4

PPC AND PRODUCTION SYSTEMS

be viewed as
Production planning and control in different production systems can
under :

1. PPC in Production to Order System

Production to order involves manufacture of products to meet specific customer
reauirements of special orders. The quantity involved is usually small. Under this system,
sequencing of each job
general purpose machines are organised department wise. The
is unique, depending upon the technological requirement. Production to order or job
on a new
shop is a complex waiting line system a job passes from a machine to wait
machine because of other jobs. Each machine has a waiting line of jobs. Planning here
is a process of prioritizing the jobs at each machine to achieve desired objectives.
Under production to order system, we may have three types according to the
regularity of manufacture namely :
(0) Products produced only once
() Products produced intermittently when the need arises.
(ii) Products produced periodically at known intervals of time.
When the products is to be produced only once, there is either scope for improvement
of production techniques by introduction of method studies, special tools or jigs and
fixtures unless the technical requirement justifies it.
When the order is to be repeated, jigs and fixtures, tools etc. should be carefully
considered to reduce the manufacturing time.
Production planning and control function is relatively difficult in production to order
or job production system because of the folowing reasons:
1. Each job has its own characteristics and needs special treatment. Every job order
has diferent sequence of operations. There is no standardised routing for job orders.
2. Specific job orders are assigned to different work stations as per the availability
of capacity.
3. Production schedules depend upon the relative priority assigned to
orders. various job
4. Scheduling is dependent on the assessment of production times.
Ihe basic question is that of scheduling when there are 'n' jobs
On m' machines, each job having pre-decided sequence of operations awaiting processing
and process
 Mehak aggar
singh
PPC and.
54
Production Systan
timings, then what should be the order of loading the jobs on machines: So t atie
asto
the expected performance standards?
2. PPC in Productionto stock or Batch
or.Intermit ent
Under the production to stock, standard products in the less variety are
Syste,
batches, stocked in storage and sold as and when demand occurs, when theproduet
in
to
or
pu
level touches a pre determined level, a fresh batch of productis produced. The
produces here in anticipation of demand. Batch production is the manufacturesystea
E

number of identical items either to meet a specific order or to satisfy the

demand. continvuox a

The decision regardingtoling and jigs andfixtures are dependent onnthe quanti A
of production batch.
In batch production too, there can be three types namely:
(a) Abatch produced only once. S
(b) Abatch produced repeatedly at regular intervals, when the need arises. S

(c) Abatch produced periodically at known intervals, to satisfy continuous demant S

Here again, planning and control become more simplified as quantities incre re
t
and as manufacture becomes more regular. Two problems that may arise in batd
t
production are due to the size of the batch and due to scheduling of production,
t
The solution to these problems depends on whether the production is governed b
(a) External customer orders only.
(b) Whether the plant is producing for internal consumption i.e, a sub-assemb
used in the final product.
If it is the case of external customer orders, the customer order size usualy
determines the batch size. The timing wil also depend on the delivery dates specie
by the customers. If it is for internal consumption, both batch size and productio
scheduling problems are matters for internal management decisions.
The problem of optimal batch size has to take into acCount and set-up costs wnld
are involved, before each production runs and the inventory carrying costs incure
when the finished product is held in stock. The batch size determines the length oru
production run and affects both the production schedule and batch size consideraa
of other products.
3. PPC in Continuous Production
Continuous production is normally assocated with large quantities of producti
rate d
and with a high rate of demand. Continuous production is justified when the
production can be sustained by the market.
Two types of continuous production can be :
(a) Mass production and
(b) Flow production d
inspie
In mass production, alarge number of identical articles are produced, but
designedfr
advanced mechanization and tooling, the equipment need not be specially
the component to be manufactured.
 Tanishk Mehrotra

55
Systems
oachie PPCand Production
Systems

In fowproduction, the plant and

equipment and layout have been primarily
designed
switch over to a different kind of
manufacture a particular product. A decision to
and the layout, especially when special
dct needs basic changes in the equipments
ystducediema purpose
machines and complex material handling systems are used.
PPC in continuous production is usually far simpler
than in a job or batch production.
before production starts, but both
aventsysteomn Evtensive effort is required for detailed planning The output is either limited by
cchedulingand control need not be elaborate usually. conform to production targets,
re of a aailable capacity or regulated within given limits to
tinuous based on periodic sales
forecasts.

