Professional Documents
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Operations Scheduling
MRP Example 1
The production manager at Aldershot Manufacturing wishes to
develop a materials requirements plan for producing chairs over an
8 week period. She estimates that the lead time between releasing
an order to the shop floor and producing a finished chair is 3 weeks.
The company currently has 260 chairs in stock and no safety stock.
The forecast customer demand is for 150 chairs in week 1, 70 in
week 3, 175 in week 5, 90 in week 7 and 60 in week 8.
Inventory/Week
Demand
On-hand
Produce/Order
260
150
70
175
90
60
110
110
40
40
135
90
60
MRP Example 1
60
90
135
W1
W2
W3
W4
W5
135
W6
W7
90
W8
60
60
135
W1
W2
82
W3
W4
W5
135
W6
W7
90
W8
60
What is the minimum required capacity that will allow to meet the
forecasted demand?
Round down [8/3] = 2 production cycles
Round up [285/2] = 143 units 143 in one cycle & 142 in the other
143
83
82
60
53
7
W1
W2
W3
W4
W5
135
W6
W7
90
W8
60
Characteristics of the
Job Shop Scheduling Problem
Job Arrival Pattern
Number and Variety of Machines
Number and Skill Level of Workers
Flow Patterns
Evaluation of Alternative Rules
Terminology
Machine 2
Machine 3
Finished Products
Machine 4
Input parts
Machine 2
Input parts
Machine 3
Input parts
Machine 4
Finished Products
Terminology
A job shop does not have the same restriction on workflow as a flow shop. In a job shop, jobs can be
processed on machines in any order
Each job requires m operations (one on each machine) in a specific order, but the order can be different
for each job
Real job shops might not require to use all m machines and yet may have to visit some machines more
than once
Input parts
One Machine in a Job Shop
Machine i
Finished Products
Terminology
Flowtime: The amount of time a job spends from the moment it is ready for
processing until its completion, and includes any waiting time prior to
processing
Average WIP level is directly related to the time jobs spend in the shop
(flowtime)
For a single machine problem, the makespan is the same regardless of the
schedule, assuming we do not allow any idle time between jobs
FCFS: First Come First Served. Jobs processed in the order they arrive to
the shop. Viewed as a fair rule.
SPT: Shortest Processing Time. Jobs with the shortest processing time
are scheduled first. Popular method to determine the next homework
assignment by many students.
EDD: Earliest Due Date. Jobs are sequenced according to their due dates.
CR: Critical Ratio. Compute the ratio of processing time of the job and
remaining time until the due date. Schedule the job with the largest CR
value next, however, if the job is late, the ration will be negative, or the
denominator will be zero, and this job should be given highest priority
(Processing time remaining until completion) / (Due Date Current Time)
FCFS Example
Flowtime: The amount of time a
job spends from the moment it is
