Controlling a manufacturing

system efficiently

IE450
Fall 2005
Dr. Richard A. Wysk

Agenda

Present a simple system

Show state of the art in scheduling
Define implementation specifics
Example problem

Readings
Chapter 7 Factory Physics

Illustrate
Control Requirements
3

M1

2
1

M2
8
UL

Task
Number
1
2
3
4
5
6
7
8

Task
Name
Pick L
Put M1
Process 1
Pick M1
Put M2
Process 2
Pick M2
Put UL

Some Observations about this

Perspective
Generic -- applies to any system
Other application specifics
Parts
Number
Routing
Buffers (none in our system)

System and scheduling specifics

Flow shop
Two machine system
Optimal formulation

Johnsons Algorithm (1954)

1. List all jobs
2. Choose shortest processing time
1.
2.

If it belongs to the 1st machine, schedule it at the 1st

machine in first available slot
If it belongs to the 2nd machine, schedule it at the 2nd
machine in the last available slot

3. Cross out that job

4. If last job, end
5. Go to step #2

Johnsons Algorithm (1954)

Operations Routing Summaries for a family of parts (M1 M2)
Part

P1

P2

P3

P4

M1

M2

Optimal sequence: P1 - P3 - P4 - P2
Is the schedule actually optimal in reality?

Traditional schedule vs.

Realistic schedule (blocking effects)
M1
M2

4
1

2
3

Make-span: 25

M1
M2

Can not begin 4

until 3 moves

4
3

+ Material Handling

2
4

Make-span: 29

Actual optimal sequence

M1
M2

4
1

Optimum by Johnsons algorithm

M1
M2

3
1

Actual optimum

Make-span: 29

4
3

Make-span: 28

Things to be considered for higher

fidelity of scheduling
Deadlocking and blocking related issues must be
considered
Material handling must be considered
Buffers (and buffer transport time) must be
considered

Jacksons Algorithm (1956)

1. List all jobs as M1 M2 , M2 M1, M1, M2
2. Schedule M1 M2 , M2 M1 using
Johnsons algorithm
3. Order M1 M2 , M2 M1 jobs
4. Place M1, M2 arbitrarily between M1 M2 ,
M2 M1

Jacksons Algorithm (1956)

Operations Routing Summaries
Part #

Sequence

Times

M1 M2

51

M1

M2 M1

34

M2

Optimal sequence:
M1: P1 - P2 - P3
M2: P3 - P4 - P1

Is the schedule actually optimal in reality?

Schedule Implementation
If no buffers exist, it is impossible to implement
the schedule as the optimum schedule by
Jacksons rule
Even if buffers exist, several better schedules may
exist including the following schedule:
M1: P1 - P2 - P3
M2: P1 - P3 - P4

Simulation specifics
Very detailed simulation models that
emulate the steps of parts through the
system must be developed.
Caution must be taken to insure that the
model behaves properly.
The simulation allocates resources
(planning) and sequences activities
(scheduling).

Why Acquire (seize) together?

To avoid deadlock
P2 (M1-M2)

M2

M1
Legend:

P1 (M1-M2)

:part, done

:part, being processed

If we acquire robot and machine separately

the robot will be acquired by the P2
a deadlock situation will occur

If we acquire robot and machine at the same time

the robot will not be acquired until M2 becomes free

Conclusion
Control is the implementation of schedules
Schedules dictate much of the system
efficiency
Implementation is not that hard