antities 4, PPC inProcess industry

is automatic and uniform.
pPC in the procesS industry is relatively simple. Routing
used. As the products are
Standard processes and specialised equipments are Departmental
standardised and goods are produced to stock and sell, scheduling is easy.
involves issue of
schedules are derived from master production schedules. Dispatching plant. The main
nand. repetitive orders tO ensure a steady flow of materials
throughout the
ease and uniform flow of work at
task of PPC in process industry is to maintain acontinuous
patch complete
the pre-determined rate in order to utilise the plant and egquipments fully and to
by the production in time.
Requirements of Effective Production Planning and
nbly Control system
1. Sound organizational structure with mechanism for proper delegation of authority
ally and fixation of responsibility at all levels.
ied
on 2. Information feedback system should provide reliable and up-to-date information
to allpersons' carrying out PPC functions.
ch 3. Standardisation of materials, tools, equipments, labour, quality, workmanship
etc.
d
4. Trained personnel for using the special tools, equipments and manufacturing
S processes.
5. Flexibility to accommodate changes and bottle necks such as shortage of materials,
power failures, machine breakdowns and absenteeism of employees.
6. Appropriate management policies regarding production and inventory levels,
product -mix and inventory turnover.
. Accurate assessment of manufacturing lead times and procurement lead times.
8. Plant capacity should be adequate to meet the demand. The plant should be
Tiexible in order to respond to the introduction of new products, changes in product-mix
and production rate.

Scheduling, Sequencing and Assignment

Production planning and control activities differ widely in production to order and
production to stock system in amanufacturing firm. In
production-to-order situations,
ue dates (delivery schedules) are important and sequencing of customer orders at
 PPC and
56 Production Syste
various work centres becomes animportant
function. Production-to-stock PPC
generally hígh volume consumer products. produdsa
Schedulíng
Scheduling involves developíng and assigning specific dates for the start
completion of the necessary tasks. The absence of proper rscheduling may lead tto
problems such as : vaso,
orders.
(() Delays iín meeting the due dates of customer bed
(ii) High work-in-process inventory
(ii) Low utilization of workers and machines dat
(v) Higher set-up time of machines. job
(v) No acurate information available for the current status of a cha
(vi) High average completion time of jobs
(vi) Higher cost of production. or
Scheduling incudes activities such as loading, sequencing, dispatching, expedty,
detailed scheduling. an
1. Loading sometimes known as shop loading or machine loading, is the assignner
of jobs to arious work centres or machines for future processing, giving due considerati S
to the sequence of operations as per the route sheet and the priority sequencing at
machíne/work centre utilzation. Loading establishes the amount of load (labour hous th
or machine hours) each work centre or machine must carry during the future plannirg u
period (weekly or monthly). This willresult in load schedules which indicate comparisoa
of labour and machine hours needed to produce the master production schedules wit
the labour and machine hours actually available in each planning period (week or mont
in the short-term planning horizon.
2. Sequencing is the process of determíning the sequence of processing of alljs
at each work centre or machine. It establishes the priorities for processing the ps
which are wating in the queue at each work centre or machine. The priority sequenarg
is done as per a priority sequencing rule, which will be discussed later in this chapte:
3. Detailed scheduling is the process of determining the start and finish tr
(dates) at each work centre or machine for all jobs. Detailed scheduling is possible o
after loading and sequencing. By knowing the duration of time each job takes to complat
the operation at each work centre/machine and also by knowing the due dates,
detailed schedule indicating the start and finish dates can be established.
4.Expediting is the special effort or action needed to keep the job moving throy
the production facility on time as per the detailed schedule. Disruptions in pro0u
due to machine/equipment break downs, non-availability of materials when ne
last-minute priority changes due to special jobs having over-riding priorities, necesu
the expediting action for some important jobs.
Scheduling in Production to order or job shop
Operations scheduling is the organising function of a production manag
Schedulingi
function is most important in production-to-order or job shop processing.
job shops involves the following activities.
 57
PPCandProduction.Systems
Assigning job orders to different machines
())decidingthe sequence of processing on different machines.
)planningthe route of material
(i) dispatch lists to various work centres
(v)ussingthe schedules.
Atracking the progressof various scheduled jobs and implementation of
systems is quite complex
Cheduling in job shop or process -focused production
becauseoffthe
followingreasonsS:
orders for which delivery
al lob shops have to produce products against customer
promised.
dates have to be lots tend to be quite small and
(b) Production may require numerous machine
change-overs.
different
(O Possibilityy of assigning and reassigning workers and machines to many
orders due to
flexibility.
i) Iosuch aflexible, variable and changing environment, schedules must be specific
and detailed work centre-wise to bring ordeliness.

