manuscripts of a = ” ferent books. The times required to perform the printing and binding operation for each book are (@) Determine the order in which the books ah Id be processed in order to minimize the total time squire to process all the books. Find also the total tin required. a Processing time (in minutes) 1 2 3 4 5 ae [409 a Printing time | 40 99 80 6 50 Binding time 50 60 of (6) Suppose that an additional operatic on 18 added to the process described above, viz., finishing. The times required for operations are given below : ing time (in minutes) a 1 2 * 3 4 5 ‘nishing time | 80 100-60 70 100 What isthe order in which the books should be processed and. find also the minimal total elapsed time. Solution. (a) Books 1 2 3 4 5 Printing 40 90 80 60 50 Binding 50 0 20 30 40 $y following the method already described the Optimum sequence for processing the books is : (a 2 5 4 3. | “Table 9 Calculation of Elapsed Time Printing Bin Pro | Pro- ing | Time | tdte | Time : ces time’ | out | time | "ym Gane 40 - 40 50 20 40, 130 - 130 60 190 40 180 - 190 40 230 7 240 - 240 30 270 w 320 - 320 20 340 50. Scanned with CamScanner ——_—eao 1.92. OPERATIONS RESEARCH ime » sequence 192 +5 . y Total minimum elapsed time for the sequence eee jie, 5 hours 40 minutes: (& Verification of condition : ; mum processing time for printing = 40 minutes Maximum processing time for binding =60 minutes =60 minutes cessing time for finishing Minimum pr for finishing 2 Maximum processing time for bindi ling, ig time Now minimum processin mes for printing and binding first and then for binding and ® Adding the processing ti 1g, we get, Books PB BAF The optimum sequence will be as follows : 5 1 4 2 3 “Table 10 Machine 1 ‘Machine 2 v ‘Machine 3 Books | Fime | Process- | Time | tate | Time | Processe | Time | idle | time | Proce | Tr ie | Getic | out | time | tw | ing time | out | time | im | ing time | oot 5 |o| s || -|s| 0 | | s0|%| m | 1 | so] 40 | 9 | - | 9 | 50 | 140 190 4 | 90 | 60 | 150} - | 150 30 180 | 10 | 270 2 | 150] 90 | 240] - | 240] 60 | 300 | 60 | 340 3 240 | 80 | 320 | - | 320] 20 | 340 | 20 | 440 inutes ‘Thus, the mini . - minimum processing time =500 minutes i.e, 8 hours 20 ™ Example 10 ee | (2) Given the following data : Scanned with CamScanner o SEQUENCING PRO, (¢) Onder of processing jobs + ACB (@) Sequence suggested : Jobs 5-3 ~6-2 1-4 (Determine the total elapsed time for the sequence suggested. {ip Is the given sequence optimal ? Gi If your answer to (i) is ‘No’, determine the optimal sequence and the total clepsed time associated with it (sotstor- Arranging the data in the order of processing : Aca. © | “G4 Job 1 2 3 4 5 6 = 2 10 9 4 7 9 6 2 4 7 6 5 4 4 Verification of condition : ‘Minimum processing time for machine A=7 ‘Maximum processing time for machine C= 6 ‘The required condition for combination is satisfied. () Total Elapsed Time for the sequence suggested “Table 11 Machine A Mackin B | Jobs Time | Process- | Time | Idle | Time | Process- | Time | idle | Time Idle | _ im’ | Getic | “out | tine | "iw | ing time | ‘out | time | “te time 5 0 7 7 - 7 2 9 7 9 4 13 9 3 7 9 16 - 16 6 22 7 22 6 28 9 6j}w] 9 Jol-fo] s |w}sfa| 4 |s}a 2 3 10 35 - 35, 5 40 6 40 6 46 7 tose ee ee leas |) oe lesa | 7 ess) | |p| 4 47 14 61 - 61 4 65 8 65 5 70 5 The optimal sequence can be found by the method already described. Adding. the Processing times for machine A and machine C and then for machine C and machine B, we get Scanned with CamScanner ~~ ane machine and C+ Bas anothe Now, considering A + C as one may MF Machine, the 7, = Prima, ™ orcs) facia oe OPERATIONS RESEARCH i) Therefore (ui) Calewlatic I Table 12 | Machine A ee ee Dome [iste |e | ie [ie | rts | ar | | | tee PT 1. ro 2 12 - 12 6 18 2 18 7 ale] 3 R 9 21 = 21 6 27 3 7 6 Bil2/ 2 21 Ww 31 - 3 5 36 4 36 6 2 | 3 | 4 | 31 mo] 45] = | 45 4 a} 9 fa] 5 |aj7| 6 |} 9 || -] se} 4 || 6 |] 4 ols) s}u]o7 fa]-foa] 2 fej2feaf is fel-| ‘The minimum total elapsed time is 67 hours) Sh M MACHINES AND ‘n' JOBS (PROCESSING ‘n' JOBS THROUGH m MACHINES) M machines, 8 Mt Let there be n jobs each of which is to be processed through is My wvsey My i the Order M,, My, My. The processing, time of A each job on each me as follows : Machines Jobs 1 2 3 My fn hy ly he M by by ty bn 1 My hy hy In he \ \ \ Mn boat 1 t Sn no he pte ~~ Scanned with CamScanner ae : \ Procedure to ‘An optimum conditions are $2 195. sequencine pro solution to this problem can be obtained, if either or both of the follo tisfed : (0) Min. ty = max. fy for (i) Min. ty.2 max: fy for Determine Optimal Sequence /Byovenee MAD 2,3, seep M—L Find min. ty min f,j and maximum of each fj, 3jy 0-01 ty— ij fOr all j=1,2,....., Sep! : ftep 2 Check the following : () Min. ty 2 Max. ty, for .m=1 i) Min. fay 2 max. ty, for seve ML, ‘rep the inequalities of step 2 are not satisfied, method fails. Otherwise proceed to next step. ‘ep 4 Convert the m machine problem into two-machine problem by introducing two fictitious machines say Gand H, such that toy Ht + hay tenet hey yy = tag thay tenet bg /tep5 Determine the optimal sequence for the 1 jobs and 2 machines by following the usual procedure as described earlier. Example 11 below. 5 jobs are to be processed on 4 machines. The processing time for each job on each machine is given as Determine the sequence of jobs that minimizes total elapsed time to complete the jobs. Machines Jobs A B c D E My 9 n @ 4 15 > M, 2 1 3 - 4 | 4 5 3 6 2 Mm 2B © nu 7 9 Solution. Verification of condition : Minimum processing time on M, =7 Minimum processing time on M, Maximum processing time on My =4 Maximum processing time on My =6 7 a “minimum t,,2 Maximum ts, max. t5 Mini inimum ,, = maximum f,,, max. t3, Tr - Scanned with CamScanner 1.96 OPERATIONS RESEARCH ‘The required condition is therefore satisfied. The problem is reduced to two mack problems by adding the processing times for machines M, + M, + M, and M, + follows . Jobs A B c D E G 15 17 13, 20 21 H 19 12 17 13 15 ‘The required optimum sequence (by following the usual procedure) c A E D B Table 13° Calculation of minimum Elapsed Time Machire 1 Machine 2 Machine 3 Machine ¢ | job P Pro g Pr 08 | ime | beer. | time | Time | Rete | Time | Time | craig | Tine Tne | | fn | cessing | ones | an | essins | out | in | time’ | out fe | - | 2 cao 7 7 {7 3 wo} wo] 3 {13} 3] Mf eae a Ae o {wf uw} 2 Jwfrw] 4 f 2} ml t ‘ ee eee | D) a} us fas fas} - fas fas | 6 fey ty] ° | 4 | n s7 | 57 a fe} ei | : i pop scar shouts for the optimal sevens 9 Thus, total minimum elapsed time Example 12 _ Scanned with CamScanner MPLE 54-2 There are seven jobs, each of which has 10 go th ZF Processing tines in hours are given ag °° MBM the machines A and B ip the ody & Job FS 2 3 4 5 7 ak A Machine A 3 2 1s 6 WW ng SL Wachine B a 0 6 2 4 Determine a sequence of these jobs that will mi and idle time for machines A and B. . NTU. Hyderabad B Tech (Se) Dee, yy PULCom. Jan, 2005; Karn. UBE. (Mech) 1995, 1999; LUBE. yn Solution iis By examining the processing times we find the s bine B. Thus we schedule job Pmallest value. It 8 1 hour for jb 6 og 6 last on machine A as shown below, | 6 ‘The reduced set of processing times becomes ioe enna eee 2 nue 3 ag ee MachingA> 3 12 15 6 gg Machine: & 10 10 6 42 3 There are two equal minimal values : processing time of 3 hours for job 1 on machine 4 £24 Processing time of 3 hours for job 7 on machine B. According to rules, job 1 is scheduled first and job 7 next to job 6 as shown below. Lf 7\6 The reduced set of processing times becomes Job: 203 0 4 5 MachineA: 12 15 6 10 MachineB: 10 10 6 42 Aggin chine there are two equal minimal values : Processing time of 6 hours for bes i aaa } A as well as on machine B. We may choose arbitrarily to process (schedule) job 4 1 o7 next to job 7 as shown below, 1] 4 LT T7T6 Jor ft ai ‘The reduced set of processing times becomes Job: 2 4 5 MachineA: 12 5 4g MachineB: 10 \y 43 a“ Scanned with CamScanner ta ee SEQUENCING MODELS AND RELATED PROBLEM: 487 se peat to yob 4-un the second schedule. The optimal sequences ate shown below r [4 Sei[eaee|e2m (e728) or, : « can calculate the elapsed time corresponding to either of the optimal sequences, vow vidual processing times given in the problem. The elapeed time and idle times for " jend B will be same for either sequence. The details corresponding to the first schedule a in table 5.5, TABLE 5.5 Machine A Machine B Idle for oe Time in_ [Time out_| Time in Time out_| machine B 1 0 3 3 i 3 4 3 9 Hn 7 0 5 = 19 19 31 2 3 19 34 34 44 3 2 34 46 46 36 2 7 46 55 56 59 0 6 35 66, 66. 67_¢ 7 Thus the minimum elapsed time is 67 hours. Idle time for machine A is 1 hour (66th-67th tout) and for machine B is 17 hours. EXAMPLE 5.4-3, A refrigeration company has six plants located in different parts of a city: Every year itis ‘Suan for each plant to be completely overhauled. The overhauling is carried out in two stages ‘ou 8 and each stage requires a crew of workmen with completely different skills. The work on pet can start only when stage A has been completed. The plant has to be closed for the entre adi) the overhauling, The company, at presen, is following the schedule of the overhent of “sic plans as given below : Time required by the Crew (days) Plant : Pro Py Py Pa Ps Ps Crew A 2 9 10 8 10 10 Crew B : 10 7 = M4 6 8 ) Determine the optimal sequence Y downtime ” {downtime of any of the sic plans casts ® 5.000 per day, idle J.500 per day and idle time fo 0 Schedules, the present one time for crew A costs. "crew B costs & 2,500 per day, which of the two or the one determined in part (i), will be more economical? Wha i Mal are their respective casts? Solution Present Schedule Mime of the ee the plants and idle time in ‘lays for crew 4 and B are calculated in table 5.6 Scanned with CamScanner 458 % OPERATIONS RESEARCH OO TABLE 5.6 Crow A Crew B Down Idle time Plant ‘Start Finish ‘Start Finish time Crew A | CrewB | [ 0 2 2 22 22 = B_| P; 12 21 22 29 17 = ~ Ps 21 31 31 40 19 = z Py 3I 39 40 34 2 5 = Ps 39 a 34 60 21 S =] Pe 9 39 60 8 19 9 = Total 121 9 i ~ Toual cost = [121 * 5,000 + 9 * 1,500 + 14 x 2,500] = € 6,53,500. Optimal Schedule Johnson and Bellman explained in section 5.4, the optimal sequensé Applying the rule by Py Py > P39 Po Po B for this schedule are calculated in table 5.7. “5 Ps, Down time of the plants and idle time in days for crew Aan TABLE 5.7 = Crew A Crew B Down Idle time San | Finish | Start | Finish | time _| Crew A | Crew B Py 0 8 8 22 2 = 8 Py 8 20 2 32 24 - E Ps 20 30 32 4l a | - - Py 30 40 41 49 19 : Po 40 49 49 56 16 - = Ps 49 59 59 65 16 6 3 Total 1 us 6 i ee R [118 * 5,000 + 6 * 1,500 + 11 * 2,500] = & 6,26,500. ~ Optimal sequence is more economical as it reduces the total cost by & 27,000 EXAMPLE 5.4-4 ro Xumber of Scanned with CamScanner 460 S OPERATIONS RESEARCH 5.8 PROCESSING n JOBS THROUGH THREE MACHINES a This sequenceing problem is competely described as follows (1) only three machines A, Band C are involved, : (1) each ob is processed i the prescribed order ABC (frst on MAChiDe A, the og and thereafter on C), (wi tno passing of yobs ts permitted (4, the same ordet over each machine is maintiay and le) the actual or expected provessing times Ay, Ass» Ay: Bis Bay. By and, ¢, C, are known and represented by a table of the TABLE $.10 “Machine times for n jobs and three machines Job B c 1 By G 2 B; CG 2 By GQ i n G The problem, again, is to find the optimum sequence of jobs which minimizes T No general solution is available at present for such a case, However, the method of section 5.4 can be extended to cover the special cases where either one or both of the following conditions hold good (if neither of the conditions holds good, the method fails and the optimal sequence has to be found by enumerating all the sequences). (J) the minimum time on machine 4 is 2 maximum time on machine B, and (2) the minimum time on machine C is 2 maximum time on machine B The method, described here without proof, is to replace the problem by an equivalent prolem involving jobs and two machines. These two (fictitious) machines are denoted by Gand H and their corresponding processing times are given by G, = A,+ By H,=B,+ C, If this new problem with the prescribed order Gi is solved by the method of section $4. the resulting optimal sequence will also be optimal forthe