ready for processing until its
completion, and includes any
waiting time prior to processing
Earliness: The amount of time a
job a early
Processing
Due date
Job
Processing Time,
pj, in Days
12
18
Completion Flowtime
Lateness
Earliness
Tardiness
Job j
pj
Dj
Cj
Fj
Lj
Ej
Tj
-1
12
-4
13
13
15
15
11
11
18
21
21
Average
12.8
3.2
4.2
Max
21
11
11
SPT Example
Shortest Processing Time
is optimal for minimizing
Average and Total flowtime
Average waiting time
Average and Total lateness
Processing
Due date
Job
Processing Time,
pj, in Days
12
18
Completion Flowtime
Lateness
Earliness
Tardiness
Job j
pj
Dj
Cj
Fj
Lj
Ej
Tj
12
-11
11
-1
18
14
14
-4
21
21
13
13
Average
9.4
-0.2
3.2
Max
21
13
11
13
SWPT Example
Job
Processing Time,
pj, in Days
12
j 1
18
-sequencing
p1
w1
p 2
w 2
p n
w n
Completion
Flowtime
Job j
Pj
Dj
wj
pj//wj
Cj
Fj
wjFj
Lj
Ej
Tj
0.4
10
-2
12
0.5
-9
18
1.5
36
-9
1.67
14
14
42
3.5
21
21
42
13
13
Ave
9.8
27.2
0.2
4.2
Max
21
42
13
13
EDD Example
Earliest Due Date
Processing
Due date
Job
Processing Time,
pj, in Days
12
18
Completion Flowtime
Lateness
Earliness
Tardiness
Job j
pj
Dj
Cj
Fj
Lj
Ej
Tj
-2
14
14
12
15
15
18
21
21
Average
11.8
2.2
0.4
2.6
Max
21
CR Example
Critical Ratio:
Processing time remaining until completion
Due Date - Current Time
Job
Processing Time,
pj, in Days
12
18
Subtract Current Time
Job j
pj
Dj
CRj
Job j
pj
Dj
Dj-CT
CRj
0.875
12
0.200
12
0.083
-1
-5.000
0.833
-3
-0.667
0.500
18
11
0.545
18
0.333
Schedule jobs 1 4 3 2 5
CR Example (cont)
Critical Ratio:
Processing time remaining until completion
Due Date - Current Time
Processing
Due date
Job
Processing Time,
pj, in Days
12
18
Completion Flowtime
Lateness
Earliness
Tardiness
Job j
pj
Dj
Cj
Fj
Lj
Ej
Tj
-1
14
14
12
15
15
18
21
21
Average
13.2
3.6
0.2
3.8
Max
21
Comparing Methods
Method
FCFS
SPT
SWPT
EDD
CR
Fj
Lj
Ej
Tj
Ave
12.8
3.2
4.2
Max
21
11
11
Ave
9.4
-0.2
3.2
Max
21
13
11
13
Ave
9.8
0.2
4.2
Max
21
13
13
Ave
11.8
2.2
0.4
2.6
Max
21
Ave
13.2
3.6
0.2
3.8
Max
21
The rule that minimizes the mean flow time of all jobs is SPT.
EDD Example
Earliest Due Date
Processing
Due date
Job
Processing Time,
pj, in Days
12
18
Completion Flowtime
Lateness
Earliness
Tardiness
Job j
pj
Dj
Cj
Fj
Lj
Ej
Tj
-2
14
14
12
15
15
18
21
21
Average
11.8
2.2
0.4
2.6
Max
21
Iteration 2
Iteration 3
Job j
pj
Dj
Cj
Fj
Lj
Ej
Tj
-2
14
14
12
15
15
18
21
21
Average
11.8
2.2
0.4
2.6
Max
4
21
2
6
-2
2
2
6
0
12
10
10
-2
18
16
16
-2
21
21
15
15
-2
12
-9
18
-9
14
14
21
21
13
13
Average
9.8
0.2
4.2
Max
21
13
13
Lawlers Algorithm
Goal: Scheduling a set of simultaneously arriving tasks on one
machine with precedence constraints to minimize maximum
lateness (tardiness).
Precedence constraints occur when certain jobs must be
completed before other jobs can begin.
Algorithm:
Tasks are ordered from last order to complete and finishing
with first.
At each step selection is made from the jobs that are not
required to precede any other unscheduled job.