Scheduling Techniques for Job Shop

The type of scheduling technique used in job shop depends on the volume of orders,
the nature of operations and the job complexity. Two types of scheduling techniques
Used are:
1. Forward scheduling
2. Backward scheduling.
1. Forward schedulingIn this approach, each task is scheduled to occur at the
earlest time that, the necessary material will be on hand and capacity will beavailable.
It assumes that procurement of material and operations start as SOon as the customers,
requirements are known. The customers place their orders on a 'needed-as-soon-as
possible' basis. The earliest completion date, assuming that everything goes as planned,
could be quoted to the potential customer. Some buffer time may be added to determine
adate that is more likely to be achievable, if it is acceptable to the customer.
scheduling is used in mary companies such as steel mills and machine tool
Forward
where jobs are manufactured to customer orders and delivery is manufacturers
s possible' basis. Forward scheduling is wellsuited requested on 'as early
able to meet the schedules. This type of scheduling is
where the supplier is usually not
Shorter lead times but accumulates high work in simple to use, gets jobs done in
2. Backward process inventories.
scheduling--This scheduling technique is often used in assembly-.
Ype industries and in job shops that commit in advance to specific delivery
determining the required schedule dates for major dates. After
Mese required dates for each
component and vworks
sub-assemblies, schedule uses
the
Ese date for each component backward to determine the proper
9y Setting back' from the finish manufacturing order. The job's start date is determined
date, the
sIate as possible,
backward schedulingprocessing time for the job. By assigning jobs
Deted until it is due but not earlier. minimizes inventories, since each job is not
Backward
sheduling. scheduling is also known as reverse
 PPC and
58
Production Systen
Stages in Scheduling
viz.:
Scheduling is performed in two stages,
Loading 2. Dispatching.
1.LoadingLoading or shoploading is the process of determining which work cent
ajob or task toa particular work centre to
receives which job. It involves assigning Loadíng of Work
period (such
performed during aschedulingdetermined
as a week).
and the
centres depen
on the available capacity (or
by loal schedules) expected avalabi
jobs are assigned to machines or work centres tali,
of the material for the job. The
SE
and machine or work centre utilization
into consideration the priority sequencing waiting at aw
Dispatching-Dispatching is sequencing and selecting the jobs
becomes available
when capacity
centre (i.e. determining which job to be done next)done. The dispatch list is a means
to be
is actually authorising or assigningthe work work centre and ranks them by a relatis
priority control. It lists all jobs available to a scheduling gets implementg fe
priority. When priorities have been assigned to specific jobs,
through the dispatch list. procedures are categorised
Finite loading and Infinite loading--Loading
loading, jobs are assigned to wot
either finite loading or infinite loading. In finite operation with the available hoursi
centres by comparing the required hours for each loading, jobs are assigned t
each work centre for the scheduling period. In infinite
infinite).
work centres without regard to capacity (as if the capacity were capacity for ead
(a) Finite loading-Finite loading systems start with a specified
centre (sequencing). 1I
work centre and a list of jobs to be processed at the work
starting times an
work centre's capacity is allotted to the jobs by simulating job
completion times. The finite loading system combines loading, sequencing and detaiE
centre, based ol
scheduling. It creates a detailed schedule for each job and each work
the capacity of the work centre.
Wi
(b) Infinite loading--The process of loading work centres with all the jobs,
they are required without regard to the actual capacity, available at the work Cenue
called infinite loading. Infinite loading indicates the actual released order demand (00
subcontractingd
on the work centre, s0 as to facilitate decision about using overtime,
using alternative routings and delaying selected orders.
Sequencing or Prioritization
performedot
Sequencing or prioritization is deciding the order of various jobs to be
the given machines or work centres on the basis of some priority rules. difficultas
Choice of the right sequencing rule based on one criterion becomes quite
no single rule is ideal for all situations. Some of the criteria used are:
(a) Set up costs or change over costs.
(b) Work-in-progress inventory cost.
(c) Idle time.
(d) Number or percent of jobs late.
(e) Average job lateness.
PPC and Production Systems 59

(f) Average flow time.

(a) Average number of jobs in the system.
(h) Average time to Complete a job.
Single-criterion Sequencing Rules
Some single -criterion priority sequencing rules are:
1. First come-first served (FCFS) rule-Jobs are scheduled for work in the same
sequence as they arrive at the facility or work centre. This rule is commonly applied in
service centres such as bankS, Super bazaars and barber shops.
2. Shortest process time job (SPT) first-The job which has the shortest
processing/ operation time on the machine or at the work centre is given the highest
priority to be loaded as the next job for processing. This rule minimises the in-process
inventory, however, at the expense of keeping the jobs having longer processing time
for a longer time in the work centre, thereby increasing the job throughput time (i.e.
manufacturing cycle time).
3. Longest processing time (LPT) job first-The job with the longest processing/
operation time is scheduled as the first job to be loaded on the machine among the jobs
waiting in queue.
4. Least slack (LS) job first-In this rule, the highest priority is given to the job
which has the least slack. Slack is the difference between available time and the duration
of processing the job. Slack = Available time - Processing time.
5.Earliest due date (EDD) job first-This rule sequences the jobs waiting in the
queue at the work centre or machine according to their due dates and the jobs are
processed according to their due dates i.e. job having earliest due date is given highest
priority while loading the job on the machine (or work centre). This rule does not ensure
that all jobs will be completed on time i.e. within their due dates.
6. Truncated shortest proçessing time (TSPT) job first-This rule
the jobs acCording to the SPTrule, except that the jobs that have been, waitingsequences
for a
time period longer than a specified truncation time are given higher priority than other
jobs.
7. Preferred customer order (PCO)rule-Jobs belonging to a
are given a higher priority than other jobs. preferred customer
8. Random-selection--This rule is not used normally. It may be
other consideration is used when no
9. COVERT (Cost important.
over time) rule-This rule uses the
(9) to the processing time (T). The job with the largest ratio of expected delay cost
Priority. ratio is given the highest

