Chapter 10 : Production Planning and Control

Lecture 3

SEQUENCING
 Scheduling
• Scheduling is defined as the allocation of resources over time to perform a collection of
tasks.

• scheduling is a decision-making function: it is the process of determining a schedule.

• Sequencing is the order of processing a set of tasks over available resources.

• Sequencing problems occur whenever there is a choice to the order in which a group of
tasks can be performed.

Objectives
➢ Maximization of the Utilization of Resources
➢ Minimization of the Work-in-process Inventory
➢ Minimization of Tardiness
Job shop Scheduling

❖ Arrival Pattern
❖ Processing pattern
❖ Machine varieties available
❖ No. of workers in shop
❖ Sequencing rule
- FCFS
- SPT
-MDD
- LCFS
-SSRO
-DSRO
Elements of Scheduling
❑ Demand Forecasting
❑ Aggregate scheduling
❑ Production plan
❑ Master Production Scheduling
❑ Priority planning
❑ Capacity Planning
❑ Sequencing
❑ Facility Loading
Job shop scheduling Scenario

Assumptions
• One machine – one job
• Processing order is fixed
• Job shifting is negligible
• Machines complete jobs
• Fixed processing time
❑ Processing time

❑ Due Date

❑ Job Flow Time

❑ Make span time

❑ Average jobs in the system

Following data refers to the jobs (P,Q,R,S) which have arrived at a machine for scheduling.
The shortest possible average flow time is ___________ days.

JOB Processing Time

P 15
Q 9
R 22
S 12
Four jobs are to be processed on a machine as per data listed in the table.

If the Earliest Due Date (EDD) rule is used to sequence the jobs, the number of jobs
delayed is

JOB Processing Due Date

Time
1 4 6
2 7 9
3 2 19
4 8 17
Four jobs are to be processed on a machine as per data listed in the table.

Using the Shortest Processing Time (SPT) rule, total tardiness is

JOB Processin Due Date

g Time
1 4 6
2 7 9
3 2 19
4 8 17
Six jobs arrived in a sequence as given below:

Average flow time (in days) for the above jobs using Shortest Processing
Time rule is
JOB Processing Time
1 4
2 9
3 5
4 10
5 6
6 8
 N job – 2 Machine System

Johnson’s Rule: technique for minimizing completion time for a

group of jobs to be processed on two machines or at two work
centers.

Minimizes total idle time

Several conditions must be satisfied

• Job time must be known and constant
• Job times must be independent of sequence
• Jobs must follow same two-step sequence
• Job priorities cannot be used
• All units must be completed at the first work
center before moving to second
 Processing time (hrs)
Job Work center A Work center B
a 2.5 4.2
b 3.8 1.5
c 2.2 3
d 5.8 4
e 4.5 2
 Processing time Job Flow time
(hrs)
Work center A Work center B
Job Work Work
center A center B
c 2.2 3
a 2.5 4.2
d 5.8 4
e 4.5 2
b 3.8 1.5
 Tie- case 1

Processing time (hrs)

Job Work center 1 Work center 2
a 1 3
b 5 7
c 6 9
d 7 1
e 4 6
 Tie- case 2

Processing time (hrs)

Job Work center 1 Work center 2
a 8 3
b 5 1
c 6 9
d 7 1
e 4 6
 Sequence – e-c-a-d-b
Processing time Job Flow time
(hrs)
Work center 1 Work center 2
Job Work Work
center A center B I o I o
E 4 6
C 6 9
A 8 3
D 7 1
B 5 1
 Sequence – e-c-a-b-d
Processing time Job Flow time
(hrs)
Work center 1 Work center 2
Job Work Work
center A center B I o I o
E 4 6
C 6 9
A 8 3
B 5 1
D 7 1
 Tie- case 3

Processing time (hrs)

Job Work center 1 Work center 2
a 8 3
b 5 7
c 2 2
d 7 1
e 4 6
 Johnson’s Rule –Extension Cases

