Opc Unit - 4

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UNIT – 4

Scheduling is the process of planning and arranging tasks or activities within a defined
timeframe. It determines what needs to be done, by whom, and when, ensuring tasks are
allocated time and resources efficiently. Scheduling is used across various domains, from
project management and production to personal time management, to ensure smooth
workflow, prioritize tasks, and meet deadlines.

AIMS OF SCHEDULING

1. Efficient Resource Allocation: Ensure resources like personnel, equipment, and materials
are allocated in the most productive way.
2. Time Management: Optimize the use of time to prevent delays and make sure tasks are
completed within the stipulated timeframe.
3. Cost Control: Minimize costs associated with resources, overtime, and downtime by
creating realistic schedules.
4. Maximizing Output: Increase productivity by arranging tasks in a way that maximizes
output or throughput.
5. Enhancing Flexibility: Allow room for adjustments in case of changes or unexpected
issues.

PURPOSE OF SCHEDULING

1. Organize Workflows: Arranges activities in a logical order to ensure a smooth workflow.


2. Meet Deadlines: Helps teams and individuals to stay on track with deadlines and
deliverables.
3. Avoid Bottlenecks: Prevents congestion in workflows by spacing out tasks and avoiding
overload at specific times.
4. Coordinate Teams: Aligns tasks and responsibilities among team members for improved
collaboration.
5. Track Progress: Allows managers and teams to monitor progress and adjust timelines as
needed.
6. Improve Efficiency: Contributes to productivity by managing time and resources
effectively, reducing waste and idle times.
In essence, scheduling is crucial for achieving timely, cost-effective, and organized project or
task completion.

TYPES OF SCHEDULING SITUATIONS

Scheduling situations vary widely across different contexts, and each type addresses specific
needs, constraints, and priorities. Here are several common types of scheduling situations:

1. Project Scheduling
Used in project management to organize tasks and phases in a timeline from start to finish.
Commonly utilizes tools like Gantt charts, Critical Path Method (CPM), and Program
Evaluation and Review Technique (PERT).
Ensures that project activities are sequenced, resources are allocated, and deadlines are
met.
2. Production Scheduling
Found in manufacturing and production, it organizes the production process, from raw
materials to finished goods.
Includes types like job shop scheduling, batch scheduling, and continuous flow scheduling.
Aims to optimize the use of equipment, minimize lead times, and ensure products are
delivered on time.
3. Employee or Workforce Scheduling
Manages the work hours and shifts of employees based on workload, peak hours, and
availability.
Common in retail, healthcare, hospitality, and other sectors with variable staffing needs.
Balances labor requirements with employee availability, aiming for minimal overtime and
increased efficiency.
4. Appointment Scheduling
Used by service-based businesses such as healthcare providers, salons, and consulting firms
to organize client appointments.
Balances client demand with available time slots, optimizing the time of service providers
and minimizing waiting times for clients.
5. Maintenance Scheduling
Focuses on planning and timing of equipment or facility maintenance tasks.
Preventive maintenance schedules prevent unexpected breakdowns, while reactive
maintenance handles unplanned repairs.
Increases equipment uptime, reduces operational interruptions, and extends asset life.

6. Transportation and Logistics Scheduling


Ensures the efficient routing and timing of vehicles, goods, and personnel.
Includes types like airline, trucking, and delivery scheduling.
Aims to minimize transit times, meet customer expectations, and reduce transportation
costs.

7. School or Class Scheduling


Arranges classes, exams, and other academic activities, balancing course requirements,
classroom availability, and instructor schedules.
Aims to avoid conflicts, ensure balanced workloads, and enhance student and faculty
experience.
8. Event Scheduling
Organizes timelines and resources for events such as conferences, concerts, and sports
competitions.
Ensures that event activities, participants, and facilities are coordinated for a smooth flow.
9. Construction Scheduling
Used in construction to coordinate tasks like site preparation, building phases, and
inspections.
Involves tools like Gantt charts and project timelines to manage subcontractors, materials,
and timelines.
10. Personal Scheduling
Used by individuals to manage personal tasks, appointments, and goals.
Helps prioritize tasks, manage time, and reduce stress in day-to-day activities.
Each type of scheduling situation has its unique requirements, tools, and challenges, tailored
to the specific goals and constraints of the context.
SHORT -TERM SCHEDULING AND LONG -TERM SCHEDULING
Short-Term Scheduling and Long-Term Scheduling are two approaches to arranging tasks or
processes within an organization or system. They serve different purposes and often operate
at different stages of a project or production process.

