Inventory Management ars ry Short Answer Questions What is inventory buffer? ~ Buffer inventory refers to the safety stock that is a surplus of the inventory stored in a warehouse. This is used as a safety net in an emergency, delays, a supply chain failure, or unanticipated increases in demand, <_ Sapply chain fallures GF unene Pee eee ee 2 Mention the inventory models for independent demand and define any one of them. % Independent demand: An inventory of an item is said to be falling into the category of independent demand when the demand for such an item is not dependent upon the demand for another item. For example: finished goods items, which are ordered by external customers or manufactured for stock and sale, are called independent demand items. Dependent demand: If the demand for inventory of an item is dependent upon another item, such demands are dependent demand. Raw materials and component inventories are dependent upon the demand for finished goods. Take the example of car, the car as finished goods is an held produced and held in inventory as independent demand item, while the raw materials and components used in the manufacture of the finished goods- Car derives its demand from the demand for the car and hence is characterized as dependent demand inventory. 3. Define the concept of decoupling inventory. % Inventory decoupling is the idea to decouple of different parts of the production system. It is the inventory shared by two operations to prevent breakdown or unevenness for machine. It provides a’ cushioning effect in the face of varying work-rates, and machine breakdowns and failure. 4. [2020 Fall Q. No. 6] What are the different types of inventory? 28 Types of inventories are i. , Raw materials ii. Work-in-progress Scanned with CamScannerEGR Avance Saraswat's A Complete PU Solutions to Operations Management Finished goods iv. Packirig material v._ MRO supplies. 5. Explain the role of Master Production Schedule. Role of master production schedule are * To translate aggregate plans into specific end items + Evaluate alternative schedules * Generate material requirement * Generate capacity requirement = Facilitate information processing. 6. [2019 Spring Q. No. 7] 2018 Spring [2016 Spring Q. No. fT Fall Wo. 3] Define ERP i +s Enterprise Resource Planning (ERP) is a method of effective planning of all the resources in a enterprise or organization. It includes the techniques and concepts employed for an integrated management of business as a whole, from the view point of the effective use of resources, to improve the efficiency and effectiveness of an enterprise. z Explain independent and dependent demand with suitable example. = If the demand of the product is depended with other products then such demand is known as depended demand. For example demand of tyre is depended because its demand will be dependent with the demand of vehicle. If the demand of the product is depended, other economic variables rather than other product than such demand is known as independent demand for example vehicle demand itself. 8. [2019 Fall Q. No. 9] Explain the meaning of MPS (Master Production Schedule). > The MPS translates the sales and operations plan into a plan for producing specific products in the future. It reflects the needs of the marketplace and the capacity of manufacturing and forms a priority plan for manufacturing to follow. This schedule drives the whole operation in terms of what is assembled, what is manufactured and what is bought. For example, in a hospital theatre there is a master schedule which contains a statement of which surgical procedures are planned and when. This can-be used to provision materials for, the operations, such as the sterile instruments, blood and dressings. It also governs the scheduling of staff for, operations, including anesthetists, nurses and surgeons. Scanned with CamScannerInventory Management ENC Unit 7 Ca , [2016 Fall Q. No. 8] What is the optimal level of inventory? aa In logistics, optimal stock refers to the exact amount of inventory a company needs to meet regular demand without experiencing a stockout. In other words, it entails maximizing income while reducing storage costs toa minimum. 