Sequencing Techniques
Hemant Jog
Chetana’s Institute/s of Management & Research
PHONE 9503040028/9834150970
EMAIL: [email protected]
1
Operations Scheduling
a) One of the planning function of operations management
b) It is most important in Job shop processing
c) Because in Job shop
1) Variety of items is large
2) Machines & workers are versatile
3) So, they perform different type of jobs
d) Examples of Job shop
1) Custom furniture making
2) Specialized equipments manufacturing
3) Restoration & refurbishing works
4) Restaurant serving different dishes on order
5) General Hospital
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2
Components of Scheduling
a) Assigning tasks / job orders to different machines (or work centers)
b) Deciding about the sequence of processing of the job on different
machines on the basis of some priority rule
(called sequencing or prioritization)
c) Planning the route of movement of the material from one
department to the other during processing
(called routing)
d) Issuing dispatch lists to the various work centers
(called dispatching)
Dispatch List is detailed schedule of various orders (work centers,
processing order, processing time, so on)
e) Tracking the progress of various jobs scheduled.
In case of delays in the implementation of schedules, revising the
schedules and expediting the completion of certain jobs
(called expediting)
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In the absence of proper scheduling
Delays in meeting the due High work-in-process
dates of customer orders inventory
High average Low utilization of
completion time Problems workers & machines
of jobs (high idle time)
No accurate
information available Higher set-up time
for the current status (overall) of machines
of a job Higher cost of
production/operations
4
Forward Scheduling
a) It means assigning customer orders or jobs to various work centers
based on the approach “as early as possible”.
b) Job is scheduled on a work centre as soon as it is free to process a
job.
c) Job is finished as soon as possible.
d) It is Based on the assumption that a customer is ready to receive the
goods as soon as these are produced.
e) It may result into high WIP if subsequent work centers are busy.
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5
Backward Scheduling
a) It is a way of scheduling which is based on the approach “as late as
possible” with the condition that the jobs are finished by their due
dates of delivery to the customer.
b) Planning starts with assigning job to last work centre & according to
the processing time at each centre scheduled is worked out up to
beginning of the processing sequence.
c) The lead times of the earlier processes have to be known accurately.
d) It may result in significant reduction of WIP.
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6
Loading
a) Loading means assigning tasks to work centers or machines.
b) Finite Loading means loading of jobs on machines or work centers is
done keeping in view their maximum capacity.
c) Infinite Loading means while assigning tasks to a machine or work
center, its maximum capacity is overlooked.
It is done when the excess work scheduled can be
1) shifted to other work centers or time periods.
2) executed by working overtime or by sub-contracting
This is termed as capacity expansion
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7
Different Methods of Sequencing /
Assignment of Jobs on Machines
Scheduling
Sequencing n jobs Sequencing two jobs on n machines in Assigning n jobs
different machine sequences (Akers method) on m machines
On one machine On two machines On three machines On m machines
First come, first served
(FCFS) method In the same job Assignment Model
sequence
Last come, first served
(LCFS) method
Due date method Johnson’s
method
Random method
Shortest processing
time (SPT)) method
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Sequencing n jobs on one machine-I
Example Order of arrival of jobs A to F,
PT = Processing time (days),
DD = due date (days from start)
First Come First Served (FCFS) Last Come First Served (LCFS)
Job PT DD Flow Time Delay Job PT DD Flow Time Delay
A 3 9 0+3 = 3 0 F 8 12 0+8 = 8 0
B 7 10 3+7 = 10 0 E 5 8 8+5 = 13 5
C 4 7 10+4 = 14 7 D 2 4 13+2 = 15 11
D 2 4 14+2 = 16 12 C 4 7 15+4 = 19 12
E 5 8 16+5 = 21 13 B 7 10 19+7 = 26 16
F 8 12 21+8 = 29 17 A 3 9 26+3 = 29 20
Total 93 49 Total 110 64
Average 15.5 8.167 Average 18.33 10.67
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Sequencing n jobs on one machine-II
Example Order of arrival of jobs A to F,
PT = Processing time (days),
DD = due date (days from start)
Due Date Method Random Method
Job PT DD Flow Time Delay Job PT DD Flow Time Delay
D 2 4 0+2 = 2 0 B 7 10 0+7 = 7 0
C 4 7 2+4 = 6 0 F 8 12 7+8 = 15 3
E 5 8 6+5 = 11 3 D 2 4 15+2 = 17 13
A 3 9 11+3 = 14 5 A 3 9 17+3 = 20 11
B 7 10 14+7 = 21 11 C 4 7 20+4 = 24 17
F 8 12 21+8 = 29 17 E 5 8 24+5 = 29 21
Total 83 36 Total 112 65
Average 13.833 6 Average 18.67 10.833
10
Sequencing n jobs on 2 machines
Gantt Chart
Example processing required in the order M1, M2 Jobs M1 M2
& processing times are as given in the table.