1. Short-Term Scheduling

• Definition: Involves planning tasks or processes over a short time frame, typically
hours, days, or weeks. It's focused on immediate priorities and addressing real-time
demands.
• Purpose: To maximize efficiency and respond quickly to changing demands, minimize
downtime, and ensure smooth daily operations.
• Examples: Daily employee shift assignments, scheduling tasks in production to meet
urgent orders, and adjusting workloads in real time.

2. Long-Term Scheduling

• Definition: Plans activities and resources over a more extended period, usually
months to years. This scheduling type focuses on high-level goals and resource
availability.
• Purpose: To allocate resources strategically, ensure steady progress, and align tasks
with long-term objectives, often based on anticipated demand.
• Examples: Planning annual production levels, setting quarterly project milestones,
scheduling maintenance for critical equipment over the year.

METHODS OF SCHEDULING

There are various methods used in scheduling, each suitable for specific types of tasks,
resources, and industries:

1. First-Come, First-Served (FCFS):

• Tasks are handled in the order they arrive without prioritization.


• Simple and fair but may not be efficient for high-priority or time-sensitive tasks.
2. Shortest Processing Time (SPT):

• Tasks with the shortest completion time are prioritized to reduce total wait time.
• Effective in reducing lead times but can delay longer tasks.
3. Priority Scheduling:

• Tasks are assigned priority levels, with higher-priority tasks processed first.
• Useful in settings where certain tasks are more critical than others.
4. Earliest Due Date (EDD):

• Tasks are scheduled based on their due dates, with the earliest due dates taking
precedence.
• Helps to meet deadlines but might not consider task length or complexity.
5. Round-Robin Scheduling:

• Each task is given a time slice or interval before moving to the next task.
• Commonly used in computer operating systems to share resources fairly among
processes.
6. Just-In-Time (JIT) Scheduling:

• Focuses on scheduling materials and resources to arrive just when needed, reducing
inventory and waste.
• Effective in manufacturing to minimize holding costs and increase efficiency.
7. Critical Path Method (CPM):

• Identifies the longest sequence of tasks that determine the project duration.
• Useful in project scheduling, helping to prioritize tasks that directly impact the
project timeline.
8. Program Evaluation and Review Technique (PERT):

• Used to estimate the time needed for project tasks with uncertain durations.
• Useful in complex projects where task durations are variable or unpredictable.
Each method has specific advantages and is chosen based on the goals, constraints, and
characteristics of the tasks or project being scheduled.

SCHEDULING FOR MORE THAN THREE MACHINES

Scheduling for more than three machines and scheduling through networks involve more
complex strategies and tools due to the increased coordination required among multiple
machines or networked tasks. Here’s a closer look at each type:
Scheduling for More Than Three Machines
When dealing with multiple machines, the scheduling complexity increases as you need to
sequence tasks across multiple resources efficiently. Here are common approaches and
methods:

1. Johnson’s Rule for Multiple Machines:

• Johnson’s Rule is effective for two-machine scheduling. However, modified versions


can sometimes be used for three or more machines by breaking down the job
sequence into smaller sets.
• It aims to minimize completion time by sequencing tasks based on processing times
across machines.
2. Flexible Flow Shop Scheduling (FFS):

• FFS is used when tasks need to go through multiple machines or stages with some
flexibility in the order.
• Suitable for production lines where products go through a specific set of machines
but not necessarily in a strict sequence.
3. Mixed-Model Assembly Line Scheduling:

• Applicable in manufacturing environments producing multiple product models on the


same set of machines.
• Helps balance the workload across machines by creating a sequence that minimizes
downtime and changeover times between different models.
4. Job Shop Scheduling:

• Each job has a unique route across multiple machines, and there is no fixed
sequence.
• Suitable for custom production environments; uses priority rules like Shortest
Processing Time (SPT), Earliest Due Date (EDD), or Critical Ratio (CR) to decide task
order on each machine.

5. Heuristic and Metaheuristic Methods:

• Heuristics: Simplified methods such as Greedy Algorithm or Nearest Neighbor can


provide good solutions quickly for complex multi-machine environments.
• Metaheuristics: More advanced methods like Genetic Algorithms, Simulated
Annealing, and Tabu Search are used to optimize schedules where traditional
methods fall short, especially in complex job shops or large-scale production.
SCHEDULING THROUGH NETWORKS
Scheduling through networks is commonly used in project management and logistics to
coordinate tasks or resources across interconnected networks. Two major techniques are:

1. Critical Path Method (CPM):

• CPM identifies the sequence of dependent tasks (the critical path) that determines
the minimum project duration.
• Tasks not on the critical path have flexibility (or "slack"), allowing schedulers to
allocate resources effectively and prevent delays in critical tasks.

2. Program Evaluation and Review Technique (PERT):

• PERT is ideal for projects where task durations are uncertain. It uses probabilistic
time estimates (optimistic, pessimistic, and most likely) to calculate expected task
times.
• By mapping tasks in a network, PERT helps manage the sequence and dependencies
of tasks, allowing for adjustments based on actual progress and resource availability.

3. Network Flow Scheduling:

• Used to manage scheduling in networked environments, such as data networks or


logistics.
• Examples include Max Flow (to determine the highest throughput possible within
network constraints) and Shortest Path algorithms (to find the quickest route from
start to finish).

4. Resource Leveling and Allocation:

• Ensures that resource use is spread evenly over time, particularly in network-based
schedules with shared resources.
• Helps prevent resource bottlenecks by adjusting task start times based on available
resources, minimizing idle times and ensuring balanced workloads.

5. Time-Driven and Event-Driven Scheduling:

• Time-Driven: Tasks are scheduled based on predetermined time intervals (e.g.,


periodic maintenance).
• Event-Driven: Tasks are triggered by specific events or conditions, common in real-
time systems where processes respond to network demands or sensor inputs.
6. Distributed Scheduling in Networks:

• Often used in IT and telecommunications, where tasks must be scheduled across


multiple nodes or processors.
• Ensures that each node in the network works cohesively, balancing loads and
reducing overall network latency.
Both multi-machine and network scheduling benefit from advanced tools and software that
provide visualization, simulation, and real-time monitoring to manage complex workflows
and dependencies effectively.

LINE OF BALANCE
Line of Balance (LOB) and Line Balancing are key concepts in production and assembly line
management, aimed at maximizing efficiency and minimizing delays by ensuring a smooth
flow of tasks.
Definition: Line of Balance is a project management and production scheduling technique
that tracks the progress of a production line to ensure each stage of production is on
schedule. It is particularly useful in repetitive manufacturing processes, where identical
products are made in high volume.
Purpose:

• To monitor the completion status of each stage or workstation in the production line.
• To ensure that production rates match demand and prevent bottlenecks or idle time
at specific workstations.
LOB Method:
1. Define the Production Process: Break down the production process into discrete stages or
tasks.
2. Set Target Completion Rates: Determine the rate at which each stage must complete tasks
to meet the overall production goal.
3. Track Progress: Use a chart to track the number of units completed at each stage and
compare this with the planned targets.
4. Identify Deviations: Highlight any stage that falls behind or progresses too quickly, leading
to inventory build-up or bottlenecks.
5. Adjust Accordingly: Make adjustments by reallocating resources, adjusting task times, or
balancing workloads to realign with the target.
LOB helps managers visually monitor production progress and identify delays or
inconsistencies early, making it easier to keep production aligned with the planned schedule.

LINE OF BALANCING FUNDAMENTALS


Definition: Line balancing is the process of arranging tasks along a production line so that
each workstation has an equal workload. It is crucial in assembly lines where products move
sequentially from one workstation to the next.
Purpose:

• To minimize idle time and reduce bottlenecks by distributing tasks evenly.


• To ensure that each workstation has an optimal workload, improving the flow and
efficiency of production.
• To increase productivity and reduce costs by minimizing delays and resource
wastage.
Key Concepts:
1. Cycle Time: The total time a product spends at each workstation. Each task on the line
should ideally fit within the cycle time to avoid delays
2. Takt Time: The rate at which products need to be completed to meet customer demand.
Takt time serves as the benchmark for each workstation.
3. Workload Distribution: Balancing workloads so that no workstation is overloaded or
underused.

LINE BALANCING METHODS


There are various methods for line balancing, often selected based on the production
process complexity and requirements.
1. Heuristic Methods:

• Largest Candidate Rule: Tasks are assigned to workstations based on their duration,
starting with the longest task. This aims to fit tasks within the cycle time, helping
balance the workload.
• Kilbridge and Wester Method: Focuses on grouping tasks based on sequence and
dependency to reduce idle time and improve workflow continuity.
• Ranked Positional Weights (RPW): Tasks are weighted based on their position in the
sequence and dependency, helping prioritize critical tasks and balance load.
2. Mathematical Optimization:
Uses linear programming models to find the optimal distribution of tasks across
workstations. This method provides precise solutions but may be complex to implement.
3. Simulation:
A digital simulation of the production line helps visualize and analyze different task
arrangements and their impact on efficiency. Simulation allows for trial and error without
affecting actual production.
4. Work Sampling and Time Study:
Observes and records task times at each workstation to identify inefficiencies. Data from
time studies helps optimize task assignments to balance the line.
5. Mixed-Model Line Balancing:
Used in production environments producing multiple models or variants on the same line.
Tasks are sequenced to minimize setup changes and reduce idle time between different
product types.