Fi d i
Select a job that achieves min
iV
Lawlers Example:
Processing for all jobs is 1 day
1)
2)
3)
4)
5)
6)
Lawlers Example:
1
D2=5
Due date
Completion Flowtime
D1=2
3
5
D3=4
D4=3
D5=5
D6=6
Processing for all jobs is 1 day
Lateness
Earliness
Tardiness
Job j
pj
Dj
Cj
Fj
Lj
Ej
Tj
-1
-3
Average
3.5
-0.67
0.67
Max
Gantt Charts
Pictorial representation of a schedule is called Gantt Chart
The purpose of the chart is to graphically display the state
of each machine at all times
Processing
Horizontal axis time
Vertical axis machines 1, 2, , m
Machine 1
Machine 2
Processing
Machine 1
Machine 2
1
1 2
3
5 6
11
Time (days)
Job 1 Job 2
Job 1 Job 2
Machine 1
3/1
5/2
Machine 2
2/2
1/1
Gantt Charts
Processing
Job 1 Job 2
Machine 1
Machine 2
Machine 1 1
Machine 2 2
1
3
Machine 1
Machine 2
5 6
11
Time (days)
11
Time (days)
11
Time (days)
2
3
Processing
5 6
Job 1 Job 2
Machine 1
3/1
5/2
Machine 2
2/2
1/1
Machine 1 1
Machine 2 2
1
3
5 6
Example
Processing time / machine number
Job
Due
date
4/1
3/2
2/3
16
1/2
4/1
4/3
14
3/3
2/2
3/1
10
3/2
3/3
1/1
Find a solution!
M1
2
M2
M3
4
3
3
1
3
4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
Deterministic Scheduling
with Multiple Machines
Example
MetalFrame makes 4 different types of metal door frames.
Preparing the hinge upright is a two-step operation.
Jobs
Natural schedule:
Is it optimal?
Machines
Total time
14
15
2
1
4
2
3
14
4
16
22
min ai , b j min a j , bi
Johnsons Rule says that job i precedes job j in the optimal sequence if
Algorithm:
min ai , b j min a j , bi
Step 1: Record the values of ai and bj in two columns
Step 2: Find the smallest remaining value in two columns. If this value in
column a, schedule this job in the first open position in the sequence; if
this value in column b, schedule this job in the last open position in the
sequence; Cross off each job as it is scheduled
Example (cont)
Jobs
Machines
Total time
14
15
Johnsons schedule:
4xxx
4xx3
4x13
4213
Natural schedule:
job
2
1
4
2
Johnsons schedule:
Is it optimal?
2
4
14
16
22
3
2
14
17
22
Sequencing Theory:
The Two-Job Flow Shop Problem
Assume that two jobs are to be processed through m machines.
Each job must be processed by the machines in a particular order,
but the sequences for the two jobs need not be the same
Graphical procedure developed by Akers (1956):
Determine a path from the origin to the end of the final block that does not
intersect any of the blocks and that minimizes the vertical movement.
Movement is allowed only in three directions: horizontal, vertical, and 45degree diagonal. The path with minimum vertical distance corresponds to
the optimal solution
Job 1
Operation
Job2
Time
Operation
Time
(A)
Lacquering (B)
Polishing
Sanding
(C)
Job2
Time
10+(3+2)=15
or
Time
14+2+2=18
C
B
Example
14+4=18
Job 1
D
A
A
B
J1 B
J2 A
C
D
B
7
J1 B
J2 A
Job2
11
D
B
C
15
C
C
18
There are a variety of factors that contribute to the difficulty of the problem
Let t1, t2, , tn be the time required to complete the respective tasks
The total work content (time) associated with the production of an item, say T,
is given by
t
i 1
Ranked positional weight technique: the method places a weight on each task
based on the total time required by all of the succeeding tasks. Tasks are
assigned sequentially to stations based on these weights
_
1
2
2