J1 3 7
Find the sequence of jobs to minimize total processing
time. J2 5 9
Solution
Now, Gantt Chart starting with J1 on M1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
M1 J1 J2
M2 Idle J1 J2
Now starting with J2 on M1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
M J2 J1
1
M Idle J2 J1
2
So, the sequence J1, J2 minimizes total processing time 11
Johnson Method: Sequencing n jobs on 2 machines
Example:
10 jobs to be processed on 2 machines in the order M1, M2. For each
job processing time in hrs is given in the table. Find overall processing
time, waiting time of the jobs & idle times of the machine.
Position in Sequence from Solution:
Job M1 M2 Start End Sequence starts with smallest
A 2 7 3 or 4 — processing time at M1
B 5 3 — 2
It ends with smallest
C 1 4 2 or 1 — processing time at M2.
D 6 7 7 — Accordingly positions of jobs in
E 2 8 4 or 3 — the sequence are given in the
F 3 9 5 — adjacent table
Optimal Sequences
G 5 10 6 —
1. H C A E F G D J B I
H 1 2 1 or 2 —
2. C H A E F G D J B I
I 6 1 — 1 3. H C E A F G D J B I
J 8 5 — 3 4. C H E A F G D J B I 12
Sequencing n jobs on 2 machines…
Each optimal sequence will have same overall processing time for 10
jobs. So,
Optimal M1 M2 Waiting
Sequence I Time
Job M1 M2 in out in out
H 1 2 0 1 1 3 0
C 1 4 1 2 3 7 1 Processing time = 57
A 2 7 2 4 7 14 3
E 2 8 4 6 14 22 8
F 3 9 6 9 22 31 13
G 5 10 9 14 31 41 17
D 6 7 14 20 41 48 21
Idle time of machine
J 8 5 20 28 48 53 20
M1 57 – 39 = 18
B 5 3 28 33 53 56 20
M2 1 – 0 = 1
I 6 1 33 39 56 57 17
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Sequencing n jobs on 3 machines
Johnsons method can be applied if any one of
Job M1 M2 M3 following conditions are fulfilled
A 1 7 8
Minimum processing time on machine M1 ≥
B 3 3 10
Maximum processing time on machine M2
C 7 8 9
Minimum processing time on machine M3 ≥
D 9 2 11
Maximum processing time on machine M2
E 4 8 9
Example:
F 5 6 14
7 jobs to be processed on 3 machines in the
G 2 1 12
order M1, M2 & M3.
Find optimal sequence, overall processing time,
waiting time of the jobs & idle times of the
machine.
Solution: ---------------------------------------------------------------
Min of M1 = 1
Max of M2 = 8 Thus, min of M3 = Max of M2.
Min of M3 = 8 Therefore, Johnson’s method can be applied
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Sequencing n jobs on 3 machines…
Considering 2 hypothetical machines X & Y with processing times by
adding corresponding times of M1 & M2 for X & M2 & M3 for Y.
