MASTER PRODUCTION SCHEDULE USING DRUM-BUFFER-ROPE SCHEDULING METHOD

A company manufactures bolts. There are 8 work centers. The shop produces 3 end products: Bolt A, Bolt B, and Bolt C, from the four types of raw materials W, X, Y and Z. Production is done in a shift of 8 hrs. working days in a week are 6. following illustrations show: The layout of the shop floor Fig. 4.3 The bill of material Fig. 4.4 4.6 Routing Table 4.4 Inventory on hand in the beginning of the week: 1. 25 pcs of assembly AR in finished work-in-process 2. 10 pcs of component W at operation 40. 3. 15 pcs of component Z at operation 30. The logical product flow diagram is shown in Fig. 4.7

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FIG.4.3: LAYOUT OF THE SHOP FLOOR

PRESS GRINDER GRINDER

SHIPPING

POLISHER

POLISHER

ASSEMBLING

DRILL

DRILL

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FIG. 4.4: BILL OF MATERIALS FOR BOLT - A

Bolt - A

AR

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FIG. 4.5: BILL OF MATERIALS FOR BOLT - B

BOLT B

BR

AR

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TABLE 4.4: ROUTING

Part X Y AR BOLT - A Operation 10 10 10 10 20 Work Center Grinder GRINDER ASSEMBLY GRINDER POLISHER Minutes 4 5 8 15 15

30
40 Z 10 20 30 BR BOLT - B W 10 10 20 10

DRILL
POLISHER POLISHER DRILL PRESS PRESS ASSEMBLY POLISHER GRINDER

20
18 9 18 28 6 9 6 15

20
30 40 50

POLISHER
DRILL PRESS DRILL

12
20 14 7
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FIG. 4.6: BILL OF MATERIALS FOR BOLT - C

BOLT - C

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FIG. 4.7: LOGICAL PRODUCT PROCESS STRUCTURE

Bolt - A
Polish18 m O-40 Drill 20 m O-30 Polish15 m O-20 Grind 15 m O-10 Assembly 8 m O-10 Grind 4 m O-10 Grind 5m O-10 Polish 9 m O-10

Bolt - B
Polish 6 m O-20 Assembly 9 m O-10 Press 28 m O-30

Bolt - C
Polish10 m O-60

Drill 7 m O-50
Press14 m O-40 Drill 20 m O-30 Polish12 m O-20 Grind15 m O-10

Press 6 m O-10

Drill 18 m O-20

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