40. [2018 Fall Q. No. 4] Explain the role of Master Production Schedule? x» Amaster production schedule (MPS) outlines what will be produced (i.e., the amount of finished products or items) and when it will be produced. A production strategy must be followed when creating the timetable. The production plan establishes the total output level in broad terms (e.g, product families, standard hours, or dollar volume). Financial goals, consumer demand, engineering capabilities, labor availability, inventory variations, supplier performance, and other factors are all factored into the plan. These are the role of MPS are as follows: : 1, Translating Production Plans: The amount of activities that balance market demand with material, labor, and equipment capacities is determined in this section of master production schedule. This is due to the fact that the master schedule turns the plan into a precise number of items that must be produced in a specific amount of time. oe 2. Evaluating Alternative Schedule: The master schedule generates trial and error schedules that show alternate production pathways. This ensures that any unanticipated production errors are dealt with immediately. 3. Utilization of Capacity: Machine and equipment load -and utilization requirements are established using master production scheduling software. This results in maximum capacity utilization and a significantly more efficient production flow. 41. [2017 Spring Q. No. 7] What are the objectives of MRP? ° Materials requirements planning (MRP) is.a computer based information system that translates the finished product requirement of the master schedule into time-phased requirements for sub assemblies, component Parts ahd raw materials, working backward from the due date using lead time and other information to determine when and how much order. MRP Performs its calculations based on the combination of both firm and forecast orders ‘12. [2017 Fall Q. No. 5] What is Inventory decoupling? % Inventory decoupling is the idea to decouple of different parts of the Production system. It is the inventory shared by two operations to prevent breakdown or unevenness for machine. It provides 4 pein Gi in the face of varying work-rates, and machine breakdowns 2" 7 Scanned with CamScannerHEIDI aac Saraswats A Complete PU Solon to Operations Management 43, [2017 Fall Q. No. 8] What do you mean by safety stock? >. Safety stock is level of minimum stock level that should be maintained in order to supply in demand fluctuation. (Z Numerical Questions, aes 1. Total Cost (TC) = Annual Carrying + Annual ‘Ordering Cost Q,,2, =oH + as Fr Rnnal Demand » Order or Setup Cost _ (es 20m "= ‘Annual Holding Cost 5 ; 3. Optimal No, of Orders (Ns) =e 4, Length or Order Cycle = 9 = Descriptive Answer Questions Ey 1. [2021 Spring @. No. 15] A ‘Cosmetic Store’ procuress and sells cosmetic goods. Data for an item are given below: Expected sales per year. = 4,800 units | > Ordering cost per year = Rs, 50 per order b Holding cost = 20% of the inventory cost Working days per year = 300 days ‘Lead time Safety stock The normal cost of the item is Rs. 200 and the item can be bought according to any of the three prices and the price schedule is: . $100 100 to 200 above 200 Daily demand can be considered a constant value. a. Determine the inventory policy that will yield a minimum total inventory cost. ) b. Calculate re-order point. c. Find out time | between orders, Price Discount (in %) No discount s Scanned with CamScannerAnnual Demand (D) Ordering cost (8) Inventory Holding cost (H) = 20% of unit price Calculation of EOQ Start with minimum price i.e. Rs 160 OQ =\2DS/H =(2x4800%50)/20% of 160 = 122.47 =Not feasible At price Rs 180 FOQ =\208/H | =\(24800*50)/20% of 180 = 11547 = feasible | Now, Total cost at BOQ TCue = QH/2+ DS/Q+PxD | = 116x(.2*180)/2+(4800%50)/116+180%4800 j =2088 + 2068.96 + 864000 _ Rs, 868,156.96 per year. TCan = QH/2+ DS/Q+PxD 200.2160) /2+(4800*50)/200+160«4800 - =3200+ 1200+ 768000 =Rs. 7,72,A00 per year. This calculation shows that the best order quantity is 200 units at the lowest purchase price. So, 200 units of order size yield a minimum total inventory cost. iii, Demand per day(d) = Annual demand Days ina year = 4800/300 = 16 units per day ROP = Demand per day* lead time + safety stock =16 «3 +15 = 48415 = 63 units Re-order point is 63 units. ¢) No of order per year = D/Q = 4800/200 =24 Times Days between order Time between orders is 12.5 days. Scanned with CamScannerTHEEIE Avance Saraswats A Complete PU Solutions to Operations Management ‘ 16] The maintenance department of large hospital uses about 1009 annually. Ordering cost $12, carrying cost $5 per case ay year and new price schedule indicates that order of less than 50 cases will cost $20 per case, 50 to 79 cases will cost $18 per case, 80 to 99 case will cost $17 per case, , id large order will cost $16 per case. Determine the optimal order quantity. Given, | Annual Demand (D) = 1000 cases per year Ordering cost) = $12 Carrying cost (H) per case yea [Seam Onerstennsss | Start with Minimum price i.e $16 BOQ = v2DS/H =¥2«1000*12/ (516) =24000/80 = 173217 units At price $17 OQ = V2DS/H =V21000%12/(5«17) =V24000/85 =1680°17 uriits At price $18 BOQ = V2DS/H =¥2«1000«12/(5%18) E0Q = v2D8/H =¥2%1000«12/(5%20) =124000/100 =15.49=15 units Now Calculating Total Cost (TC), | / TCis = QH/2+ DS/Q+PxD =15%5/2#1000*12/15+20%1000 =37.5+800+20,000 =§ 20,8375 Scanned with CamScannerrs - TC = QH/2+ DS/QtPxD . =16*5/2+1000%12/16+18*1000 =40+750+18000 =$18,790 TC = QH/2+ DS/Q+PxD =17*5/2+100012/ 174+16%1000 =$16,748.38 So, the minimum cost order size is 17 units. 