By applying LOB and line balancing techniques, companies can maintain a steady workflow,
prevent bottlenecks, reduce production costs, and increase output, making these methods
essential for efficient production line management.

DISPATCHING
Dispatching is the process of issuing orders or instructions to start, carry out, or complete
tasks in a production or service environment. The dispatcher plays a critical role in
coordinating and overseeing this process to ensure efficiency, smooth operations, and timely
completion of work.

DUTIES OF DISPATCHER

1. Order Release:

• Issue orders to start jobs or tasks based on the schedule, ensuring they are launched
at the right time and in the correct sequence.
• Confirm that all necessary materials, tools, and information are available before
releasing an order.
2. Job Prioritization:

• Prioritize tasks based on urgency, customer requirements, due dates, or production


goals.
• Adjust priorities as needed to handle high-priority or urgent tasks efficiently.
3. Coordination of Resources:

• Ensure that resources such as personnel, equipment, and materials are available for
each job.
• Coordinate with departments to ensure seamless handover and efficient resource
allocation.
4. Monitoring and Tracking:

• Track the progress of jobs in real time and ensure they stay on schedule
• Record and document work completed, delays, or issues encountered during the
process.
5. Problem Solving:

• Address any disruptions, such as equipment breakdowns, delays, or resource


shortages, by adjusting schedules and reallocating resources as necessary.
• Communicate issues with managers and production teams, providing solutions or
alternative plans.
6. Quality Assurance:

• Ensure that tasks meet quality standards and that all necessary checks are performed
before moving to the next phase.
• Oversee rework or adjustments as required to meet quality and production
standards.
7. Communication:

• Serve as a liaison between departments, updating teams on task progress, potential


delays, or changes in priorities.
• Provide instructions, guidance, and information to production teams to keep them
aligned with the schedule.

DISPATCHING PROCEDURE

1. Order Preparation:

• Confirm that each order or job has the necessary details, materials, and resources
allocated.
• Check that all prerequisite tasks are complete before starting the new order.
2. Task Assignment:

• Assign tasks to specific workstations, machines, or personnel based on the schedule


and availability.
• Use dispatch lists, work tickets, or digital tools to communicate assignments clearly.
3. Prioritization and Sequencing:

• Determine the sequence in which tasks should be started, especially when dealing
with multiple jobs or overlapping schedules.
• Adjust task priorities as needed based on due dates, customer demands, or
production goals.
4. Order Release:

• Release the order to the production team, ensuring they have all the necessary
information, including task instructions, materials, and quality standards.
• Provide any additional guidance or clarify any special requirements related to the
task.
5. Real-Time Monitoring:

• Continuously monitor the progress of each job, tracking whether tasks are completed
on time and identifying any deviations.
• Update the status of each task in the system and record any delays, adjustments, or
resource issues.
6. Issue Resolution:

• Quickly address any issues that arise, such as equipment malfunctions, material
shortages, or workforce constraints.
• Coordinate with other departments or resources to keep tasks on schedule or adjust
the schedule to minimize impact.
7. Feedback and Documentation:

• Document task completion, record any issues encountered, and log deviations from
the schedule.
• Provide feedback to relevant departments on any issues, suggesting improvements
or adjustments for future jobs.
8. Continuous Update of Dispatch Schedule:

• Update the schedule and dispatch list as jobs are completed or new tasks are added.
• Re-prioritize as necessary, ensuring that tasks are always aligned with current
production needs and goals.
In summary, dispatching involves preparing, assigning, and overseeing tasks to keep
production processes efficient and on schedule. The dispatcher’s ability to prioritize,
coordinate resources, resolve issues, and maintain communication is essential for smooth
and timely operations.

TYPES OF FOLLOW-UP

Follow-up in production is essential to monitor progress, ensure quality, prevent delays, and
resolve issues as they arise. Different types of follow-up are used depending on the
production environment and objectives. Additionally, effective follow-up methods are crucial
for preventing production delays, which can arise from a variety of causes.

