Scheduling

Chapter 17
Scheduling
Lecture Outline
Objectives in Scheduling
Loading
Sequencing
Monitoring
Advanced Planning and Scheduling Systems
Theory of Constraints
Employee Scheduling
Copyright 2011 John Wiley & Sons, Inc.
17-2
What is Scheduling?
Last stage of planning before production occurs
Specifies when labor, equipment, and facilities
are needed to produce a product or provide a
service
17-3
Scheduled Operations
Process Industry
Linear programming
EOQ with noninstantaneous
replenishment
Mass Production
Assembly line balancing
Project
Batch Production
Aggregate planning
Master scheduling
Material requirements
planning (MRP)
Capacity requirements
planning (CRP)
Project -scheduling
techniques (PERT, CPM)
17-4
Objectives in Scheduling
Meet customer due dates

Minimize job lateness
Minimize response time
Minimize completion time
Minimize time in the
system
Minimize overtime
Maximize machine or
labor utilization
Minimize idle time
Minimize work-in-process
inventory
17-5
Shop Floor Control (SFC)

Schedule and monitor day-to-day job shop
production
Also called production control and production
activity control (PAC)
Performed by production control department
Loading - check availability of material, machines, and
labor
Sequencing - release work orders to shop and issue
dispatch lists for individual machines
Monitoring - maintain progress reports on each job
until it is complete
17-6
Loading
Process of assigning work to limited resources
Perform work with most efficient resources
Use assignment method of linear programming
to determine allocation
17-7
Assignment Method
4. If number of lines equals number
of rows in matrix, then optimum
subtract minimum value in each
solution has been found. Make
row from all other row values
assignments where zeros appear
2. Perform column reductions
1. Perform row reductions
subtract minimum value in each

column from all other column
values
3. Cross out all zeros in matrix
use minimum number of

horizontal and vertical lines
Else modify matrix:

subtract minimum uncrossed
value from all uncrossed values
add it to all cells where two lines
intersect
other values in matrix remain
unchanged
5. Repeat steps 3 and 4 until

optimum solution is reached
17-8
Assignment Method
Initial
Matrix
Bryan
Kari
Noah
Chris
1
10
6
7
9
2
5
2
6
5
PROJECT
3
4
6
10
4
6
5
6
4
10
17-9
Assignment Method
Initial
Matrix
Bryan
Kari
Noah
Chris
1
10
6
7
9
Row reduction
5
4
2
5
0
0
1
1
1
2
0
0
5
4
1
6
PROJECT
3
4
6
10
4
6
5
6
4
10
2
5
2
6
5
Column reduction
Cover all zeros
3
2
0
3
3
2
0
3
0
0
1
1
1
2
0
0
4
3
0
5
0
0
1
1
1
2
0
0
4
3
0
5
Number lines number of rows so modify matrix

17-10
Assignment Method
Modify matrix
1
0
0
1
0
0
3
1
1
2
2
0
Cover all zeros

2
1
0
3
1
0
0
1
0
0
3
1
1
2
2
0
2
1
0
3
Number of lines = number of rows so at optimal solution
Bryan
Kari
Noah
Chris
1
1
0
0
1
PROJECT
2
3
0
1
0
2
3
2
1
0
4
2
1
0
3
Bryan
Kari
Noah
Chris
1
10
6
7
9
PROJECT
2
3
4
5
6 10
2
4
6
6
5
6
5
4 10
Project Cost = (5 + 6 + 4 + 6) X $100 = $2,100

17-11
Assignment Method - Setup

Solution goes here
Only 1 leader can
be assigned to
each project
Click Solve for

solution
Sum of all rows and

columns = 1
17-12
Assignment Method - Solution
Assignments indicated by 1
Cost of solution
17-13
Sequencing
Prioritize jobs assigned to a resource
If no order specified use first-come first-served (FCFS)
Other Sequencing Rules
FCFS - first-come, first-served

LCFS - last come, first served
DDATE - earliest due date
CUSTPR - highest customer priority
SETUP - similar required setups
SLACK - smallest slack
CR - smallest critical ratio
SPT - shortest processing time
LPT - longest processing time
17-14
Minimum Slack & Smallest Critical Ratio

SLACK considers both work and time remaining
SLACK = (due date todays date) (processing time)
CR recalculates sequence as processing

continues and arranges information in ratio form
CR =
time remaining
work remaining
due date - todays date

remaining processing time
If CR > 1, job ahead of schedule

If CR < 1, job behind schedule
If CR = 1, job on schedule
17-15
Sequencing Jobs Through One Process