3, [2020 Spring Q. No. §] Explain the concept of bills of material and Prepare the | product structure tree from the following given information; Product A is made of two units of B and three units of C. B is made of two units of D and four units of E. D is made of one unit of E and three unit of F. C is made of two units of F and four units of R. If 100A are required, how many units of each component are needed? A bill of materials (BOM) is a detailed list of the raw materials, components, and instructions needed to build, manufacture, or repair a product or service. A bill of materials is typically presented in a hierarchical format, with the finished product at the top and individual components and materials at the bottom. Product Structure Tree BQ) CG) DQ) ew | [Fe Ri) | E(t) FQ) Figure :- Product structure tree If 100A are required, then total Units of each component are needed is A =100 B =2*100=200 C =3100=300 D * 200 = 400 | E, =1% 400=400 E, =4 x 200= 800 | E =400+800=1200 F, =3% 400= 1200 i Fy =2%300=600 F = 1200+ 600 = 1800 R =4x300=1200 4. [2020 Fall Q. No. 14] ABC company used 1000 units of component to its final product annually. The new supplied ofthe company offers new price sched 501079 80 to 99 100 and More “The ordering cost are Rs.12 and carrying cost is 15 peroent Determine lhe optimal order quantity. Scanned with CamScannerEEE ey Price (P) * Rate (r) Purchase price per unit (Pi) =30 =P *r=30%15%=45 (P) = 28 G=Pp x r= 28% 15% =42 (Ps) = 26 G=Psx r= 26% 15% =3.9 (PR) =24, Ga Pyxr=24x15%=36 Calculation of BOQ based on the lowest price (P,) = Rs. 24 F200 es Vo zs Pxr00o«12 “\ 36 = (ET 3 = 81.6482 Units Since, EOQ, is less than 100 units, calculate EOQ at the third lowest price (P;) ) Calculation of EOQ; based on the third lowest Price (P:) = Rs. 26 200 £00; -a/ G _, [=ioOoIa =\39 = 6153.85 = 7844=78 Units Since, EOQhis less than 80 units, calculate BOQ at the ihr lowest price (6) Calculation of EOQ, based on the third lowest Price (P:) = Rs. 28 B0Q; =» [20 -\ an [Roo 42 25714 = 7559 = 76 Units BOQ, lies between 50'to 79 units. Total cost in 76 units Total Cost(TC) =D xP + Beto xc 76 = 1000 x 28 + 002 x12+> (28% 0.15) = 28000 + 13.16 « 12+ 38 «4.2. = 28,317.52 Scanned with CamScannerbasis anidiaial i D E0Q, Total Cost of 10 units =D x Pat Hog, x 0+ Bc 1000 100 = 1000 « 24-+ Fog" x 12-475" * (24x05) = 24000 + 120 +180 = 24,300 Now, . D Total Cost of 80Units = D* Ps + 55g, x0 +292 xc = 1000 « 26 + 1000 xia (26 « 0.15) = 26000 + 150 + 156 = 26,306 Total Cost of 100 units is less than total cost of 76 units and 80 units 5, [2019 Spring O. No. 13][2016 Jamuna store stocks toy race cars. ‘The store has been given a quantity discount schedule for these cars, This quantity schedule is shown below: “The normal Oost of the toy car is $5, Ordering cost is $49 per annual, annual demand is 5000 race cars, and inventory camying cost as a percent of price is 20%. What order ‘quantity will minimize the total inventory cost? Here, Given Annual Demand (D) = 5000 race cars Ordering cost (§) =$49 Inventory Carrying Cost (H) = 20% of unit price ‘Start with minimum price Le $4.75 2D: oq #4 /222 2x 5000 x 49 0.2% 4.75 = (51578947 = 718.18 = not possible Atprice $4.8 714.43 =-not possible ———=_ Scanned with CamScannerHELIS Advance Saraswat’ A Complete PU Solutions lo Operations Management At price $5 DS BOQ =\/r rx S000 AS 700 = Feasible Now, TC =Su+Bser 700 02% 5+ 500 49 +5 x 5000 =$25,700 TCreeo =Su+Bs+ rp : é 1000 5000 y ay ¥02* 48+ 7999 * 49448 5000 =$25,75 -SH+254Px Team =ZH+GS+ PD * 5000 7 * 0.2% 4.75 + 5999 % 49 + 4.75 x 5000 = $24,822.50 So, the minimum cost order size is 1000 units. 