Chapter 17 - Scheduling

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Integrated Production Systems I

Lecture 6:
Scheduling
Learning Objectives
• Explain the meaning of scheduling, and determine which type of
schedule is appropriate for different types of productive systems.
• Discuss loading, sequencing, and monitoring work.
What is Scheduling?
• Last stage of planning before production occurs
• Specifies when labor, equipment, and facilities are
needed to produce a product or provide a service.
Objectives in Scheduling
• Meet customer due dates • Minimize overtime
• Minimize job lateness • Maximize machine or labor utilization
• Minimize response time • Minimize idle time
• Minimize completion time • Minimize work-in-process inventory
• Minimize time in the system
Shop Floor Control (SFC)
• Schedule and monitor day-to-day job shop production
• Also called production control and production activity
control (PAC).
• Responsibilities of production control department:
• Loading - check availability of material, machines, and labor
• Sequencing - release work orders to shop and issue dispatch lists
for individual machines
• Monitoring - maintain progress reports on each job until it is
complete
Loading
• Process of assigning work to limited resources.
• Perform work with most efficient resources.
• Use assignment method of linear programming to determine
allocation.
Sequencing:
Sequencing Rules
• Prioritize jobs assigned to a resource
• Mainly used for single machine (centers) situations.
• Sequencing Rules:
• FCFS - first-come, first-served
• LCFS - last come, first served
• DDATE - earliest due date
• CUSTPR - highest customer priority
• SETUP - similar required setups
• SLACK - smallest slack
• CR - smallest critical ratio
• SPT - shortest processing time
• LPT - longest processing time
Performance Measures
• Flowtime (completion time)
• Time for a job to flow through system
• Makespan
• Time for a group of jobs to be completed
• Tardiness
• Difference between a late job’s due date and its completion
time
SPT & DDATE
• SPT: schedules the job with the shortest processing
time first.
• It tries to minimize the average time a job spends in the
system to eliminate system congestion.
• DDATE is known as earliest due date (also EDD):
• It tries to improve customer satisfaction by scheduling
the jobs with the earliest due date first.
Minimum Slack & Smallest Critical Ratio
• SLACK considers both work and time remaining
SLACK = (due date – today’s date) – (processing time)

• CR recalculates sequence as processing continues and


arranges information in ratio form
time remaining due date - today’s date
CR = work remaining
= remaining processing time

If CR > 1, job ahead of schedule


If CR < 1, job behind schedule
If CR = 1, job on schedule
Simple Sequencing Rules:
Ex. 17.2 p. 567
PROCESSING DUE
JOB TIME DATE
A 5 10
B 10 15
C 2 5
D 8 12
E 6 8

• Sequence the five jobs using FCFS, DDATE, SLACK, and SPT.
• Determine the mean completion/flow time, mean tardiness and maximum tardiness
for each rule.
Simple Sequencing Rules:
Ex. 17.2 p. 567

Job Start Time Processing Completion Due Tardiness


time Time Date

Total
Simple Sequencing Rules: FCFS
FCFS START PROCESSING COMPLETION DUE
SEQUENCE TIME TIME TIME DATE TARDINESS
A 0 5 5 10 0
B 5 10 15 15 0
C 15 2 17 5 12
D 17 8 25 12 13
E 25 6 31 8 23
Total 93 48
Average 93/5 = 18.60 48/5 = 9.6
Simple Sequencing Rules: DDATE
DDATE START PROCESSING COMPLETION DUE
SEQUENCE TIME TIME TIME DATE TARDINESS
C 0 2 2 5 0
E 2 6 8 8 0
A 8 5 13 10 3
D 13 8 21 12 9
B 21 10 31 15 16
Total 75 28
Average 75/5 = 15.00 28/5 = 5.6
Simple Sequencing A(10-0) – 5 = 5
Rules: SLACK B(15-0) – 10 = 5
C(5-0) – 2 = 3
D(12-0) – 8 = 4
E(8-0) – 6 = 2

SLACK START PROCESSING COMPLETION DUE


SEQUENCE TIME TIME TIME DATE TARDINESS
E 0 6 6 8 0
C 6 2 8 5 3
D 8 8 16 12 4
A 16 5 21 10 11
B 21 10 31 15 16
Total 82 34
Average 82/5 = 16.40 34/5 = 6.8
Simple Sequencing Rules: SPT

SPT START PROCESSING COMPLETION DUE


SEQUENCE TIME TIME TIME DATE TARDINESS
C 0 2 2 5 0
A 2 5 7 10 0
E 7 6 13 8 5
D 13 8 21 12 9
B 21 10 31 15 16
Total 74 30
Average 74/5 = 14.80 30/5 = 6
Simple Sequencing Rules: Summary

AVERAGE AVERAGE NO. OF MAXIMUM


RULE COMPLETION TIME TARDINESS JOBS TARDY TARDINESS
FCFS 18.60 9.6 3 23
DDATE 15.00 5.6 3 16
SLACK 16.40 6.8 4 16
SPT 14.80 6.0 3 16
Guidelines for Selecting a
Sequencing Rule

• SPT most useful when shop is highly congested


• Use SLACK for periods of normal activity
• Use DDATE when only small tardiness values can be
tolerated
• Use FCFS when operating at low-capacity levels
• Do not use SPT to sequence jobs that have to be assembled
with other jobs at a later date
Problem 17.8 p. 588
Processing

Job time Duedate

A 3 10

Today is Day 4 B 10 12

C 2 25
FCFS, SPT, SLACK,
D 4 8
DDATE?
E 5 15

F 8 18

G 7 20
Problem 17.8 p. 588
Today is Day 4

Start Processing Completion


Job time time Time Duedate Tardiness
Sequencing Jobs Through Two
Serial Process
Johnson’s Rule:
1. List time required to process each job at each process. Set
up a one-dimensional matrix to represent desired sequence
with # of slots equal to # of jobs.
2. Select smallest processing time at either process. If that
time is on process 1, put the job as near to beginning of
sequence as possible.
3. If smallest time occurs on process 2, put the job as near to
the end of the sequence as possible.
4. Remove job from list.
5. Repeat steps 2-4 until all slots in matrix are filled and all jobs
are sequenced.
Johnson’s Rule:
Ex. 17.3 p. 571

JOB PROCESS 1 PROCESS 2


A 6 8
B 11 6
C 7 3
D 9 7
E 5 10
Johnson’s Rule

JOB PROCESS 1 PROCESS 2


A 6 8
B 11 6
C 7 3
D 9 7
E 5 10

E A D B C
Johnson’s Rule

E A D B C

E A D B C Process 1
(sanding)
5 11 20 31 38
Idle time

E A D B C Process 2
(painting)
5 15 23 30 37 41

Completion time = 41
Idle time = 5+1+1+3=10
Monitoring
• Work package
• Shop paperwork that travels with a job
• Gantt Chart
• Shows both planned and completed activities against a
time scale
• Input/Output Control
• Monitors the input and output from each work center
Gantt Chart
Job 32B
3 Behind schedule

Facility Job 23C


2 Ahead of schedule

Job 11C Job 12A


1 On schedule

1 2 3 4 5 6 8 9 10 11 12 Days
Today’s Date
Key: Planned activity
Completed activity
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