Cost over time ratio = Expected delay cost (C)

Processing time (T)
ULeast
total cost of change-over cost-The sequencing of jobs is done by analysing the
makingall the machines change over between jobs.
 PPC and
60 Production:
Illustration. XYZ Company has received the following jobs at a Work
Systen, PPC and Production Systens 61

processed. The processing time (in days), arrival date and

due date (in centre
to
terms of sho, (¬Y Leastslack (L.S) rule :
calendar days) are given. Determine the sequencein which these jobssshould be Job Processing Available
according toeach of the following priority rules viz., FCFS, SPT, LPT, EDD, TSPT C process% sequence Duration (days) time (days)
Slack
(days)
Sequence
(Rank)
COVERT. 15
A (185 -95) = 90 (90 - 15) = 75 5
Assume today is day 100 and the jobs cannot be delayed for more than 60 days fu
TSPT rule. Assume expected cost per delay as 10 per day.
B 20 (200- 110) = 90 (90 - 20) = 70
C 10 (175- 112) = 63 (63- 10) = 53 2
Job Processing time Arrival date Due date D 30 (235- 125) = 110 (110-30) = 80 6
(days) (shop calendar day) (shop calendar day) E 25 (180 - 125) = 55 (55 - 25) = 30 1
F 18 (220 -130) = 90 (90- 18) = 72 4
A 15 95 185
B 20 110 200 Job sequence:E, C B, F A,D
C 10 112 175
D 30 125 235
(a) COVERT rule : The covert rule computes possible delays for individual jobs
E 25 125 using rule such as FCFS. If one or more jobs are delayed, the ratio of delay cost to
180
F 18 130 220
processing time (i.e. C/T) is computed. Then the jobs are sequenced in the decreasing
order of CT ratio. The calculations are shown below:
Solution: C/T
Job Processing Completion Due date Delay Expected
(a) Priority rule: FCFS
Duration (days) date (days) (days) \(days)Cost of delay
ratio
’ sequences: A, B, C,D, E, F
(b) Priority rule: SPT (days)
sequences:C, A, F, B, E, D Nil Nil
95+15=110 185 NI
(c) Priority rule: LPT 15
’ sequences:D, E, B, F A, B 20 110+20=130 200 Ni Nil Ni
(d) Priority rule: EDD Nil Nil Nil
’ sequences:C, E,A,B, FD 10 130+10=140 175
Nil Nil Nil
D 30 140+30=170 235
(e) Priority rule: TSPT ’ sequences: For 150 150/25=6
TSPT rule, it is specified that the jot3 25 170+25=195 180 15
cannot be delayed by more than 60 days if we apply the Ni Nil Ni
violates the constraints, the sequence will be SPT rule. If none of ue 18 195+18=213 220
examine this, we should know the wait time of identical for the SPT and TSPT rule
determined as below: the jobs as per SPT rule, whichis Job sequence : E, A, B, C, D, F
Job sequence
(SPT rule) Processing Arrival Start Wait Combined CriteriaSequencing Rules
Duration (days) date (da,'s) date (days) time (days) (a) Dynami lack (DS) rule
C Operation (S/RO) rule.
A
10 112 112 Nil (b) Dynamic lack per Remaining
15 95 (c) Critical Katio (CR) rule.
F 122 27 are described below.
Ine dynamic sequencing rules repeatedly at
18
B
20
130 137 1S 7
Slack (DS) rule-When the least slack rule is used
dynamic slack rule.
110 155 +2 45 (c) Dynamic jobs, it is known as
25 each machine/ work centre for sequencing the this rule,the
D
30
125
1752 50 Remaining Operation(DS/RO) rule-In remaininc
125 (b) Dynamic: Slack per of operations
The SPT sequence 200 75 available for the job to the number
results in delay of 75 days for job D, ratio of total slack time
days specified. the60 operationis obtained.
Therefore, job Dwould be which is more than and including the current
B, D, E. scheduled before job E(as per SPT
the sequence would be C, A, F, rule)
 PPC and
62 Productionn System, PPC and Production Systems 63
Total slack time
operations remaining
(9ós/RO Rule
DS/RO ratio = Total number of current operation Solution:
including the
Arrival Total Dynamic slack
ratio is scheduled first. Job Due time
The job with the smallest DS/RO No. time (hrs) processing (hrs) (Available time
critical ratio rule is designed to
(c) Critical Ratio rule (CR)The give
schedule priority t (24 hour basis) time (hrs) Total operation time)
jobs that have the most urgently needed work to meet the shipping 2.0 + 12,0, 20 20 - 14=6 hrs
Due date-Date now 1 12
14 2.0 + nil 12 12 --2 =10 hrs
Critical ratio (CR) = Days required to complete thejob 2 50 -34 = 16 hrs
15.5 4.0 + 30 50
3 25- 13 = 12 hrs
15.5 3.0+ 10 25
4
Due time- Time now D.D -D.N 6.0 + 20 45 45 - 26 = 19 hrs
or 5 16.5
38- 29 = 9 hrs
Or Time required to complete the job L.T.R 6 18.0 4.0 + 25 .38
where D.D. = due date D.N. = date now Calculation of DS/RO ratio
L.TR. = lead time remaining or processing time Remaining Operations (RO) DS/RO ratio
Job No. Dynamic Slack (DS)
2+1= 3 2.0
Days remaining 6
or C.R. 1
Days required for processing Nil + 1 = 1 10 = 10
10
4 + 1 = 5
16 3.33
5
Time remaining 16
3 3 + 1 = 4 12 = 3.0
or
Time required for processing 4
12 1 =6.33
2 +1=3
19
The job with the lowest CR is given highest priority in sequencing. 5
4 + 1 =5
=1.8