6. [2019 Fall Q. No. 15] Find the reorder point if the annual demand for a product is 12000 units operating for 300 days in a year, having a lead time of 10 days for new order to arrive, “ Here, Given D — =2,000.units L. =10days Demand per day (d) 2 = ~ co units per day ROP =dxL=40%10=400units 1 [208 Spring Q. Wo. 15] ‘Spring Q. No, 15] Surge Electric uses 4,000 toggle switches a year. A suppliet has approached the company with following price schedule: lt cost approximately Rs. 18 to prepare an order and receive it and carrying cost are 18 percent of purchase price per unit on an annual basis. Determine the optimal order quality. Scanned with CamScanneros Here, Given a "p= 4000 toggle switches $ =$18 H =18% Start with Minimum price ie Rs. 82 =i BOQ =’ __, Roxas =\ 018 x82 = 98 = not possible Atpprice Rs. 85 4000 x 18 18 x 90 = 94 is feasible solution Now Calculating Total Cost, TC -2u+Bser = oe x95 + Ap x 18+ 95 * 40e0 = Rs, 381,569.65 TCsx0 =$u+§s+ PD * _ 500 80 3 x 85 + Spy 18 +85 4000 = Rs. 343,969 TCyo0 =Su+Bs+ px 1000 = 100 3a x 92 + fppy* 18+ 82 4000 = Rs, 3,35,452 ++ So, the minimum cost order size is 1000 units. Scanned with CamScanner‘Advance Sareswai’s A Complete PU Solutions to Operations Management Company, which sells industrial fluid-contro, + devices. One of Central's most popular values is the Western, which has an annua demand of 4,000 units. The cost of each value is $90 , and the inventory carrying cost is $9. Marilyn has made a study of the costs involved in placing an order fr any of the values that central stocks and she has concluded that the average ‘ordering cost is $ 25 per order. Furthermore, it takes about § working days for an order to arive from the supplier. During this time, the demand per week for values sproxinaely 80. What isthe economic order quantity? t Whatis the average inventory level? i, Whats the optimal number of order per year? |v, Whats the optimal number of days between any two orders, assuming 250 working days per year? ¥. Whats the total annual inventory cost? vi, Whats reorder point? | | Here, Given, Annual Demand (D) — = 4000 units Inventory Carrying Cost (P) = $90 Price of each value(H) =$9 Average Ordering Cost (6) = $25 L =5days 80 aq = = 16 units (Assuming 5 days week.) i. Economic Order Quantity (BOQ) = eps J2 x 4000 x 5 Pay ae = 149 units ii. Average inventory level = 422 = 745 units ieee i fil, Now = Q— = qq" = 26 orders per year Hl A. fv, Cycle time = 7555 * 250 = 9 week D v. TC -SurBserxo M9, , $000 4 7x 9+ Tap * 25 +90 « 4000 = $361341.64 vii ROP =dxL =16x5=80 Scanned with CamScanner| Invern Maogeent DT iyn Hart is the purchasing agent for Central Valve | gy forse hi ea which sells industrial values and fluid ~ control devices. One of sntral's | most popular values is the Western, which has an annual demand of 4,000 units. The cost of each value is $90, and the inventory carrying cost is $9. Marlyn has made a study of the costs Involved in placing an order for any of the values that central stocks and she has concluded that the average ordering cost is $25 per order. Furthermore, it takes about § working days for an order to arrive from the suppl. During this time, the demand per week for values is approximately 80. iL Whatis the economic order quantity? ii Whatis the average inventory level? i Whatis the optimal number of order per year? iv. What is the optimal number of days between any two orders, assuming 250 working days per year? v. Whatis the total annual inventory cost? vi. Whats reorder point? Here, Given Annual Demand (D) = 4000 units Inventory Carrying Cost (P) Price of each value (H) Average Ordering Cost (S) i ii Average inventory level = 442 = HH N op “te ae = 26 orders per year om h 149 iv. Cycle time = 799g * 250 = 9 week 1 -$u+8s+r =P 9 + 4 25 + 90 4000 » = $361341.64 vi ROP =dxL=16%5=80 Scanned with CamScannerTHEGIN Aiance satasviatis a Complete PU Solitons to Operations Management ee 10. [2017 Fall @. No. 13) ‘The maintenance department of a company uses 936 units of material annually, The cost of placing an order is Rs. 45. The holding cost is 25% oj Unit price of materials and the vendor charges different price rates to the company for a different range of orders. If it orders less than 300 units, the price is charged Rs. 60, for 300 to 499 units the price is Rs. 58 and for 500 units and more the price is Rs. 57 only. Determine the optimal order quantity. Sam Ripa ESSAI ere Rs. 60 Rs. 58 Rs. 57 = 76.84 = not possible At price Rs. 58 = [28 Bog = /"8 Pec 025 x58 =76.22= not possible Atprice Rs. 60 20S 50Q i _— x00 = = 7493 ~ 74s feasible Now Calculating Total Cost, D TC ~SH+Bssmp 986 % 0.25 * 60+ 57 x 45 + 60 x 936 = Rs, 57284.18 a Scanned with CamScanner; * Inenon Maragnet RSE D Tem =gH+gstPxD 936 = 80 025 x 58 + 399 * 45 + 58 «906 = Rs, 56603.40 D rem -GueBerien 025% 57+ 28x 45 + 57 x 936 = Rs, 56998.74 So, the minimum cost order size is 300 units. w Bat 90% service level = 1.645 : ROP =dxL+76 = 6000 x 6 + 1.645 x2 = 3603.29 units 41. [2016 Fall Q. No. 15 | The Annapurna Hotel in the preceding example uses approximately 600 base of soap each day and this tends to be fairly constant. Lead time for soap delivery is normally distributed with a mean