original problem. EXAMPLE 5.5+1 A machine operator has to perform three operations: turning, threading and knurling 0 4 number of different jobs. The time required to perform these operal Job is known. Determine the order in which the jobs should be the total time required to turn out all the jobs. Also find the idle tions (in minutes) for eas processed in order to min® times for the three operations TABLE 5.11 Job | Time for turning (minutes) | Time for threading (minutes) | Time Jor knurling (i 7 3 e i 2 12 6 “ 3 5 4 ° 4 2 6 R 5 9 3 8 6 wu 1 13 . jel (GND .U-BBA April, 2008, GIUBE. (Mech) Scanned with CamScanner SEQUENGING MODELS AND RELATED PROBLEMS & 461 solution Here, min A, = 2, max B, = 8% and min C= comple by the procedure described in section 5.5, The equivalent problem involving 6 jobs and two fictitious operations G and ff becomes Processing times for 6 Jobs and two fictitious operations 4, Since min C, = max fy, we can solve this G, = Turning + Threading | M, = Threading + Faurling Job I J (minutes) (minutes) 1 1 ~ 2 2 18 20 |- 3 9 13 4 8 14 4 5 12 " 6 12 4 Examining the columns G; and H,, we find that the smallest value is & under operation G, inrow 4, Thus we schedule job 4 first (on operation G, and thereafter on 1/,) as shown below. a ‘The reduced set of processing times becomes Job G mM 1 u 21 2 18 20 3 9 13 5 12 W 6 12 4 ‘The next smallest value is 9 under column G, for job 3. Hence we schedule job 3 as shown ‘below, 4 3 The reduced set of processing times becomes Job G, Ay 1 nl 21 2 18 20 5 12 MW 6 12 4 lang Thete are two equal minimal values : processing time of 11 minutes under column G, for Processing time of 11 minutes under column / for job 5. According to the rules, job 1 Scheduled Next to job 3 and 5 is scheduled last as shown below. | 4[3 [1 5 The reduced set of Processing times becomes Job G Hy 2 18 20 6 12 14 " . Sa, mat Value is 12 under column G; for job 6. Hence we schedule job 6 next to job 1 | Sequence becomes 4[3]1[e«]2[s5 we ial oeen, calculate the elapsed time corresponding to the optimal sequence, using the j "8 times given in the problem. The details are shown in table 5.12. ~ Scanned with CamScanner wee H »opERATIONS RESEARS ee TABLE 5.12 Turning operation | Threading operation | Jo [Fine | Time out [Tine in| Tine out | | 7 2 2 g : a 1 8 12 | 7 10 2 20 a 10 2 2 2 | 2 Pry 3 3 39 | [Es 33 2Y | og se Thus the minimum elapsed is 77 rinutes, for threading operation is 2 + knutling operation is 8 minutes. AMPLE 55-2 There are five jobs, ea the order ABC. Processing ‘minutes. [le time for turning o 1411434745 Solution Here, min 4, = 3, example $- Since min C,= max B, we can sshe tis H becomes in column H, job 1 next as it has next highe € ee thas st " shown bel till higher entry 13 in column #7, This 4TiTs 3] Scanned with CamScanner __ SEQUENCING MODELS AND RELATED PROBLEMS + 463 Jeb 2 is now scheduled next to job 3 and the optimal sequence becomes Gop I sol of ties will be Obviously, the other op and sT4[if2]q3 The minimum elapsed time can now be calculated corresponding to any optimal sequence, sy fist using the individual machining times given in the problem. The details are shown in table 5.14. TABLE 5.14 ra ‘Machine A Machine B ‘Machine © Time in| Time out |“ Time in [ Time out_| Time in_| Time out 4 0 5 5 7 7 13 1 5 8 8 12 1B 20 3 8 12 2 15 20 30 2 12 20 20 25 30 39 3 20 27 27 28 39 44 The minimum elapsed time is 44 hours, idle time for machine A is 44 - 27 = 17 hours, fxmachine B is 5 +1 +5 +2 + (44 ~ 28) = 29 hours and for machine C is 7 hours. Minimum ‘sped time and idle times for machines 4, B and C will be same for other optimal sequences, There is no waiting of jobs between machines A and B, the jobs have to wait for loading on satine C for (I + $+ 5 +11) = 22 hours resulting in some in-process inventory cost. BAUPLE 5.5-3 Find the sequence that minimizes the total elapsed time required to complete the following ‘sks, Each task is processed in any two of the machines A, B and C in any order. Task [G.ND.UB.Com. April, 2010; P.U.B.Com, 2002) ilation, There are 6 possible ways of processing the tasks : 1) Each task is processed by machines A and B in the order AB. » examining the processing times we find that the smallest Value is 3 for task 4 on machine “lls for task 7 on machine B. Thus we schedule tasks 4 and 7 as shown below. ee 47 JT I [7 ting the process as detailed in section 5.4, we get the following sequence : 4[s[3[2[é[if7 by) Scanned with CamScanner 464 “> OPERATIONS RESEARCH Total elapsed time is calculated in the table below. TABLE 5.15 Machine A Machine B Task Time in Time out Time in Time out 4 0 3 3 mT 5 3 8 n 18 3 8 1B 18 27 2 B 19 27 35 6 19 26 35 3 1 26 38 B 50 7 38 4 30 33 - Total elapsed time = $3. (ii) Each task is processed by machines A and B in the order BA Task Machine Proceeding as in section 5.4, we get the following sequence : T]ijlef[2];3][s]4 Note that this sequence is just the opposite of the one obtained in part (i). Total elapsed time is now calculated as usual in the order B.A. Total elapsed time is found to be = 53. (iii) Each tasked is processed by the machines B and C in the order BC Task imsne? wat Wane (Cree? Machine “B [7 8 9 8 7 8 3 (CAN meee yeea | tesa 8 4 Proceeding as in case (i) above, the optimal sequence is : 7Tl6[3[4]2 JJ s] Total elapsed time = (iv) Each task is processed by the machines B and C in the order CB Concluding from cases (i) and (ii) we can sTif274 [3 [6] Total elapsed time (») Each task is processed by the machines A and C in the order AC ‘The optimal sequence and total elapsed time can be found to be : ~~ 4i3iel{7[2fijqs] TET. = 46. (vi) Each task is processed by the machines A and C in the order CA ‘The optimal sequence and the total elapsed time are + _ sTijv2T7[¢][3]4] TET. = 46. Scanned with CamScanner RELATED PROBLEMS ¢ 465 From the above six cases it is concluded that tasks should be proc: iat oder AC oF CA. The optimal sequences ae 36-72-15 op 5 ae ad -1-6-3-4 wit eam total elapsed time 46, x6 PROCESSING TWO JOBS THROUGH m MACHINES This sequencing problem is described as follows: | (a) there are m machines, denoted by 4, B, C, ... K, (8) only two jobs are to be performed: job I and job 2, (c) the technological ordering of each of the two jobs through m machines is known, ‘ordering may or may not be the same for both jobs. Altemative ordering is not | permissible for either job, (@ the actual or expected processing times Ay, Byy Cyy ny Ki; Aa, Byy Cyy ong Ky are known, and aes (@) cach machine can work only one job at a time and storage space for in-process inventory is available. ‘The problem is to minimize the total elapsed time 7 ie,, to minimize the time from the start cf ist job 10 the completion of the second job. Such a problem can be solved by graphical method which is simple and provides good bough not necessarily optimal) results. EXAMPLE 5.6-1 Using graphical method, determine the optimal sequence needed to process jobs I and 2 on fiemachines, A, B, C, D and E. For each machine find the job which should be done first. Also caleuate the total time needed to complete both the jobs. TABLE 5.16 JobI Sequence A B c D E Time (hrs.): 1 2 3 5 1 Job2 Sequence :C A D E B Time(vs):3 4 2 1 5 [DOEACC, 1999, 98; Karn.U.B.E. (Mech.) 1993} Solution The graphical procedure is described with the help of the following steps : Step 1 Draw two axes at right angles to each other. Represent processing time on job 1 along ‘zontal axis and processing time on job 2 along vertical axis. Scale used must be same for "the jobs. Step 2 ig, [230Ut the machine times for the two jobs on corresponding axes in the given technological “=: This is shown in figure 5.2. Step 3 cnglthine 4 requires 1 hour for job 1 and 4 hours for job 2. A rectangle LMNP is, thus, ay for machine A. Similar rectangles are constructed for machines B, C, D and E as shown. Sep 4 ptt 4 program by starting from origin (Q) and moving through the various stages of ‘aug (Points) till the point marked ‘finish’ is reached. Choose path consisting only of a ay Vertical and 45° lines. A horizontal line represents work on job | w /hile job 2 remains ese tl line represents work on job 2 while job 1 remains idle and a 45° line to the base Simultaneous work on both jobs. Scanned with CamScanner 466 % OPERATIONS RESEARCH as) ob 2 —> be — > He 9 me fe 0123 4 6 67 & 9 10 11 12 13 14 A He Be Ct Dt E Job 1 —> Fig. 5.2. Graphie solution of 2 job and 5 machine problem. Step 5 Find the optimal path (program). An optimal path is one that minimizes idle time for job 1 je time for job 2 (horizons! (vertical movement). Likewise, an optimal path is one that minimizes movement), Obviously, the optimal path is one which coincides with 45° line to the maximun extent, Further, both jobs cannot be processed simultaneously on one machine. Graphically, th means that diagonal movement through the blocked out areas is not allowed. ‘A good path, accordingly, is chosen by eye and drawn on the graph (path OXYZ). Step 6 Find the elapsed time. It is obtained by adding the idle time for either job to the processite time for that job. The idle time for the chosen path is found to be 3 hours for job 1. Total elapsed time = 12 + 3 = 15 hours (considering job 1) = 15 +0 = 15 hours (considering job 2). Step 7 ‘The optimal schedule corresponding to the chosen path is shown in Fig. 5.3. L___,__, o 2 4 6 8 10 12 18 is ‘Time (hrs.) —» Fig. 5.3 Scanned with CamScanner SEQUENCING MODELS AND RELATED PROBLEMS + 467 is machines for the two jobs as evident from The optimal sequence or schedule on va pe S358 Machine A job I precedes job 2, machine B Job 1 precedes job 2, machine C job 2 precedes job 1, machine D job 2 precedes job 1, and — machine E job 2 precedes job 1 EXAMPLE 5.6-2 Use graphical method to minimize the time required to process the following jobs on the machines. For each machine specifv the job which should be done first. Also calculate the total Thapsed time to complete both jobs TABLE 5.17 Machines Job 1 Sequence: A BoC DUE Time hr):| 6 8 4 I 4 Job2 Sequence: |B c oA D Eg Time (hr):|_10__ 8 6 4 2 [KU Karnataka BE, June, 2011; PU.B. (E. & Ec.) April, 2006] Solution Step 1 Draw two axes at right angles to each other. Represent processing time on job 1 along horizontal zis and processing time on job 2 along vertical axis. Scale used must be same for both jobs. Step 2 Lay out the machine times for the two jobs on corresponding axes in the given technological che This is shown in Fig. 5.4. Idle time forjob2 40} 36 | 32} 8 é ar re oe 12 Ane — Bele Cre DFE Job-1—* Fig. £4. Graphical solution of 2 job and § machine problem. Scanned with CamScanner 468 % OPERATIONS RESEARCH | Step 3 _ Machine 4 requires 6 hours for job 1 and 6 hours for job 2. 5 ‘quare PORs constructed for machine A, Similarly, rectangles are constructed for machines B, a Dattts, shown, and F 5, Step 4 Make a program by starting with zer of completion (points) till the point marked ‘finish’ is reached, Choose path Consisting on} Hapiontal, vertical and 48° tines. A horizontal line represents work on job I wie pi reminn ile a vertical Tine represents work on job 2 while job 1 remains idle and a 48" ie (0 the hag represents simultaneous work on both the jobs Step § Find the optimal path (program). An of well as job 2. Obviously, the optimal path extent. Further, © time (origin O) and moving through the vais py S slags imal path is one that minimizes idle time on job 1 y is one which coincides with 45° line to t the maximum both jobs cannot be processed simultaneously on one machine. Graphically, this means that diagonal movement through the blocked ot ut areas is not allowed. A good path accordingly, is chosen by eye and drawn on the graph (path OUVWXYZ), Step 6 Find the elapsed time. It is obtained by adding the idle time for either job to the Processing time for that job. The idle time for the chosen path is found to be 4+ 6 = 10 hours for job 1 and 4 hours for job 2. ++ Total elapsed time = 34 + 10 = 44 hrs, (considering job 1) = 40 + 4 = 44 hrs, (considering job 2). Step 7 ‘The optimal schedule corresponding to the chosen path is shown in Fig, 5.5. A Bc D E Job 1 6 10 18 22 28 40 44 B c Ab E Job 2 ' 1018-24 28 40 44 0 5 10 15 20 25 39 3 40 44 Time (hrs.) —» Fig. 5.5 The optimal schedule on various machines for jobs 1 and 2 as evident from Fig. 5.5 is Machine A job 1 precedes job 2, machne B job 2 precedes job 1, machine C job 2 precedes job 1, machine D job 2 precedes job 1, and — machine E Job 2 precedes job 1. Scanned with CamScanner Coon ‘eintroduction . 