Ilustration. ABCcompany has 6 jobs arriving at random at several work stations 6

9
and passing through them, requiring different processing times. For a particular work 5, 2
rule : 6, 1, 4, 3,
station, the data is given below. Sequence as per DS/RO
(1) (2) (3) (4) (5) (6) (7)
Due
(i) efiticalratio rule Available
Critical ratio
fvailable time
Job Arrival Processing Due time No. of Time reqd. Processing
fo subsequent. time Job time (hrs,) Processing time
time time regd. for this SUbsequent time (hrs.)
Hours) No.
(Hours) operation operation operation =2.0
(Hours) 4.0
=1.5
2
20 1 3.0
1 12 o'clock 2.0 4.00 PM 2 12 2
4.5 = 1,125
12 2 4.5
4
2 2.00 PM 2.0 5.00 PM nil nil 3,5 = 1.166
50 4
3.30 PM 4.0 8.00 PM 4 30 3 3.5
25 3
Z.5 = 1.25
4 3.30 PM 3.0 7.00 PM 3 10
45 4 7.5 1 =3.5
4.30 PM 6.0 12.00 PM 2 20 6
38 14.0
4.0 8.00 AM 25 5
6 6.00 PM 4 4
next day
5, 2, 1,6
CR. :| 3, 4,
Sequence these jobs according to (0) DS/RO rule and (i) Critical ratio rule. Sequence as per
 65
64 PPC and| PeCandProductionSystems

Evaluating Sequencing Rules

Production Systa Solution:
D. A, B,CE
In deciding which sequencing rule performs best in a EDDrule sequence:
particular
necessary to determine the criteria that will be used to evaluate job shap, t, Due date Job latenessa
and Flow time (days)
The most commonly used criteria are compareete nde Job
Processing
time (days) (days) (days from now)
(a) Average flow time-It is the average amount of time Nil
each job 12 17
shop (system). spends inte D
12
10
22 18
A 30
22
9
Average flow time or Total flow time for all jobs 27
Average completion time Number of B
6
36 1
jobs in the system C 43
42
(b) Average number of jobs in the 7
E
of jobs in the shop each day. system or shop-It is the average numbe 43 143.
22
Total

Average number of Total flow time for all jobs completion time = 43 days
jobs in the system (1) Total flow time = 143 days
Total
Total processing time (i) Total flow time 143 =28.6 days
(c) Average job
lateness-It is the average amount of time that each jobs actual
Completion time (or date) Average flow time= No. of jobs 5
exceeds its promised due time (or (ii)
date). Average number of)
Total flovw time 143 = 3.325 jobs
Total processing time 43
Average job lateness= Total job lateness
Number of jobs in the (v) jobs in the system
22 = 4.4 days
(d) Change over
cost-It is the total cost of making all the system
Total job lateness
in a group of jobs. lateness = No. of jobs 5
machine change overs (v) Average job
Illustration. The processing time and due dates for 5
in the table
below: jobs, A, B. C, Sequencing Problems discussed so
D&Eare given scheduling, loading and sequencing have been specified
Job work-centres as
Processing time (days) Several techniques for unique and they move through the job
A Due date (days from Manyjobs in job shopsare operations are same for some jobs,
environment,
B
10 now) far.
sheets. The sequences
of assembly line
by the route work centres. In
C
8
18 varying loads in different essentially the same. The
6 22 orders may require durations and the sequences may be of the following
combination of one or other
D
12 27 most operations, their
models will differ in the
7 17 Various sequencing
Sequence these
(0) Total
jobs according to EDU rule 42 factors:
jobs 'n.
and calculate (a) The number of machines/equipments
(ii) Total completion time. 'm'.
filow time. number of shop.
(ii) Average flow time.
(b) The
production facility, viz., flow shop or jobviz, 'static' or 'dynamic.
(iv) Average number of (©) The type of which the jobs arrive at the facility, evaluated (e.g. utilization
jobs in the system. (0) The manner in alternatives will be
(v) Average job
lateness. The criterion by which the sequencing processing time, the average lateness of
(e)
machines/equipments as measured by the inventory.
O
time and the minimization of work- in-progress
Jo0, the total set up
may be classified as:
The solution techniques
(a) Machines in series.
 67