of six days and standard deviation of two days. If a service level of 90% is desired. Find the ROP.. Here d = 600 base of soap { SL =90% 2 _ =1.28 (from table under the standardize normal curve) L =6days Or = 2days aR = dx Lt zdour = 600 x 6 + 1.28 x 600 x 2= 5136 b) No. of days = a = 8.56 days \ goo Scanned with CamScannerOperations Scheduling ‘Scheduling epee ha a Theoretical Questions, See Operations ¢ ek ie 4. [2021 Spring Q. No. 8] How Johnson's rule differ from assignment method? Johnson's rile: In’ operations research, Johnson's rule -is a method of scheduling jobs in two work centers. Its primary objective is to find an optimal sequence of jobs to reduce makespan (the total amount of time it s to complete all jobs). It also reduces the amount of idle time between we two work centers. The method minimizes the makespan in the case of two work centers, Furthermore, the method finds the shortest makespan in the case of three work centers if additional constraints are met Assignment method: The assignment method is any technique used to assign organizational resources to activities. The best assignment method will maximize profits, typically through cost controls, increases in efficiency levels, and Joetter management of bottleneck operations. [2020 Fall Q.|No. 5] Explain backward and forward scheduling. Backward {ntegration involves buying part of the supply chain that occurs prior to the company's manufacturing process, while forward integration involves buying part of the process that occurs after the company's manufactyiring process, 2020 Fall ae 8 Write the meaning of critical % A sequenicing rule that is an index number computed by dividing the time remaininjg until due date by the work time remaining, The critical ratio (CR) is an index number computed by dividing the time remaining until due date by the work time remaining. As opposed to the priority rules, critical ratio is dynamic and easily updated. It tends to perform better than FCFS, SPT, EDD, or LPT on the freee job lateness criterion. The formula for critical ratio is ) 4 Scanned with CamScannerOperations Scheduling Timeremaining _ __Due date - Today's date Critical Ratio (CR) ="Workdays remaining ~ Work (Lead) time remaining ‘The critical ratio gives priority to jobs that must be done to keep shipping on schedule, A job with a low critical ratio (less than 1.0) is one that is falling behind schedule. If CR is exactly 1.0, the job is on schedule. A CR greater than 1.0 means the job is ahead of schedule and has some slack, { [2019 Spring @. No. 4][2016 Spring Q. No. 8] What is operations scheduling? ||, Operations scheduling is critical to the, success of an organization; — | ~ trowever, it can be very complicated task. Effective schedules are needed to meet promised customer delivery dates on inventory targets, Scheduling involves the allocation of resources over time to accomplish specific tasks. The number of resources and tasks involved can be very large, and the implications of one schedule must be gauged against other schedules. Effective scheduling helps managers achieve the full potential of their supply chains, Making efficient use of the labour, increasing the profit, minimizing the inventory, reducing the production cost, increasing the output, improving the service level are the objectives of operations scheduling. 5. [2018 Spring Q. No. 8] Outline the different methods of scheduling, 's. These are the methods used for the operations scheduling: 1. Johnson's Two Machine Algorithm: It is Very effective when the operations sequencing has two machines and the processing time depends on the sequence in which the jobs are loaded. Index Method: It is used for the purpose of the loading and also for allocating the different jobs to the different machines. Critical Path Analysis: It helps. in the determination of the scheduling of the activities of the projects. Critical Ratio Scheduling: It helps in the establishment and the maintenance of the priorities among the jobs in a factory. 6. [2018 Fall Q. No. 9] Write about the types of scheduling. ™ a are the types of Operations scheduling: Forward operations scheduling: All the activities are scheduled from the date of the planned order releases or we can say that It determines start and finish times of next priority job by assigning it the earliest equitable time slot and from that time, determines when the job will be finished in that work center. “2. Backward Operations scheduling: Activities are scheduled from the date or the planned receipt date or what we can say that it determines the start and finished time for waiting jobs by assigning them to the latest equitable time slot that will enable each job to be completed just when itis due but done before. Scanned with CamScanner[2016 Fall Q. No. 4] What do you mean by Job shop technology? 