Case 1 : n Jobs -3 machine

Condition : Max( machine 2)  Min (machine 1) or Max( machine 2)  Min (machine 3)

Processing time (hrs) Processing time (hrs)

Job machine1 machine 2 machine 3 Job Machine A machine B

a 6 5 7 a

b 9 3 3 b

c 5 4 8 c

d 8 2 5 d

e 7 3 6 e
 Processing time (hrs) Job Flow time
Machine1 Machine 2 Machine 3
Job MC-1 MC-2 MC-3
I o I o I o
C 5 4 8

A 6 5 7

E 7 3 6

D 8 2 5

B 9 3 3
 n Jobs -4 machine

Processing time (hrs)

Job machine1 machine 2 machine 3 machine 4

Processing time (hrs)
a 6 5 4 7
Job Machine A machine B
b 9 3 3 3
a
c 5 4 1 8
b
d 8 2 5 5
c
e 7 3 2 6
d

e
Four jobs have to be sequenced on a single facility, with the objective of minimizing
the maximum tardiness(=max |completion time – due date ). The jobs have due
dates and processing times as follows

Job Processing Due Job PT DD JFT Tardines Job PT DD JFT Tardines

time date s s
P 2 5

Q 10 6

R 3 3

S 4 7

The last job to be taken up is___

Six jobs have received for processing. Their processing time and delivery dates
are given . Using FCFS despatching rule , find the average lateness.

Job Processing Delivery date

time
P 2 4

Q 5 18

R 3 8

S 4 4

T 6 20

U 4 24
Four jobs need to be processed sequentially on two machines, first on machine M and
then on machine N. Each machine can process only one job at a time. The processing
times are given below.
The optimal sequence that will minimize makespan ( total time required to complete all
jobs) is ___ .
When jobs are processed based on the optimal sequence that minimizes the total
makespan time, the idle time on machine N is __ .
Processing
Job Flow time
time (hrs)
Job Machine M Machine N
M N
Job M N
I 3 6 I o I o

II 5 2

III 1 2

IV 7 5
At a particular point of time Five jobs are to be processed in a machining centre. The
respective processing times and the due dates are given below
When the jobs are assumed to enter the shop in sequence of SPT, the mean flow
time and the average tardiness, respectively are ___ ,____ .
When the jobs are assumed to enter in the sequence of EDD, the number of tardy
jobs are ____.

Job Processing Due date Job PT DD JFT Tardines Job PT DD JFT Tardines
time s s

J1 13 65

J2 32 48

J3 34 34

J4 4 36

J5 5 35
In a gear manufacturing company, three orders P, Q and R are to be processed on a
hobbing machine. The orders were received in the sequence P-Q-R. The table
indicates the process time remaining and the production calendar due date for
each.
Considering today as the Day 10 in the production calendar of Hobbing Shop, the
sequence of orders scheduled using ‘Critical Ratio’ rule is

ORDER Processing time Due Date

remaining ( Day)
P 4 Day 20
Q 16 Day 30
R 6 Day 19
Five jobs need to be processed on a single machine. All the jobs are available for
processing at time t = 0. Their respective processing times are given below.
The average completion time (in minutes) of jobs as per the Shortest Processing
Time rule is

Job Processing Job Processing

time time

1 13

2 4

3 7

4 14

5 11
Data for four jobs that need to be processed on a single machine are given below. All
the four jobs are available at time zero. If the jobs are scheduled using the Earliest
Due Date (EDD) algorithm, then the job with maximum tardiness is

Job Processing Due date Job PT DD JFT Tardines

time s
P 12 20

Q 9 40

R 21 30

S 10 19
A job shop incurs a cost of Rs 60 per day for each a job in the shop. At the beginning of a month
there are five jobs in the shop with the following data What is the minimum total cost?
How many jobs will fail to meet the due date?

Job Processing Due date Job Processing Due date

time time

1 5 10

2 3 12

3 8 20

4 2 9

5 6 8