ProductionSystems
66 PPC and
(b) Machines in parallel.
(c) Series- paralll machines.
Production Sysa PPCand
(b)Consider the
shortestprocessing(SPT)
sequencing rule. Then the job sequence
Flow time (mins.)
C B,A.
The sequencing problems are referred to as 'n'job-'m' isF E, D, Processing/operation time (mins.)
problems. machine problems ar Jobsequence
1 1+2=3
1

Model No. I : Sequencing njobs on one machine-In 2 3+3= 6

one machine, the processing time of each job and their due dates of sequencing E 3 6+4= 10
Apriority rule is then decided in order to delivery
are requng 4 10 +6 = 16
rules are possible such as: First come, firstsequence the various jobs accordingly. Vat.
served (FCFS) method Last time, first senw
C 6 16 + 7 = 23
7
(LC FS) method, due date method, shortest processing time (SPT) method, Longg Total = 59
A
processing time (LPT) method.
It has been established that the
SPT is the best method in terms of all
criteria. The most common comparisian compais 59 = 9.83 mins
are: criteria for various methods or priority rulg Average flow time 6 hence the choice.
(a) total flow time
minimizes the average flow time and material
typesetter of printingmaterial.
(b) average flow time The SPT rule Typesetting Solutions is a major
Illustration.Ganapati typesetting printing
(c) average lateness. recently received six orders for processing times, and due
based at Indore. It has order of their arrival,
their according to
Illustration. The operation time for 6 jobs are given below.
which minimizes the average Table shows the sixe jobs in the
the customers. Sequence the given jobs methods
these
flow time. Find the sequence dates (days hence) of
delivery to
date, random, and
SPT. Compare
FCFS, LCFS, due
Job (n) the priority rules ofnmean flow timeand average
lateness.

A
Operation time (f) on the criteria of
Processing
Due date
(days from
Imins. Jobs
B time the start)
6 mins. (n the order
C (days)
D
4 mins. of arrival)
3 mins. 3 10
A 7
F
2 mins. 7
1 min. 4 4
C
Solution. 2 8
(a) Consider the D 5 12
is A, B, C, D, E, F. longest processing (LPI)
sequencing rule. Then the job F
Job sequence
Processing 1 operation time (mins.) sequence on one machine
Solution. Scheduling n jobs(FCFS) Method
Served
7 Flow time (mins.) ()Firm Come, First Due Date Flow Time Late by
Schedule of Processing time (days from now) no. ofdays
6
7
(days)
4 jobs (days) 0+3= 3 0

137+6= 13
D
9 0
A 3 3+7= 10
2
+4 = 17 10 7
17+3 = B 7 10 + 4 = 14
1
20 +2 =20 4
7
14 + 2 = 16
12
22 +1 =22 2
4
16 + 5 = 21 13
Average flow time = 7+13 +17 + 20 +22 + 23 102 23
5 17
6 = 17 mins. 12 21 + 8 = 29
6
F
8.166666667 Average per job
 69
68
PPC and.
Total Flow Time = 3+ 10+ 14 + 16 + 21 + 29 = 93 davs
Mean Flow Time = 15.5 days
Production Sip, PPCandProductionSystems

(v)'Shortest
Processing Time(SPT)
Method
Due Date
Fow Time
Late by
no. of days
Processingtime (daysfrom now) (days)
(ii) Last Come, First Served (LCFS) Method Scheduleof| (days) 0+2=2
Schedule of Processing time Due Date Flow Time jobs 4
2+3=5 0