23. A job shop is a sort of manufacturing facility that produces small batches of a wide range of specialized products. Most of the goods produced in a job shop require a particular set-up and sequencing of process stages. ve Answer \! 4. [2010 Spring @. No. 7] Differentiate between backward and forward scheduling, 1% Operation scheduling defines as establishing of times at which to begins and complete each event or operation comprising a procedure. ‘These are the types of scheduling: a. Forward Scheduling bv. Backward Scheduling. ‘These can be explained as ' a Forward Scheduling: Forward scheduling determines start and finished times of next priority job by assigning it the earliest available time slot and from that time, determinés when the job will be finished in that ‘work center. In short, it involves starting work as soon as it arrives. yr Backward Scheduling: Backward scheduling determines the start and finished time for waiting jobs by assigning them to the latest available slot that will enable each job to be completed just when it is due, but done before. In short, it involves starting jobs at the last possible ‘moment to prevent them from being late. Forward and_ backward scheduling methods are shown in the following figures. Forward Settg es eg ra Backwad Sched | Obici aw Operation Fred | aerial mat 2 <—— Stay scheduling due data recuired and work Todays Date CL] Operaton Tine [=] rans or Queue Tine Scanned with CamScanner\Z Numerical Questions. Average Completion Time SS inh Total job wor .. Utilization = “Sum of total ow time ‘Average number of jobs inthe system Seale tal late days. |. Average Job lateness = fanbara jobs ae a —_Time remaining _ it Due date — today's date 5. Critical Ratio (CR) = Woon eats = eS i" aoe Where, CR = 1, then jo is exactly on schedule GR < 4, then job is behind schedule CR > 4, then job is ahead of schedule and has some slack 2021 ‘Spring Q. No. 13 | Five jobs have to be processed with two workstations cutting and drilling shown as follows: E tt. 6 You are required to prepare the optimal plane schedule, Also calculate: a. Total completion time b. Total Job waiting time c. Total machine idle time Optimal sequence of the Job. Cutting Denting A B A B c[A B DICIA BL E[D|cC]A Total completion time - 59 hr fel Scanned with CamScannerWHEL Aaience Saraswats N Complete PU Soliton of Operations Menagement Time 07 ae ear ae cma Dili Oe Pee u 6 8 89 Where, ZZ = Idle Time ‘ b. Total job waiting time = 14 ¢. Idle time for cutting = 6 hr Idle time for printing = 8 hr la lak kek Es aE SR 2. [2021 Fall @. No. 14] An organization has four jobs on order, as shown in the following table. today is 300 in what sequence would the jobs be ranked according ‘Average Completion Time = Sum of Total flow time / Number of jobs Utilization = Total job work time / Sum of total flow time Average number of jobs in the system = Sum of total flow time / Total job work time Average Job lateness = Total late days / Number of jobs w Average completion time (Days) =116/4= 29. Utilization (%) = (69/116)*100 = 59.48% ‘Average Number of jobs Average Lateness (Days) i i ae Process Time Flow Time 2 7 ac 35 ; 5 16 56 32 ; ; : a BB fs Foie 2 5 oy 314 a Scanned with CamScannerOperations Scheduiing tion time (Days) = 209/4 = 57.25 Utilization (%) = (69/229) "100 = 30.13% Average Number of jobs = 229/69 = 331 Average Lateness (Days) =0/4=0 average compl Process Time ‘Average completion time (Days) = 138/4=345 Utilization (%) = (69/138) *100=50% Average Number of jobs = 138/69=2 ‘Average Lateness (Days) = 0/4=0 ‘The results of three rules are summarized in the following table: dee ‘completion | Utilization (1 noe | umber] ae e SPT is superior in all three measures because its average completion time, average number of jobs and average lateness is lower than as compared to other measures. : 2020 Spring Q. No. 4] The following set of six jobs is to be processed through two work centers first denting and then painting. Process time at each of the work centers is shown in the following table. ; Work time forjobs (hrs) Painting 6 Required: a. Whats the optimal sequence for these jobs tobe scheduled? . Chart these jobs through the two work centers. Whats the total length of ime of his opal soliton? 