Job M1 M2 M3 Job X Y
Sequence to
Start End
start with
A 1 7 8 A 8 15 3 -
Min. processing time
B 3 3 10 B 6 13 2 -
at X &
C 7 8 9 C 15 17 7 -
end with
D 9 2 11 D 11 13 4 or 5 -
Min. processing time
E 4 8 9 E 12 17 6 -
at Y or
F 5 6 14 F 11 20 5 or 4 -
Max processing time
G 2 1 12 G 3 13 1 -
at X
Optimal Sequence I G, B, A, D, F, E, C
Optimal Sequence II G, B, A, F, D, E, C
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Sequencing n jobs on 3 machines…
Optimal Sequence I M1 M2 M3 Waiting
Job M1 M2 M3 In Out In Out In Out Time
G 2 1 12 0 2 2 3 3 15 0
B 3 3 10 2 5 5 8 15 25 7
A 1 7 8 5 6 8 15 25 33 12
D 9 2 11 6 15 15 17 33 44 16
F 5 6 14 15 20 20 26 44 58 18
E 4 8 9 20 24 26 34 58 67 26
C 7 8 9 24 31 34 42 67 76 28
Overall processing time = 76 hrs
Idle time for M1 = 76 – 31 = 45 hrs
Idle time for M2 = (2 – 0) + (5 – 3) + (20 – 17) + (76 – 42) = 41 hrs
Idle time for M3 = 3 – 0 = 3 hrs
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Sequencing ‘n’ jobs on ‘m’ machines
o Johnsons method can be applied for
• sequencing n jobs on m machines in the order M1, M2, …, Mm
• if any one of following conditions are fulfilled
Minimum processing time on machine M1 ≥
Maximum processing time on machine M2, M3, …, M(m-1)
Minimum processing time on machine Mm ≥
Maximum processing time on machine M2, M3, …, M(m-1)
Example: Job M1 M2 M3 M4
7 jobs to be processed on 4 machines in A 3 1 4 12
the order M1, M2, M3 & M4. B 8 0 5 15
Find optimal sequence, overall C 11 3 8 10
processing time, waiting time of the jobs D 4 7 3 8
& idle times of the machine. E 5 5 1 10
(We will be using abbreviation PT for F 10 2 0 13
Processing time) G 2 5 6 9
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Sequencing n jobs on m machines …
Solution: Job M1 M2 M3 M4
If any one of Johnson’s conditions are fulfilled A 3 1 4 12
1) Min PT on machine M1 ≥ B 8 0 5 15
Max PT on machine M2, M3, …, M(m-1) C 11 3 8 10
Min PT on M1 = 2 D 4 7 3 8
Max PT of M2 = 7, M3 = 8 E 5 5 1 10
So, 1st condition is not fulfilled. F 10 2 0 13
2) Min PT on machine Mm ≥ G 2 5 6 9
Max PT on machine M2, M3, …, M(m-1)
Min PT on M4 = 8,
Max PT on M2 = 7, M3 = 8
So, Min PT on M4 > Max PT on M2 &
Min PT on M4 = Max PT on M3
But, 2nd condition is fulfilled.
Hence, Johnson’s method can be applied
…
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Sequencing n jobs on m machines …
Considering 2 hypothetical machines X & Y with PT equal to addition
corresponding PTs on M1, M2, M3 for X & M2, M3 & M4 for Y.
Job M1 M2 M3 M4 X Y Start End Sequence to
Start with Min PT on X
A 3 1 4 12 8 17 1 -
&
B 8 0 5 15 13 20 5 or 4 -
7 -
End with Min PT on Y
C 11 3 8 10 22 21
or
D 4 7 3 8 14 18 6 -
End with Max PT on X
E 5 5 1 10 11 16 2 -
F 10 2 0 13 12 15 3 -
G 2 5 6 9 13 20 4 or 5 -
Optimal Sequence I A, E, F, G, B, D, C
Optimal Sequence II A, E, F, B, G, D, C
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Sequencing n jobs on m machines …
Optimal Sequence II M3 M4
M1 M2
Job M1 M2 M3 M4 In Out In Out In Out In Out
0 3 3 4 4 8 8 20
A 3 1 4 12
E 5 5 1 10 3 8 8 13 13 14 20 30
F 10 2 0 13 8 18 18 20 20 20 30 43
B 8 0 5 15 18 26 26 26 26 31 43 58
G 2 5 6 9 26 28 28 33 33 39 58 67
D 4 7 3 8 28 32 33 40 40 43 67 75
C 11 3 8 10 32 43 43 46 46 54 75 85
Overall processing time = 85 hrs
Students may solve the problem further to find
The waiting time of the jobs & idle times of the machine.
(85-46) + 23 = 62, 85-54 + 27 =58,
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