jobs (days) (days from now) (days) Late by 2

3 5+4=9 2
no. of days A
7 9+5= 14
6
F 8 12 0+8 = 8
4
8 11
4 14 +7= 21
5 5 10 17
8 8+5 = 13 29
5 E 21 + 8 =
D 7 perjob
2 4 13 +2 = 15 11 8
12
6 Average
C 4 7 15 +4 = 19 12 F days
+ 29 = 80
B 7 10 19 + 7 = 26 16 2+5 +9+ 14 +21
Time=
A 3 9 26 + 3 = 29 20 Total Flow = 13.33
days methods
MeanFlowTime
Time various
MeaniFlow
comparisonofthe
Total Flow Time = 8+ 13 + 15+ 19 + 26 + 29 = 11011.33333333 Average per jt A Aeragelateness per
job 15.5
Mean Flow Time = 18.33 days days Method 18.33
8.17
13.83
(i) Due Date Method FCFS
11.33
18.67
Schedule ofProcessing time Due Date Flow Time Late by
LCES 6
10.83 13.33
jobs (days) (days from now) Due Date
(days) no. of days
D Random haveto
where njobs inall
2 6
4 0+2 = 2
C problems same
4
7 SPT isusedin almostthe
E 5
2+4 = 6 0 method-Johnson'smethod Theprocedureis
6+5= 11 machines.
A 3 3 Johnson's three, ormore followingcases:
B 7
11 +3 = 14 5 sequerncedon tWo, modification. thismethodforthe
10 dc applicationof
14 +7 = 21 11 onlyslight
F 8 12 cases, with understandthe
21 + 8 = 29 17 try to machines
Let us two
Sequencing njobson machines
Total Flow Time = 2+6+ 11 + 14 t 21 + 6 Average perjob 1. on three
Mean Flow Time = 13.83 days 29 = 83 davs Sequencingn jobs mmachines
2. Sequencing njobson
machines jobsonthe
(iv) Random Method 3. two order ofallthe the twO
on processing
Schedule of Processing time Due Date
Flow Time Sequencingn jobs twomachines, the
processing times ofall the
jobson
jobs (days) Late by on
(days from now) sequencingn jobsthesame. The
B 10 (days)
0+7=7
no. of days In is always
machines
F 8 12 LWO
D 2 4
7+8 =15 3
machines are given.
15 +2 = 17
A 17 +3 = 20 13 Machines
completedand nojobis
11 facilities.
previousjobis between
C 4 7 20 + 4 = 24
17 Jobs waiting
5 8 24 + 5 = 29 beforethe
21 started previousjobis
be whilethe
jobcan
Total Flow Time =7+ 15 + 17 + 20 + 24 + 29 = 112 days
Mean Flow Time = 18.67 days
10.83333333 Average per joD O Other any otherjob
allowed to pass
70
pPCand Productians, 71

Johnson's Rule PPCandProductionSystems

WC,.
Step No. 1:Listthe procesing/operation times for''n' jobs on the smallest timeeis 1.5 hours for job Donbeginningof the sequence. atie
machines. twov The next the job next tojob Cfrom
the
and F on WC,. Since
there is
Das
Assian jobsmallest jobs E Assignthe
Step No. 2:Scan all the procesing/operation times for time is 2.0 hours for smaller sub-script i.e. jobE. jobafter
work centres and select the shortest processing/operationthe' n' jobs on the next
The next choose the job havingbeginningofthesequence. The thejobFand
machine.
time in either bohn between jobs
the
E& F
from the
nextjobafterjobD, to be accommodatedinthe
gap between
Step No. 3:If the shotest processing/operation time happens tah F as job Bhas
iob F. The last job A.
the first work centre/machine, place that job, first in the sequence. to be far a inh Fis inthe sequencei.e. EFBA
If it is at job
work centre/ machine, place the job last in the sequence. the thelast thesequenceisCD
Step No. 4 : Remove the job assigned to the sequence in step No. 3
froms
Hence
Flow Time andIdle Time
consideration (i.e. cross off both times for the assigned job). Cumulative
Calculationof
Step No. 5:Repeat steps 2,3 and 4 until all the jobs are assigned into the sen. charts
Note : In the case of a tie (i.e. a job having the same Method-UseofGantt (F) 6.25
(B) 10.25 (A)
12.25

operation time on bo (D 2.25

(E) 4.25
machines or two jobs having the same operation time on either of the machi 0 (C) 0.75
(2.0)
(4.75)
choose the job with the smallest sub-script first for assigning into (4.0
when job Aand job Bhas the same time on either the sequences WC, (0.75) (15) (2.0) (2.0)
17 0
machine
job Afirst as compared to job B). On the other hand, if any
M, or machine M, c 0
|10.25(F) 13.75 (B)
16.0
6.25 (E)
job
operation time on machine M, and M,, then give preferencehasto the the
same, proces 0.75 (C) 3.25 (D)
(2.25) (1.0)
operation time on M, to be considered first for assigning that job processing tin (3.5)
The above rules are known as 'thumb into the sequence. (3.01
i4.0)
rules' to be followed in case of a tie betwe WC, (0.75) (23) Time scale
two jobs or between two machines.
Illustration. The following data is available for six jobs A, B, C, D, E&F = 17 hours
to be processed on two work
centres, WC, and
whicha time or cycle time 4.75 Hours
WC,. The estimated Total flow
two work centres, Sequence processing tine
are given in hours for the six jobs at the Idle time on
WC, =
Hours
the total flow time to these jobs' so tha WC, = 0.75
complete all the jobs and the total idle times are Idle time on 5.5 hours
minimized. idle time = 28.50
Total 12.25 + 16.25=
operation time =
Estimated processing times (hours) Total cycle time
Job Check idle time= Twice the
WC, operation time +
Total
= 2 x 17
2 WC, Total 28.5 + 5.5 = 34 Hours

4 1
C 2.25 machines
0.75 three
D
1.5 2.5
Sequencing n jobson
E 2.0 3.0 machinesinseries
F 2.0 4.0 'n'jobs, m =3
jobs.
Solution, Job Chas the
3.5 No. passing of
shortest processing time in
hour), As this time happens to be on WC, assign job C either work
Cross out the processing times for job C, which is
as the
first job incentre
the
(i.e. 0.75 Machunes
Johnson's rule.
already sequence. known as n/3
remaining processing times, job Ahas the shortest time ( i.e. 1 assigned. Scanning the
Jobs
extension ofJohnson's
rule
WC,. Assign job Aas the last job in the sequence and cross out theHour) inwork centre is given by followingexample.
times for job A.
The solution
explained in the
This rule is
 3