4. -Whatis the idle time? Scanned with CamScannerHELI Avance Sarasuat's A Complete PU Soliton of Operations Management AY a. Optimal sequence of the job. Painting Denting E I Bye ested |B. BIA CTE] BIATF[ [cle BAT F[D[clE b. Solution, Chart of Work Center ii 9 19 34 52 68 Painting | I Dentng | 5 3 10 2 7 5152 6168 76 ¢. Total length of time for optimal solution. = Idle Time Painting = 76 - 68 = 8 hrs Denting = 76-65= 11 hrs. 2020 Fall Q. No. 12] Five batches of jobs are to be conducted in sanding machine and painting machine in order. Following are the Processing times in hours. Si aint ‘Apply Johnsons rule and find, a. Optimal sequence of jobs b Prepare the chat ¢. Total completion time 4. Flow ime ofeach ob a Scanned with CamScanneroptimal Soquenceo Job | aes Sming | 5 0 7 ae 6 8 5 4 [Painting | ¢ Calculation of Total Completion time Idle Time for Sanding = 3 Hours Idle time for Painting =3 Hours Total Idle time = 6Hours b, The flow time of this job sequence is illustrated below: Te 02: 7 4 % Sanding wa he 0 o 16 17 24 8 3 it f t tt D c A BOE Where, — CQ iale Time ‘t Job Completed d. Flow time of Each Job Total elapsed time = 31 hours 5. [201 Spring @. No. 12] Six jobs are to be processed through a two step operation. ‘The first operation involves sanding, and the second involves painting, Processing times are as follows: Scanned with CamScannervance Sars A Complete PU Soliton of Operations Management Determine @ sequence that graphically. | Now, = E De E D I E =O EPO E oe cs Aer Bree The optimal sequence is: E~D = C- A-B-F The sequential times are: [Sanding [ 2 [ 3 76 Wee (eT [Painting Te Ts [| 7 Sorpea@oe 8 ‘The flow time of this job sequence is illustrated below: Time 02 5 10 20 27 i Sanding D c A B Painting _N ! Time 0 8 15 2 mia wt t rf t foireat | ‘dle Completion Time Total completion time is 31 hours 6. [2019 Spring @. No. 15] Five jobs are waiting to be assigned at Cozy Architecls Theit work times and due dates are given inthe following table, Set the processing ‘Sequence according to FCFS and SPT rules. Scanned with CamScannersus Here, a. F-C-F-Ssequence is: A-B-C-D-E Measurements of effectiveness for FCFS are Sum of total flow time _77 Number ofjobs = 5 = 154 days a _—Total job work time 28 Utilization Sum of total flow time ~ 77 * 100% = 364% Average completion time = aa Sum of total flow time ‘Average number of obs inthe system = TT oa me 7 5 = 55 = 2.75 jobs Te ‘Average job lateness a = B en2days SPT rule: Sequence B- D-A-C-E 2 _.. __ Total job work time Average Completion time ="30 Ghost flow time -3 x 100% = 43.1% ="“total job work time ~ 28 = 232 jobs Sum of total flow time _ 65 Average number of jobs in the system =" total job work time di Average job lateness = ate 7. [2019 Fall @ No. 12] There are five jobs in a manufacturing company being processed through two work centers (drill press and lathe). The time for processing each job is as following (time in hours): 18 days ‘Apply dabrenn'= = Scanned with CamScannerTHEDII Advance saraswat A Complete PU Soon of Operations Management a. Optimal Plan Schedule b. Total Completion Time c._ Flowitime of each job. Now, Tah a] The sequential times are We; 3 7 10 5 ‘WC, 6 12 7 4 2 The flow time of this job sequence is illustrated below: Tme 03 10 20 28 33 wer E 4 D [6 | Wee 8 tt Time 0 3 910 2 oa OS B t- t tt t z 9 c IY tate + Jobs Completed Thus, Total consumption time is 35 - } > 8. [2018 Spring O. No. 16] Five especially jobs in a manufacturing environment must be processes through two work centers (drill press and lathe). The time for Processing each job follows (all times are listed in hrs) Apply Johnson's rule and calculate: Scanned with CamScanner| 4. Optimal Plan Schedule b. Total Completion Time Time “18 4 2 2 30 3738 40 t t t t Idle ‘t Jobs Completed Total completion time is 46 hours. 9. [2018 Fall @. No. 15] Use Johnson's rule to find the optimum sequence that will minimize the total completion time for processing the six jobs shown through two work centers. The first work center involves drill process and second involves lathe. Processing time at each of the work centers are in hours shown in below. show the chart of these jobs through the two work center. Scanned with CamScanner“The Optimal Plan Schedule is: B ‘The sequential times are: Idle Time for Machine A = 4 Hours Idle time for Machine B. =7 Hours ° Total Idle time =11 Hours Where, — KCQldieTime 4 Job Total elapsed time is 82 hours. Scanned with CamScannerR017 Spring Q. No. 12] From the following information given, identlyopinal — and idle time in total from both centers using Johnson’ rule, The time-phased flow of this job sequence is illustrated below: Flow time Time 3 10 20 w BY We: B El A me N ! Tme 0 3 910 a B 24 t t t t Idle ‘t Complete Tine Total completion time is 34 hours. Idle time for WG is 1 hour. Idle time for WC is 5 hour. 11, [2017 Fall Q. No. 14] The following jobs are wal machine center, Jobs are logged as they