Opc Unit - 4
Opc Unit - 4
Opc 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
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.
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:
• 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 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:
• 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:
• 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.
• 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.
• 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.
• 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.
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.
• 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:
• 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:
• 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:
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:
• 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:
7. Cost Follow-Up:
• 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:
• 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:
CAUSES OF DELAYS
1. Material Shortages: