Production Planning,

Control & Scheduling

Production Planning (meaning)

Production Planning involves
management decisions on the
resources that the firm will require for
its manufacturing operations and the
selection of these resources to
produce the desired goods at
appropriate time at the least possible
cost.
Activities involved in Production
planning
*Planning & designing the product
*Determining the equipment & capacity requirements
*Determining the sequence of operations
*The nature of operations to be performed along with time
 requirements
*Specifying certain production quantity & quality levels
Factors determining production
planning
i. Volume of production
Extensive planning in high volume
production & limited in custom job
shop production.
ii. Number of production processes
In job shop production planning is
informal and left over to the workman
whereas in high volume production
enormous planning is required.

Contd…
iii. Nature of operations
The degree to which production
planning is carried varies with the
nature of the process.

Production Control Elements

1. Control of Planning
*Assure receipt of latest forecast data from sales &
production
*Bill of material data from product engineering
*Routing information process engineering

2. Control of materials
*Control of inventory & movement within the shop
Contd…
3. Control of tooling
*Check on the availability of tooling
*Issue of tools
4. Control of manufacturing capacity
*Determine the availability of equipment & labour capacities
*Issue realistic production schedule
*Provide a means of recording completed production
Contd…
5. Control of activities
*Release order & information at assigned items

6. Control of quantity
*Follow up of progress of production
*To ensure required quantities are processes
*To ensure corrective actions are initiated

Contd.
7. Control of material handling
*Release orders for movements of work
*Ensure availability of material at each stage of operation

8. Control of due dates

*Check on relation of actual & planned schedule
*Determine cause of delay & stoppages
Contd…
9. Control of information
*Distribute timely information & reports showing deviations
from plans
*Corrective action to be taken
*Provide data on production performance measurements for
future planning.
Stages in PPC
Three stages in PPC:
i. Planning
Choosing the best course of action among
several alternatives
ii. Operations
Execution as per plan
iii. Control
Maintaining the performance by comparing
the actual results with performance
standards set and taking appropriate action

Shop floor activity control

It directs how, when & where the
products/components should be
made in order to ensure the delivery
of goods as per schedules or due
dates.

*Priority Control: ensures that the activities are carried out as

per determined priority plan.
*Capacity control: ensures that, the amount of equipment &
labour hours necessary at various work centres to carryout
the scheduled work are provided
Objectives of Production Activity Control
*To know the current status of job
*To determine what should be the next job
*To ensure correct quantities of material are in the right place.
*To maximize operational efficiency
*To minimize WIP inventory
*To minimize set up costs
*To maintain control of operations
Operations Planning & Scheduling
Scheduling involves developing &
assigning specific dates for the start
& completion of necessary tasks or
operation in a production shop floor.

It involves:
a. Loading: machine loading of jobs to work centres

b. Sequencing: it is the process of determining the sequence

of processing of all jobs at each centre or machine.

c. Detailed scheduling: it is the process of determining the

start & finish times at each work centre or machine for all
jobs.

d. Expediting: it is an special effort or action needed to keep

the job moving through the production facility on time as
per the detailed schedule.
Contd..
e. Input/output controls: plans & schedules call for certain
level of capacity at a work centre or machine, but actual
utilization may differ from what was planned.
Scheduling Techniques for Job Shop
*Forward scheduling: each task is scheduled to occur at the
earliest time that, the necessary material will be on hand
and the capacity will be available.
2. Backward scheduling: jobs that commit in advance
delivery dates & scheduling is done accordingly.
Priority Sequencing
The priority indicates the sequence in
which the jobs will be processed on
the machine or in the work centre.

When the machine or the work centre

is free, the job with highest priority is
assigned.
Single Criterion Priority Sequencing
Rules:
*First come first served (FCFS):
Jobs are scheduled for work in the
same sequence as they arrive at the
facility or the work centre.

2. Shortest Process Time (SPT) Job:

The job which has the shortest
processing /operation time is given

priority to be loaded as the next job

for processing.

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:

The highest priority is given to the job
which has least slack.
Slack = Available Time – Processing
Time

5. Earliest Due Date (EDD) job first:

Sequences the jobs waiting in the
queue at the work centre according
to their due dates, like jobs having
earliest due date is given highest
priority.

6. Truncated Short Processing Time (TSPT) job first:

This rule sequences the jobs according

to the SPT rule, except that the jobs
have been waiting for a time period
longer than a specified truncation time
are given higher priority than other
jobs.

7. Preferred Customer Order (PCO):

Jobs belonging to a preferred
customer are given higher priority
than other jobs.

8. Random – Selection : to select

randomly which job has to be
given priority.
This rule is normally not used. It may
be used only when no other
consideration is important.

9. Cost Over Time (COVERT):

This rule uses the ratio of expected
delay cost (C) to processing time (T).
The job with the largest ratio is given
the highest priority.
Cost over time ratio which is equal to;

Expected Delay Cost ( C ):

 -------------------------------------
Processing Time (T)
Contd..
10. Least Change Over Cost:
The sequencing of jobs is done by
analysing the total cost of making all
the machine change over between
jobs.
Dynamic Sequencing Rules (Combined Criteria
Rules)
1. Dynamic Slack (DS) Rule:
When the least slack rule is used
repeatedly at each machine/work
centre for sequencing the jobs, it is
known as dynamic slack rule.

2. Dynamic Slack per Remaining Option (DS/RO) rule:

In this rule, the ratio of total slack
time available for the job to the
number of operations remaining
including the current option is
obtained.
The job with smallest DS/RO ratio is
scheduled first.

3. Critical Ratio Rule (CR):

The critical ratio rule is designed to
give priority to jobs that have the
most urgently needed work to meet
the shipping schedule.
Due date – Date now
CR = -------------------------------
 Days required to complete the job
Days remaining
or ----------------------------
Days required for processing
Lowest CR is given highest priority

Evaluating Sequencing Rules

In deciding which sequencing rule
performs best in a particular job
shop, it is necessary to determine the
criteria that will be used to evaluate
and compare the rules.

1. Average Flow Time: It is the

average amount of time each job
spends in the shop.
Total flow time for all jobs
AFT = -----------------------------------
Number of jobs in the system

2. Average number of jobs in the

system: it is average number of jobs
in the shop each day.

Total flow time for all jobs

= ------------------------------------
Total processing time

3. Average job lateness: it is the

average amount of time that each jobs
actual completion time (date)
exceeds its promised due time (date)
Total job lateness
= ------------------------------
Number of jobs in the system
Contd…
4. Change over cost: It is the cost of making all the machine
change over in a group of jobs.

Line Balancing
It is defined as ‘the appointment of
sequential work activities into work
stations in order to gain a high
utilization of labour and equipment &
therefore minimize idle time’.
Balancing efficiency
Minimize the amount of idle time

Sequencing Models
*Model 1
n jobs , one machine
Solution : Shortest Possible Time

*Model 2
n jobs, one machine, sequence dependent
On set up time
Sol: minimum set up time calculation

Model 3:
n jobs, m=2 machines
Sol: Apply Johnson’s rule

Model 4
n jobs, m=3 machines in series
Sol: combine (M1+M2) & (M2+M3) & apply Johnson’s rule

Model 5:
n jobs, m machines in series
Sol: By CDK algorithm (Campbell, Dudek & Smith)
Model 6:
n jobs , m machines , parallel
Sol: LPT
Model 7:
n jobs m machines, in series & parallel
Sol: complex mathematical computer programming

Johnson’s rule
Johnson’s rule of algorithm is used
for sequencing ‘n’ jobs through two
work centres/machines.