7 Notations, Terminology and Assumptions —« S Sequencing Algorthm 5 | | | «Solved Examples, INTRODUCTION ‘The sequencing. problem arises w te is need for detenmining 3 performing a number of jobs by a number of facies according to sme pre-asie spe output in terms of time, cost or profit, Some practical situations in which know fof doing things is always desired are listed below: Patients wasting sn a hosptal for di S number of items being processed through a finite number of ma "The general sequencing problem may be described as: Let there Be "job time on cach of m machines, The sequence (order) ofthe machines un which ex the machine isgiven. The actual or expected time required by the jobs on each sequencing problem, therefote, i to find the sequcnce out of (!) total elapsed time between the start of the job in the first mash the last machine. NOTATIONS, TERMINOLOGY AND ASSUMPTIONS Notations eR ANS 14, = Processing time (time regited) for #0 mash T= Total elapsed time for processing all the jobs. This includ oo Idle time on machine j from the end of 1) to the start of job e Scanned with CamScanner Replacement and Maintenance Models | | | © Introduction 16 Types of Faure ‘+ Replacement of Items Whose Efficiency Deterorates with Time © Replacement of Items that Fail Suddenly Solved Examples Review Questions Seif Practice Probioms Hints and Answers INTRODUCTION The problem of replaceme wipments, pars, «te, become less effective o uscless du t either sudden or gradual deterioration in their efficiency failure or ‘reakdown, By replac frequent intervals, maintenance and other overhead costs ‘ereduced. However, such replacements would increase the need of eaptal cost for new ones, TYPES OF FAILURE Tact “flr” here willbe discusodin the context ofrelacement dssisions. There are wo types o res (Grad faite, and G) Soddn fiire. Gradual Failure Gradual failures progressive in natre, Thais. asthe lf ofan item inereases is opera Sona effcency also deteriorates resulting in © inreas runing (maintenance and operating) costs (2) sera in its productivity (@) decrease in the resale or salvage value. “Mechanical items like pistons, rings. bearings, ete. and automobile tyres fall under this ea Seddon Faiture This:ype of failure occurs initems aftr sos prio of giving desired service ‘ration hil inservice. The period of giving deve service sot constant but lows some reguensy “bation which may be progressive ory. Scanned with CamScanner BE Ores Resear: Pts and Soon failure: W the probability of failure ofan item increases With the jy wea ne. For example, igh bulbs ad bes tape \ the lite ot . (0 Prvgre such failure is called po (0 Retrogressive faiture: 1 the probability ot failure inthe be tame passes the chances of is failure become less, thy ii) Random failures In this type of failure, the constant faul font random ‘bom equijyment have boen found REPLACEMENT OF ITEMS WHOSE EFFICIENCY DETERIORATES wiry, Te 8 a8s0 fate axe. For example, vac inlent of the aye of the tube ne When operational efficieney of Sime with anew one. For example, when it may not be economical to allow ma altemative choices and oe may’ ike t9 compare available altematives onthe ace oF the ruin Cites Maintenance and operating eoss) involved. In this section, We shall deter 148 techn, ig such comparisons under differen comparisons iti gsr t suitable expressions for running costs a . Model! Replacement Policy for items Whose Running Cost Incroases with Timoand Vays, Money Remains Constant During a Period Theorem 1 the costof is given as fameton increasing with time sls ag Value is constant swith time (gradual f Hiscconomical wy ofa mach ses With time an asi the system, Hesides, the COU Be ain eofan nena () IF time is measured continuously, then the average annual cost will be minimized by replacing be nachine when the average cost o date becomes equal tothe eutrent manta (6) I time is measured in discrete units, then the average ann cost will be minimized by replacing de machine when the next period's maintenance cost becomes greater thes the current aver cost Symbols Let C = capital or purchase cost of new equ = scrap (or salvage) value of the equipment atthe end ofty (= running cost of equipment for the year 1 n= replacement age of the equipment (2) When time ‘'isa continuous variable: Ite equipment is Uused for ¢ years, then the total eos! over this period is given by TT Capital (or purchase) cost — + Running cost for ¢ years rap value at the end of ¢ years = C-84 fra Therefore, the average cost per unit time incurred over the Period of y s+ Siena Replace the equipment when the avera ‘annual running cost. That is ATC, te in Policy annual Cost for n years becomes equal 10 M8 Ro) 1{c : Scanned with CamScanner wl SS Hopcamart na vearrevarce Mores BEES Vda divetetevurtabtes Whe average van py When me he he wvernge cot ne 11 ver the period ab piven bry \ amy ye Sand, 00 an he tomutonically decreasing and increasing respectively, then there will Mtavaluce for which ATC, hus we shall ave equities AIG. 4» AIG, « AM. © ATC a ATC 4 AT 2 Any = AIC, 2 9 wt eee fe if the mext your, running: cont, (n+ 1) bx mare than average cont of nth year, ATC then it Poh ecole repeat thee of upeuah Tag ere cant th sear, ATE nines 5 muh par Ifthe present Sear’ running, st te Pe gy mot replace. That bs ‘than the previous year’s average ont, ATC, then mel beng y *y! nine fens 7 aul | Roplacoment Policy for tems Whoso. Modell ronoy Changes with Constant Rate yave of Mony Criterion 1 the eet ofthe tine value of mney so be condered, then replacement [sisnanalysis mus be based upon an equivalent anual cos. or example i the ened ce fs too percent per year je oF Rs 10040 be pent afte is sao called value of dirs the valve of money tha de fale is known as is depreciation rato ot [maid factor. The discounted values the amount of money equ at the ine ofthe policy doin foil wp fads at compound