72
PPC and 73

Example : Consider 4jobs. ABC& D which have tto be

M, M, and M,. The processing times for each job on
given in the table.
on
each the three m
of
PPC processed Production
s andProductionSystems
efficient heuristiC
procedure suggested by Campbell, Dudek and
sequence. The
Smith, known
CDKalgorithm extends
three mati An used to find the optimal a ne¥r optimal
e the CDS algorithm, isto a general n/m problem and provides problem.
solution.
Processing time (hours) on machines rule
the n/3 Johnson's examples illustrates the CDS algorithm
for n/m
Job The following algorithm generate (m - 1) - 'n' job x 2
M, M, Given that there are m'
machines, the
12 6
M, machines problem.
three- 'n' jobs x 2 machines
problems
B will be (4 - 1) or
C
6 4 10 In this example, there three solutions.
7 8 will have
which means we
Processing time (hours) on machines
D
8 6
3
Using Johnson's rule, find the 7
M, M4
Step No. 1 :Form a new optimal sequence. Solution : Job M, M,
machines as shown below:
matrix converting the three 11
14
machines into two Imadr A
B 18 15 18 13
14 18
4 11
Job Processing time in hrs C
11 27 32 21
A
M, +M, 16 14 16
12 + 6= 18 M, + M, E
operation
machines problem will contain the
C 6+4 = 10 6+ 10= 16 Solution (1), The first 'n' job x 2
M, & M, as given below:
D
7+5=12 4+ 8= 12, times of the first and the last machine i.e.
Step No. 8+3 =11 5 + 6=
11 Processing time in hours
The optim2:Apply
al Johnson's rule as stated in model No, 3..
3 + 7 = 10

:To sequence
Job M, M,
Note
get optimal convert an n/3 isBAcD
(a) The sequence, certainproblem into an n/2
A 7 14
13
Applying Johnson's rule
the sequence will be
on machine smallest
M,. duration condi
on tions have to be problmet,em and apply 18
18
(b) The
smallest duration
machine M,is at least as They are Johnson's rue, D
4
11 21 E A D B
on machine M,. on great as the largest duration
Since the above machi ne M, is at
least as
E 6 16

optimal sequence. Eventwoif conditions are met great as the Applying Johnson's rule, the sequence will be
conditions are not met,example, the largest
optimal solution. the in this duration Solution 2. In this, the 'n' jobs x 2 machines problem is derived by adding the
the rule still solution gives processing time on the first two machines (M, + M,) and the last twO machines (M, +
Sequenci
n' inhs ng n jobs on m
and provides a near
an
M) for each job.
elapsed time. 'm' machines, flow shop,machines
Static arrivadl
Processing time in hours
M, + M,
patern, Job M, + M,
Jobs minimizations of total
B
7+ 11 = 18
18 + 15 = 33
2 + 14 = 16
18 + 13 = 31
Applying Johnson's rule
the sequence will be
Machines 4 + 11 = 15 14 + 18 = 32
D 11 + 27 = 38 32 + 21 = 53 E A
E 6 + 16 = 22 14 +16 = 30
74 PPC and
Pr oduct
Solution 3. Inthis, the 'n' jobs x2 machines problem is derived
ion :
processing time on thefirst three i.e.,(M, + M, + M,) andthelàst by at ing
+ M, + M,) for each job. three maching
Processing time in hours
Job M, +M, +M, M, +M, +M,
A 20 27
B
Applying Johnson's rule
51 46 the optimal sequence willbe
C 29 43
D 70 80
E 36
ACE D B
46
Since there are m= 4 machines, there will be (m -1) or (4 - 1)
x 2 machines problems generated by this heuristic. =3 nos. of 'h'w
The three sequences obtained are:
1. S, ’ CEADB
2. S, -’ CE|D BA
3. S, - ACE DB
From the above three,
flow time or cycle time has sequences, the sequence which gives the
to be chosen as the optimal minimum totl
drawing the Gantt Machine loading chart as sequence. This is done by
Sequence S,: illustrated below:
Machines
0(C)4 (E) 10 %4: 17 (D) 28 (B) 46
M
(4) (6) (7) (11) (18) Jdling
0 4 (C) 15 l= ldling
(E) 31 (A) 42 (D) 69
M, (B) 84
(4) (11) (16)
J= ldling (11) (27) (15) Idling
15| (C) 29 31 (E) 45(A)47
69 (D) 101 (B)
M, Idling
l19
(15) (14) l(2) (14) (2) (22)
(32) Idling
| l= ldling (18)
0
29| 47 (E)63
M. 77 101
ldling D) 122
B) 135
(29) (18) (16) (04)
(24)
I
ldling (21) 03)