2
2
3, 4
7
5
9, 6
8, 10
11
12
6
6
2
2
12
7
5
1
4
6
7
Task
Positional Weight
1
2
3
4
5
6
7
8
9
10
11
12
70
58
31
27
20
29
25
18
18
17
13
7
Tasks
2, 3, 4
5, 6, 9
7, 8
10, 11
12
Processing time
12
14
15
12
10
Idle time
Task
Immediate
Predecessors
Time
12
2
3
4
5
6
7
8
9
10
11
12
1
2
2
2
2
3, 4
7
5
9, 6
8, 10
11
6
6
2
2
12
7
5
1
4
6
7
C=15
Tasks
2,3,4
5,6,9
7,8
10,11
12
Processing time
12
14
15
12
10
Idle time
15
Cycle Time=15
T1=12
T2=6
T5=2
T7=7
T10=4
T12=7
T3=6
T6=12
T8=5
T11=6
T2=6
T4=2
T5=2
T9=1
T10=4
T12=7
Evaluate the
balancing results by
the efficiency ti/NC
The efficiencies for
C=15 is 77.7%,
C=16 is 87.5%, and
C=13 is 89.7% is
the best one
Tasks
2,3,4
5,6,9
7,8
10,11
12
Processing time
12
14
15
12
10
Idle time
C=16
Station
Tasks
1 2,3,4,5
Idle time
6,9
7,8,10
11,12
C=13
Station
Tasks
2,3
4,5,7,9
8,10
Idle time
6
11,12 The production rate
has to be reduced from
0
one unit/15 minutes to
one unit/16minute;
Tasks
2,3,4
5,6,9
7,8
10,11
12
Processing time
12
14
15
12
10
Idle time
C=16
Station
Tasks
1 2,3,4,5
Idle time
6,9
7,8,10
11,12
C=13
Station
Tasks
2,3
4,5,7,9
8,10
11,12
Idle time
13 minutes appear
to be the minimum
cycle time with six
station balance.
Increasing the
number of stations
from 5 to 6 results
in a great
improvement in
production rate;
Customers arriving
Service Facility
Discouraged customers leaving
The study of the waiting times, lengths, and other properties of queues.
(Mathworld)
Applications:
Telecommunications
Health services
Traffic control
Predicting computer performance
Determining the sequence of computer operations
Airport traffic, airline ticket sales
Layout of manufacturing systems
http://www.bsbpa.umkc.edu/classes/ashley/Chaptr14/sld006.htm
FIFO data-structures
Queue discipline
System capacity
Single or Batch
May depend on the number of customers waiting state dependent
Stationary or Non-stationary
Queue discipline
Preemptive case
Non-preemptive case
Shorthand: A / B / X
Assumes: Y is infinity,
Z = FCFS
Symbol = Explanation
A
B
X
Y
1, 2, ... , infinity
1, 2, ... , infinity
t2
t3 t4
t5
t6
t7
Time, t
past state of the system does not help to predict next arrival / departure
n-1
n+1
Calculating Expected
System Measures for M/M/1
CHARACTERISTIC
Utilization
Exp. No. in System
Exp. No. in Queue
Exp. Waiting Time
Exp. Time in Queue
Prob. System is Empty
SYMBOL
L
Lq
W=L/
Wq=Lq/
P0
FORMULA
/
/ ( ) = / (1-)
2/ ( ) = 2 / (1-)
1 / ( ) = / (1-)
/ ( ) = 2 / (1-)
1 ( / ) = 1 -
Calculating Expected
System Measures for M/M/m
http://www.ece.msstate.edu/~hu/courses/spring03/notes/note4.ppt
Calculating Expected
System Measures for M/M/m
Assumption
- m servers
- all servers have the same service rate
- single queue for access to the servers
- arrival rate n =
- departure rate
n , n 0, 1, 2, , m 1
n
m , n m, m 1 ,
m-1
(m-1)
m+1
Calculating Expected
System Measures for M/M/m
P0
m 1
n 0
n!
m
1
1
m!
Wq Lq
L Lq m
m m m1
Lq
P
2 0
m!1
W Wq 1
m-1
(m-1)
m+1
Other Systems
M/M/1/K - system with a capacity K
eff = effective arrival rate
M/D/1;
M/G/1;
M/G/
Homework Assignment
Read Ch. 8 (8.1 8.10)
Read Supplement Two (S2.1 - S2.13)
8.4, 8.5, 8.7, 8.12, 8.15,
8.18, 8.23, 8.25, 8. 27, 8.28
References
Presentation by McGraw-Hill/Irwin
http://www.geocities.com/qtsplus/DownloadInstructions.htm#DO
WNLOAD_INSTRUCTIONS
QTS analysis for Excel