interest large enough to pay the rete cant ben dus Ee excels ae terest rte on Rs 100 is 7 per cent per yea alu (or worth) of Bs 100 tobe spent after n years walte ‘Running Cost increases with Time but Value of During the Period then prese ae (00+ ry" shared isthe discount rate or depreciation value, After having the idea of discounted cost, the objective ‘bald be to determine the critical age at which an item should be replaced so thatthe sum of all discounted cossisminimum, Present Worth Factor Criterion Inthiscase the optimal valuc of replacement age of an equipment can be ‘Sermined under two different situations, (0 Therunning cost of an equipment which deteriorates over a period oftime increases monotonically and the value of the money decreases with a constant rate. Ifr is the interest rate, then A Pufo(ltn" ‘Scalled the present worth factor ( Pwf) of present value of one rupee spent ‘Sowards, But if'n = | the Pufis given by d=(1+n ® med is called the discount rate or depreciation value. Money to be spent is taken on loan for a certain period ata given rate under the condition of ""¥¥yment in instalments n years from time now Scanned with CamScanner ‘Perations Research: Problems and Solutions: nent of items on the basis of present worth factor (Pw) i 5 and revenues for each replacement altematives. | preferred. Let © = purchase cost of an item R = annual running cost ‘n = life of the item in years $= scrap (oF salvage) value ofthe item atthe eng r= annual interest rate SMTi ig s is given by S(Pwf for n the present worth of the total cost during 7 Total cost = C+ R (Pwf for re interest rate for m years) Ifthe running cost of the item is different in its different operational life, then the pre lerest rate for years) ent Worth of the leg during 1 years is given by Total cost = C+ R (Pwf for re interest rate for i years) ~ S (PwE for r% interest rate fy where /= 1, Theorem 2 The maintenance cost increases with time and the money value dcereases with constant depreciation value is given. Then replacement policy will be : (a)_ Replace if the running cost of next period is greater than the weighted av (b)__Do not replace if the running cost of the next period is less than the weig! costs. Policy or REPLACEMENT OF ITEMS THAT FAIL SUDDENLY Individual Replacement Policy _Underthis policy, an item (or equipment) is replaced justafter its fale en system. ement Policy Under this po! (Gi) in groups at the end of some suitable time: any item fails before the time specified, it may be replaced in in the gt Group Rep! during a specified time period, failure, with the provision that i items are replaced (i) individually as and when they fi od without waiting forth ividualy SOLVED EXAMPLES 0,1 A firm is considering replacement of a machine, whose cost price is Rs oe oe tobe a oll ea ‘The running (maintenance and operating) costs are found from experience Year 1 2 3. 4 |. Running cost (Rs) : 200 500 800 1.200 1,800 2,500 3.200 4.00 a When should the machine be replaced? [Purvanchal Univ., MCA, 1996; Meerut Unis MSc (Mat ie 200 andthe cost ofthe mash ge Soluti cost (nthe srap value S= Rs Solution We ae given the running cost. Rn). Seat onder to determine the optimal time nwhen the machine shouldbe ep ost the life ofthe machine as shown in Table 20.1 iced, first we coh cost per year dur Scanned with CamScanner ‘Table 20,4 Caleutay, fn a “eon ws tetas votes EES ‘Running Com a ARE Run od Untlative Cox tee iy INE Conny agg sa Rin) Ro) (ny co ny ae mt Average Gon es (sy Re Cost is sy atc, 1 ed 200 2 500 700 2.000) {9=(5) +) 2 2 200) 2 3 50. 1.500 12.000, aa 12,000, 1.200 12500 700 6380 : os 129 ‘300 4500 s roy 4.500 “n 18700 2.500 12600 375 ‘ 7.000 i 16500 Bos) 1 3200 10,200 ne 19.500 ater 8 4.000 14200 ae 20 ain 5 J 26200 ars fom Table 20.1, it may be noted that the average cost per ; ao h4. Als he average cost in seventh yar ee oe sachine should be replaced after every six years mau See pies 6.100 and its scrap value is Rs 100, The maintenance costs found Year sod 2 3 Maintenance : 100 250 400 When should the machine be replaced? 4 5 6 7 8 00 91.200 1,600 2,000 (Kerala Univ., MCom, 1996; CA (Ni 1994) Solution Since the scrap value of the machine is Rs 100, resale valu ofthe machine aftera year remains constant throughout. The costs required can now be calculated as shown in Table 20.0 Table 20.2. Calculations of Average Running Cost Yeorof Maintenance Cost Cumulative Cost Depreciation Cost Toal Cost (Rs) average Cow (Ry 0 2 8 o OO _O-9+0 T TH 100 6.000 6100 e100 6.000 6380 2 250 e 6,000 6.750 3 400 750 if 739 ‘4 600 1.350 6.900 oe s 900 2,280 6,000 a As | 6 1,200 3.450 in ; J o7 1,600 5,050 | os ; 2.050 sao 2.000) - Hence, the machine nth year i minimum. From Table 20.2, it may be noted that the value ATC, during the sixth yea id be replaced after every 6th year. year and resale pres ofa certain equipment Example 203 Following table gives the running cos PSY ~ 6 7 | “Fose purchase price is Rs $,000. 5 ; 4 stv 2900 3400 4000 | Yer : ood foo 1800 2100 2500 28 ys Running cost (Rs); 1,500 e070 1.200 Meerut Univ:, M Sct Maths.) 2000) value(Rs) 3.50028 [Mee hat year is the equipment duc? Scanned with CamScanner examples that follow explain this method. - © EXAMPLE 11.2-4-—SeW oOnmr-S The cost of a machine is & from experience are as follows: $0 and its scrap value is € 100. The maintenance costs found Year 1 2 3 4 5. 6 7 8 Maintenance 100 250 400 = 600 © 900 1,200 1,600 2,000 cost @) : When should the machine be replaced? UN.LU, Hyderabad B.Tech. (C.Sc.) Dec., 2011; June, 2009: PI.U. BE. (Mech.) 2008; May; 2006; MBA June, 2003} Solution Letit be prot fitable to replace the machine after n years, Then m is determined by the minimum value of T,,.. Val lues Of T,,¢ for various years are computed in table 11.1. TABLE 11.1 eo @ @ o) & © “ars of| Purchase price} Annual Summation of | Total cost Average annual service | — Scrap value | maintenance | maintenance cost cost 03 , os LO ,f0 [e-s+ Epo] -|c-8+2 se] 7 z z = z z 2 6,000 100 100 6,100 6,100 6,000 250 350 6,350 3,175 ‘Scanned with CamSeanner 1056 % OPERATIONS RESEARCH 50 6,000 400 15 600 1,350 900 2,250 1,200 3.450 1,600 5,050 6,000 2,000. 