Types of Follow-Up

1. Progress Follow-Up:

• Monitors the ongoing status of production tasks to ensure they meet scheduled
timelines.
• Tracks completion rates, identifies any deviations from the schedule, and allows for
quick adjustments.
2. Quality Follow-Up:

• Ensures that products or components meet quality standards at each stage of


production.
• Helps detect and address defects early, preventing rework and keeping production on
track.
3. Material Follow-Up:

• Tracks the availability and flow of materials required for production.


• Ensures that materials are delivered on time and are available at the right place,
reducing the risk of interruptions.
4. Dispatch Follow-Up:

• Confirms that finished products or goods are dispatched or delivered according to


schedule.
• Prevents bottlenecks in storage or delays in customer delivery by ensuring timely
dispatch.
5. Inventory Follow-Up:

• Monitors stock levels of raw materials, components, and finished goods.


• Prevents production stoppages due to material shortages by maintaining optimal
inventory levels.
6. Equipment Follow-Up:

• Tracks the condition, performance, and maintenance schedule of production


equipment.
• Helps ensure that equipment is in good working order and ready for use, minimizing
downtime.

7. Cost Follow-Up:

• Focuses on tracking the cost efficiency of production processes.


• Identifies areas where costs exceed the budget, allowing for adjustments to keep
production cost-effective.

PREVENTING PRODUCTION DELAYS

1. Effective Planning and Scheduling

• Plan and schedule production based on realistic timelines and resource availability.
• Use scheduling tools (e.g., Gantt charts, PERT, or CPM) to visualize dependencies and
reduce bottlenecks.
2. Ensure Material Availability:

• Implement Just-In-Time (JIT) or similar inventory management strategies to ensure


timely availability of materials without overstocking.
• Regularly review inventory levels and set reorder points to avoid material shortages.
3. Regular Equipment Maintenance:

• Schedule preventive maintenance to avoid unexpected equipment breakdowns.


• Monitor equipment performance data to anticipate maintenance needs.
4. Efficient Workforce Management:

• Ensure that skilled personnel are available and properly assigned to tasks.
• Provide ongoing training to enhance skills and improve productivity.
5. Implement Quality Control at All Stages:

• Conduct quality checks throughout the production process to catch defects early.
• Use statistical process control (SPC) or Six Sigma methods to minimize variation and
maintain quality.
6. Real-Time Monitoring and Adjustments:

• Use real-time tracking systems (e.g., ERP, MES) to monitor progress and quickly
identify deviations.
• Be prepared to make on-the-fly adjustments to the schedule or resources if delays
are detected.
7. Strong Communication Channels:

• Maintain clear communication between departments to coordinate activities and


respond to issues promptly.
• Use collaborative tools or meetings to keep everyone updated on production status

CAUSES OF DELAYS

1. Material Shortages:

• Insufficient or delayed supply of raw materials or components can halt production.


• Can result from poor inventory planning, supplier issues, or unexpected demand
spikes.
2. Equipment Failure:

• Breakdowns or malfunctions can significantly delay production if no backup


equipment is available.
• Often due to inadequate maintenance or aging machinery.
3. Labor Shortages or Unavailability:

• Absenteeism, lack of trained staff, or labor disputes can impact productivity.


• Can be worsened by high turnover rates or seasonal demand fluctuations.
4. Poor Scheduling and Planning:

• Unrealistic schedules or poor resource allocation can lead to delays.


• Misaligned schedules, lack of planning for contingencies, or miscommunication also
contribute.
5. Quality Issues:

• Defective products or materials require rework, slowing down production and


increasing costs.
• Inadequate quality control or inconsistent material quality often leads to delays.
6. Supply Chain Disruptions:

• Supplier delays, logistical issues, or transportation bottlenecks can delay material


delivery.
• External factors such as weather, economic disruptions, or global events can also
impact the supply chain.
7. Changes in Production Requirements:

• Last-minute design changes, customization requests, or product modifications can


disrupt the production schedule.
• Leads to rework, additional testing, or longer setup times.
8. Poor Communication and Coordination:

• Lack of communication between teams can lead to misaligned schedules or


duplicated efforts.
• Inefficient coordination can prevent timely issue resolution and hinder production
flow.
9. Unpredictable Demand Fluctuations:

• Sudden changes in demand can cause overproduction or underproduction.


• Difficulties in forecasting can lead to inventory imbalances and production
inefficiencies.

In summary, an effective follow-up process, efficient planning, and proactive management of


resources can significantly reduce the chances of production delays. By identifying common
causes of delays and addressing them through preventive measures, companies can
maintain a steady and productive manufacturing flow.

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