arrive: Scanned with CamScanner‘Im what sequence would the jobs be ranked according tothe folowing decisions rl a)FCFS, »)EDD, c) SPT, and. ¢) LPT? All dates are specified as manufacturing planning calendar days. Assume that all jobs arive on day 275. Which decisions is best and why? - "Measurements of effectiveness for FCFS are { “ _Sumof total flow time _ 257 _ 47 «aye ‘Average completion time ="— Number of jobs 5 | Total job work time _ 72. sg 99 Utilization = Bumof total flow time ~ 237 * 100% = 303% Sum of total flow time Average number of obs in the system. =~ totatjob work time BI 72 Total late days. 74 Average job lateness =—"No-affabe = 5 7148 days ‘SPT rule: Sequence B- A-D-E-C Sum of total flow tim: Number of jobs Total job worktime __72 = 3,29 jobs Average completion time 34.6 days — = "Sum of otal flow time ~ 173 *.100% = 41.61% ‘Average number of jobs inthe system = Sumof total flow time total job work time 21 =F -42days ‘SPT rule: Sequence E - D - A. “Flow Tina | oh Bue Dai ob Lata me} Average completion time _ Sum of total flow time _ 131 5 Number of jobs =26.2 days Scanned with CamScannerOreraons Scheduing UATE / Total job worktime 7) Viilization = “Gum of total flow time = 731 * 100% = 54.96% & _ Sum of total flow time _131 Average number of jobs in the system ‘total job work time = 181 jobs Totallatedays 21 Average lateness =" ofjobe = =42 days Sum of total flow time 301 Number ofjobs 5 = 60.2days ston 2-_Lotal job worktime 72 Utilization = “Sum of total flow time = 301 * 100% = 23.92% Average completion time = Average number of jobs in the system = Sum of total low time _ 301 “a7 total job work time = 4.1 jobs : Total late days _ 104 ‘Average lateness = “Nocipee => = 208 days ‘sequence is; A-B-C-D-E ‘SPT rule: SequenceB | a46days | 41.61% - 42days -A-D-E-¢ ‘SPT rule: SequenceE| 262days | 54.96% ‘tatjobs | 42a -D-A-B-¢ : LPT rule: Sequence | 602days | 23.92 4.1 obs C-B-A-D-E % SPT is best because, Average completion time s lest average number of job is lower and average lateness § ‘utilization is higher, Jso low in SPT. Scanned with CamScannerHEIN ‘Aico sarasiatis A Complete PU Sotton of Operations Management 412. [2016 Fall Q. No. 12] Six Jobs are to be processed through a two steps operation, The first operation involves sanding and the second involves painting. Processing __ times in days are a8 follows: ‘Apply Johnson's rue and calculate i. Optimal schedule ii__ Total completion time (4ays) [Ere D Sd eT en ee 2 a D-C-A-B-F ° acer 2 3 5 7 4 = 6 8 7 4 3 The time-phased flow of this job sequence is illustrated below: Flow Time Time 0 25 10 20 2 31 wr [elo] c A [3 F Wee OP ee B Time 0 t 16 t 28 2 f 8 t 23 t te + Complete Time Total completion time is 35 hours, 13, [2016 Spring Q. No. 15] A company has five jobs waiting processing. Processing time and due dates are @ given in the table, Scanned with CamScannerOperations Scheduling in what sequence would the jobs be ranked according to the folowing rues: a. FCFS b. SPT Which decison is best and why? Now, Measuring of Effectiveness for SPT are: Sum of Total flow time _ 8 Average Completion time |= a eer ofigbs = iS days . : __ total Job work time — = Gum of total flow time 43 = 43.1% ‘Sum of total flow time Average number of jobs in'the system = — job Wark me -& = 2.32 jobs ‘ _ Total late days _ Average joblateness = eo yobs "3 414. The following set of six jobs is to be processed through two work centers. Preessng time at each of the work center is shown in the fering ane aa “Work Time for Jobs (Hours) = Work Center 1 ; 2 3 18 18 16 10 =18 days amoow tell Scanned with CamScannerHELIN orc sara A Cane PU Soon of Opens Meagement Required: = ‘a. What is the optimal sequences for these jobs to be scheduled? b. Chart these jobs through the two work centers. ‘The séquence of operations performed are: ‘The sequential times are: |_ Work Center 1 3 6 10 15, 18 16 "Work Center 2 T 12 15 14 9 8 The time-phased flow of this job sequence is illustrated below: Time_0 34 52 Be [wes jelal F Bf 6 = WS bb IC B A FO p. Noe KW E 03 10 7 5152 SCS My t ? + t t t 8 A F D c E ite + Complete Time 15, The following set of five jobs is to be processed through two work centers at @ Printing press. The sequence is first printing, then binding. Processing time at each ‘of the work centers is shown in the following table: Required: Saat ‘a. What isthe optimal sequences for these jobs to be scheduled? . Chart these jobs through the two work centers, The sequence of operations performed are: 4 Scanned with CamScannerIdle Compete Time The time-phased flow of this job sequence is illustrated below: ‘Thus, the five jobs are completed in 35 hours. QoQ Scanned with CamScanner