7,050 13,050 Table 11.1 shows that the average annual cost is minimum & 1575) during the sith yoy and then rises. Hence the machine should be replaced afler 6 years of its use. EXAMPLE 11.22 a The maintenance cost and resale value per year of a machine whose purchase price i & 7,000 is given below. c TABLE 11.2 Year 1 2 3 4 5 6 [7 8 ‘Maintenance cost in® | 900 | 1,200 | 1,600 | 2,100 | 2,800 | 3,700 | 4,700 | 3.09 Resale value in ¢S) | 4,000 1200 | 600 | soo | 00 | 400 | 4m When should the machine be replaced ? UN.TU. Hyderabad B.Tech. Now,, 2010; R.T.M. Nagpur U.B. Tech. June, 2006; Karn. U.B.E. (Mech) 1997; LLM. Kolkata, 1994) Solution Capital cost C = % 7,000. Let it be profitable to replace the machine after n years. Then 1 should be determined by the minimum value of Tye. Values Of Tu for Various years are computed in table 11.3, a TABLE 11.3 Ww Q) G) a (5) (6) a) Years of | Resale Purchase Annual | Summation Total cost Average annual cost service | value | price-resale | maite- | of maintes value (C~ $) | nance cost | nance cast * ” + a] SO. zg) [ ~S+ $70 ie-ss 5/0) 10 0 n ww] ®) ®) ®@ ® ®@ ® 1] 4,000) 3,000 900 900 3,900 3,900 : ee $5,000 1,200 2,100 7,100 3,550 ; Fes 5,800 1,600 3,700 9,500 3,166.67 : Soo fan 2,100 5,800 12,200 3,050 ye a - 2,800 8,600 15,100 “3,020 “4 pied > 3,700 12,300 18,900 “3150 | fal ae toon | 4200 | 17,000 23,600 33043 | - $900 | 22.900 29,500 3,687.50 We observe from the table that . yest Hence the machine should be replaced oe a* tual cost is minimum @ 3,020) in the Si end of S years of service, EXAMPLE 11.2.3 wvice The purchase price of a machine is z aand its scrap value is only & 6,400. The yoo”: The stall soo Imaintenaner "installation charges amour © Cost in various years is given bel0™ ( ‘Scanned with CamScanner 1 3 year We 3 4 5 6 7 ointenance cost: I 3.000 4.000 6,000 8,400 11,600 16,000 19,200 Afr how many years should the machine be replaced ? Assume that the machine replacement one done only atthe year ends [PTU. Bech (Mech) May, 2011] solution Here, cost of the machine, C = & (52,000 + 14,400) = & 66,400. scrap value, S = & 6,400, ‘The optimum replacement period is determined as in table 11.4. TABLE 11.4 a @ 8 4 6) 6) years of | Purchase Annual | Summation of | Total cost Average annual senice | price ~ resale} maintenance | maintenance cost value cost ‘cost ) (cs) ry Epo |c-s+3,so|+}e-s+ iyo] z z z z < H 60,000 1,000 1,000 61,000 61,000 2 60,000 3,000 4,000 64,000 32,000 3 60,000 4,000 8,000 68,000 22,667 4 60,000 6,000 14,000 74,000 18,500 s 60,000 8,400 (22,400 82,400 16480 4 | 60,000 11,600 34,000 94,000 \ 15,667 7 60,000 16,000 50,000 1,10,000. 15,714 8 60,000 19,200 69,200 1,29,200 16,150 inal? ob8¢¥e from the table that average annual cost is minimum 15,667) inthe sixth year. “ee the- machine should be replaced at the end of 6 years of service. ' Pla) F102, Therefore, when the group replacement price per bulb exceeds ® 1.02, the policy of strictly ‘sdwvidual replacements becomes more economical. Banece (4.93) LER wis -H ce rere ner ee of individual replacement policy of an installation of 300 light {) Cost of replacing an individual bull 1s 2 Conditional probability of failure is given below: Week no : 0 1 2 3 4 Conditional Probability of failure : 0 01 03 07 10 Abo cat Calculate the number of light bulbs that would fail during each of the four weeks [PT.U. B Tech. April, 2012; 11.Sc. Dip. Indl. Man., 1976) Scanned with CamScanner 1082 # OPERATIONS RE Solution Let p, be the probability that a light bulb fail Pn 0, 1 3-01 = 02, 7-03-04, and paz t-07= 03. fs daring the ah week of tte Since the sum of all the above probabilities is unity. all probabilities higher tha pg zero. Thus all light bulbs are sure to burn out By Let N, represent the number of replacements bulbs are new initially. Then we have the 4th week made at the end of th Weck when at. Week Expected mumber of failures ° No > 300 1 Ny = Naps = 300 * 0.1 = 2 Nur Ny + Nps = 300 x 02+ 30* 0.1 = 60+ 3 -6 3 Ny = Nops + Nips + Naps = 300 = 0.4 +30*0.2+63*01 = 132 4 Nu = Nana + Nips + Naps + Nap = 300 * 3+ 30x 04 $63x02+132x01 = 18 ‘Nusiber of light bulbs failing during week 1, 2,3and 4 are 30, 63, 132 and 128 respee ‘Thos we find tht the number of bulbs failing each week increases till he 3d week nis: decreases during the 4th week. Average life of ight bulbs = SP, = 1 01 2 142% 02+3%04+4%03=29904 300 “Average number of failures per week = 5° = 103 (approx). “: Cost of individual replacement of bulbs = 2.x 103 = € 206) week. ‘Scanned with CamScanner “ ee 348 OPERATIONS RESEARCH Example 2 A manufacturer, finds from his past records that the casts per year assoc sated with a machine with « purchase price of Rs. 50,000 are as given below : Year (n) es Running cost . (maintenance cost) 15000 16000 18000 21000 25000 29000 34000 40000, Rs. Scrap value + 35000 25000 17000 12000 10000 5000 4000-4000, Determine the optimum policy. asing with time. Therefore, CS will Solution. Here, C=50/000, $(n)= Scrap value is deere de in tabular form as below + change with time. The calculations can be ma TCH Year | Main cost My aa Cost e-S | ¢- i =M, ce ae EM. 4 1 2 3 4 5 6 1 15000 15000 15000 30000 30000 2 16000 31000 25000 56000 28000 3 18000 49000 33000 82000 27333:33, 4 21000 70000 38000 108000 27000 5 25000 95000 40000 135000 27000 6 29000 124000 45000 169000 2816.67 7 34000 158000 46000 204000 29142.857 8 40000 198000 46000 244000 30500 ‘The average annual cost is minimum at the end of 4" and 5" year. Hence, the machine should be replaced at the end of 5" year. Example 3—©§ ——— (a) Machine A costs Rs. 36,000. Annual operating costs are Rs. 800 for the first year, and te the machine. If increase by Rs. 8000 every year. Determine the best age al which to replace the optimum replacement policy is followed, what will be the average yearly cost of owning and operating the machine ? (6) Machine B costs Rs. 40,000, Annual operating costs are Rs. 1600 for the frst ¥l = then increase by Rs. 3200 every year. You now have a machine of type A which is one ee : old. Should you replace it with B, if so when ? Assume that both machines have " resale value, Scanned