QUESTION (Minimizing Total Production Time) Sequencing Jobs Through Two Work Centers

QUESTION (Minimizing Total Production Time)
Sequencing Jobs through Two Work Centers

-When several jobs must be sequenced through two work centers, we may want to select a sequence that
must hold for both work centers.
-Johnson's rule can be used to find the sequence that minimizes the total production time through both
work centers
Johnson's Rule of Sequencing Jobs.
In Operations Research, Johnsons Rule is a method of scheduling jobs in two work centres. Its primary
objective is to find an optimal sequence of jobs to reduce make span (i.e. total amount of time it takes to
complete all jobs,). Job times must be mutually exclusive of the job sequence.
It also reduces the amount of idle time between the two work centres. The method minimizes the make
span in the case of two work centres.
The technique requires several pre-conditions:
 The time for each job must be constant
 Job times must be mutually exclusive of the job sequence
 All jobs must be processed in the first work centre before going through the second work centre.
 All jobs are equally prioritized.
Johnson's Rule is as follows:
1. List the jobs and their times at each work centre.
2. Select the job with the shortest processing time in either work center. If the shortest time is at the
first work center, put the job in the first unassigned slot in the schedule. If the shortest time is at
the second work center, put the job in the last unassigned slot in the schedule.
3. Eliminate the job assigned in step 2 from further consideration.
4. Repeat steps 2 and 3, working towards the centre of the job schedule until all jobs have been
scheduled
EXAMPLE 1:
Each of five jobs needs to go through work center A and B. Find the optimum sequence of jobs using
Johnson's rule.
Job times (hours)
Job Work center A Work center B
A 3.2 4.2
В 4.7 1.5
C 2.2 5.0
D 5.8 4.0
E 3.1 2.8
1. The smallest time is located in Job B (1.5 hours). Since the time is in Work Center B, schedule this job
last.
Eliminate Job B from further consideration.
????B
2. The next smallest time is located in Job C (2.2 hours). Since the time is in Work Center A, schedule
this job first.
Eliminate Job C from further consideration.
C ? ? ?B
3. The next smallest time after that is located in Job E (2.8 hours). Since the time is in Work Center B,
schedule this job last.
Eliminate Job E from further consideration.
C ? ? EB
4. The next smallest time after is located in Job A (3.2 hours). Since the time is in Work Center A,
schedule this job first.
Eliminate Job A from further consideration.
СА ?ЕВ
5. The only job left to consider is Job D.
CADEB
So, the jobs must be processed in the order C-A-D-E-B, and must be processed in the same order on both
work centers
QUESTION 1: Minimizing Total Production Time
It is early Saturday morning and The Finest Detail has five automobiles waiting for detailing service.
Each vehicle goes through a thorough exterior wash/wax process and then an interior
vacuum/shampoo/polish process.
The entire detailing crew must stay until the last vehicle is completed. If the five vehicles are sequenced
so that the total processing time is minimized, when can the crew go home? They will start the first
vehicle at 7:30 a.m.
Time estimates are shown below.
Job Exterior Time (Hours) Interior Time (Hours)
Cadillac 2.0 2.5
Bentley 2.1 2.4
Lexus 1.9 2.2
Porsche 1.8 1.6
Infiniti 1.5 1.4
SOLUTION:
Least Time Job Work Centre Schedule Slot
1.4 Infiniti Interior 5th
1.6 Porsche Interior 4th
1.9 Lexus Exterior 1st
2.0 Cadillac Exterior 2nd
2.1 Bentley Exterior 3rd
Gantt Chart
Exterior 0 L 1.9 C 3.9 B 6.0 P 7.8 IDLE 9.3 12.0
Interior 0 Idle 1.9 L 4.1 C 6.6 B P 9.0 | 10.6 12.0

It will take from 7:30 a.m. until 7:30 p.m. (not allowing for breaks) to complete the five vehicles.
QUESTON: 2
Jobs A, B, C, D, E, F, and G must go through process I and II in that sequence (Process I first then
Process II).
Use Johnson's Rule to determine the optimal sequence in which to schedule the jobs to minimize the total
required time. How much total time is required to process all the seven jobs?
Job Processing time in I Processing time in II
A 4 5
B 16 14
C 8 7
D 12 13
E 3 9
F 9 6
G 8 5
REQUIRED:
(i) Calculate the Total Production Time.
(ii) Illustrate this using a Gantt Chart
QUESTION 3
(a) A company receives parts from suppliers to be used in its manufacturing department. The quality
control department must perform two operations when shipments are received
Operations A – draw a random sample, packages, and deliver to testing lab.
Operation B – test the materials and issue a disposition report.
There are currently six shipments waiting to be processed. The time estimates for processing
these six shipments through quality control are shown in the table below:
Shipment Operation A (hours) Operations (hours)
1 1.5 1.0
2 1.1 2.7
3 1.2 1.4
4 0.7 1.6
5 1.6 1.5
6 1.9 2.9
(i) Using Johnson’s Rule, determine the sequence of processing the shipments through Quality
Control Department
(ii) How much total time is required to process all six shipments through Quality Control
Department? Illustrate this on a Gantt Chart

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QUESTION (Minimizing Total Production Time)

Sequencing Jobs through Two Work Centers

Interior 0 Idle 1.9 L 4.1 C 6.6 B P 9.0 | 10.6 12.0

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