with CamScanner for machine A th Operating | Cumulative operating | _ Arc rear | ear ate cont | clsetw, [ers 7 | 2 : [6 ar) a ee > | 8800 45000 | 3 16800 26400 36000 62400 5 32800 84000 36000, 120000 ii] = js] = | Table shows that the best age for the replacement of machine Ais at the end of 5 average yearly cost of owning and operating for this period is Rs. 20,800. (0) For machine R the average cost per year can be calculated as shown below f 7 7 a 7 ATC(C,) vr | Opens | Comintern) cs sci | 1 2 3 4 5 6 1 1600, 1600, 40000 41600 41600 2 4800, 6400 40000, 46400, 33200 3 8000 14400 40000 54400 18133.33 4 11200 25600 40000 65600 16400 5 14400 40000 40000 80000 JEON 6 17600 57600, 40000 97600, To2o8.c0, From the above table it is clear that the minimum average cost for machine Bis lower than that for machine A, machine A should be replaced by machine B _To decide the time of replacement, we should compare the minimum average cost for Machine B (Rs. 16000) with yearly cost of maintaining and using machine A Since there is no Salvage value for both machines, we shall consider only the operating cost. ana pe SHOUld keep the machine A so long as the yearly operating cost i lower than Rs. 160) replace when it exceeds Rs. 16000. Re. ie ‘one-year old machine A, Rs. 8,800 would be required to be spent in the next year, while 0 would be needed in next year. Thus, we should keep machine A for one year and replace it thereafter. Example 4 a 0 Pa sqft data on the operating costs per year and resale price of equipment A whose purchase price 000 are given below : Year Oo : 1 2 3 4 5 6 7 rece ne eest ts): 500 1900-23) 29K) BND ANY SA value (Rs): 5000, 2500 600 400 400 400 Scanned with CamScanner REPLACEMENT cost Associated with their Replacement Usually, the sudden failure items are inexpensive but the cost consequences of their ze/or installation cost involved in replacing them are considerable. ‘sometimes the failure of such items may cause a complete breakdown of the system. For example, a condenser of an aircraft costs litte, but its failure may result in total collapse of the aircraft. ‘Similarly, if truck tyre fails in service it may cause accident, the cost of which may be high as compared to the cost of tyres. In case of industrial equipment/machinery failure in service Muse loss of production, defective production or risk to workers, ‘The different categories of cost associated with sudden failure are : {Replacement cost. It is the purchase price of the item at the time of replacement. (i Consequential costs, These are the cost associated with the loss incurred in the event of sudden failure. (ii) Installation costs. The installation cost of the equipment/machinery depends upon their location or accessibility, visibility, interchangeability etc. In order to minimize the cost ass policies are considered : (@) Individual replacement (6) Group replacement fail jed with sudden failure items, two types of replacement _ Individual Replacement The items under this policy are replaced individually on failure only, hence the average replacement cost per year = Average number of expected replacement per year x Cost of an individual replacement Number of units in operation Expected life of an item x Cost of an individual replacement 8.6.2. Group Replacement When large number of items are in use, it may be observed that replacement of individual units upon their failure costs relatively high, whereas, if the entire group is replaced the unit cost works out to be comparatively a much lower value. Thus, it may be advantageous to replace whole lot at a certain interval together with the individual replacement as and when needed. Group replacement policy is a planned replacement in which all items are replaced at the end of prefixed period (optimal time interval) irrespective of whether they have failed or not, plus individually as and when they fail. fea the group replacement is done at shor intervals, the cost of group replacement per perio! ple, But the cost of individual replacements increases because ‘of the large number of imetement needed. Thus, the total cost starts declining up to a certain point when the time increases and then it starts rising when the individual replacement component of the cost fretisa gre prec Beater influence on the cost. It is necessary to determine this optimal interval of time for P replacement, Scanned with CamScanner 364 OPERATIONS RESEARCH Illustrative Problems (Ecanregppbe 8 ¢ aaa The following mortality rates have been observed for a certain type of light bulbs Month : 1 2 3 4 5 Percent failing by : 10 25 50 80 100 month end There are 1000 bulbs in use and it costs Rs. 10 to replace an individual bulb which has burnt out. fat bulbs were replaced simultaneously, it would cost Rs. 2.5 per bulb. It is proposed to replace all the bulbs at fixed intervals, and individually those which fail between the interoals. What would be the best policy to adopt ? Solution. From the data given in the problem it is clear that no bulb will last after 5 months. This means that bulbs which have survived until four months, are sure to fail during 5"" month, From the % failure given above, we can obtain the % failure rates and the probability of these failure rates of bulbs for each of the five months. Month x, | Cumulative % failure upto | % failure during | Probability P (x,) that a new Z the end of the month the month __| bulb shall fail during the month 1 10 10 0.10 2 25 15 os 3 50 5 0.25 4 80 30 0.30 5 100 20 0.20 idual replacement No. of units in operation vei ver cost = No-of units in operation cost of an individual replacement Average replacement cost = ed life of the bulb per month (a) Cost of indi Now, expected life of the bulb =E x; P(x;) =1x01 +2 «015 +3 x 025 + 4x 030 +5%020 =0.10 + 030 +075 + 120 + 100 =335 Rs.10 1000 ‘Therefore, average replacement cost/month =100 , 19 3.35 Now, cost of individual replacement . 2985.00 (8) Cost of Group Replacement Let N, represent the number of replacements made at the end of i®* month when all the 1000 bulbs are new initially. Scanned with CamScanner

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