Flow time (completion time)
Time for a job to flow through system
Makespan
Time for a group of jobs to be completed
Tardiness
Difference between a late jobs due date and its
completion time
17-16
Simple Sequencing Rules
JOB
PROCESSING
TIME
DUE
DATE
A
B
C
D
E
5
10
2
8
6
10
15
5
12
8
17-17
Simple Sequencing Rules: FCFS

FCFS
SEQUENCE
A
B
C
D
E
START
TIME
PROCESSING COMPLETION DUE

TIME
TIME
DATE
0
5
5
10
15
2
17
8
25
6
Total
Average
5
15
17
25
31
93
93/5 = 18.60
10
15
5
12
8
TARDINESS
0
0
12
13
23
48
48/5 = 9.6
17-18
Simple Sequencing Rules: DDATE

DDATE
SEQUENCE
START
TIME
C
E
A
D
B
0
2
8
13
21

TIME
TIME
DATE
2
2
6
8
5
13
8
21
10
31
Total
75
Average75/5 = 15.00
TARDINESS
5
8
10
12
15
0
0
3
9
16
28
28/5 = 5.6
17-19
Simple Sequencing
Rules: SLACK
SLACK
SEQUENCE
START
TIME
E
C
D
A
B
0
6
8
16
21
A(10-0) 5 = 5
B(15-0) 10 = 5
C(5-0) 2 = 3
D(12-0) 8 = 4
E(8-0) 6 = 2

TIME
TIME
DATE
6
6
2
8
8
16
5
21
10
31
Total
82
Average82/5 = 16.40
TARDINESS
8
5
12
10
15
0
3
4
11
16
34
34/5 = 6.8
17-20
Simple Sequencing Rules: SPT

SPT
SEQUENCE
START
TIME
C
A
E
D
B
0
2
7
13
21

TIME
TIME
DATE
2
5
6
8
10
Total
Average
2
7
13
21
31
74
74/5 = 14.80
5
10
8
12
15
TARDINESS
0
0
5
9
16
30
30/5 = 6
17-21
Simple Sequencing Rules: Summary

RULE
FCFS
DDATE
SLACK
SPT
AVERAGE
COMPLETION TIME
18.60
15.00
16.40
14.80
AVERAGE
TARDINESS
9.6
5.6
6.8
6.0
NO. OF
JOBS TARDY
3
3
4
3
MAXIMUM
TARDINESS
23
16
16
16
Best values
- SPT will minimize mean flowtime and maximize the number of jobs
finished in time
- DDATE will minimize mean tardiness and maximum tardiness
17-22
Sequencing Jobs Through

Two Serial Process
Johnsons Rule
1. List time required to process each job at each process. Set up
a one-dimensional matrix to represent desired sequence with
# of slots equal to # of jobs.
2. Select smallest processing time at either process. If that time
is on process 1, put the job as near to beginning of sequence
as possible.
3. If smallest time occurs on process 2, put the job as near to
the end of the sequence as possible.
4. Remove job from list.
5. Repeat steps 2-4 until all slots in matrix are filled and all jobs
are sequenced.
17-23
Sequencing
With
Excel
17-24
Johnsons Rule
JOB
PROCESS 1
PROCESS 2
A
B
C
D
E
6
11
7
9
5
8
6
3
7
10
17-25
Johnsons Rule
JOB
PROCESS 1
PROCESS 2
A
B
C
D
E
6
11
7
9
5
8
6
3
7
10
17-26
Johnsons Rule
E
A
5
11
Process 1
(sanding)
20
31
38
Idle time
E
5
A
15
D
23
B
30
Process 2
(painting)
C
37
41
Completion time = 41
Idle time = 5+1+1+3=10
17-27
Excel for Johnsons Rule
User inputs processing

times and sequence
Excel calculates
completion times
and makespan
When the set of

jobs is completed
17-28
Guidelines for Selecting a

Sequencing Rule
SPT most useful when shop is highly congested

Use SLACK for periods of normal activity
Use DDATE when only small tardiness values can be
tolerated
Use LPT if subcontracting is anticipated
Use FCFS when operating at low-capacity levels
Do not use SPT to sequence jobs that have to be
assembled with other jobs at a later date
17-29
Monitoring
Work package
Shop paperwork that travels with a job
Gantt Chart
Shows both planned and completed activities against
a time scale
Input/Output Control
Monitors the input and output from each work center
17-30
Gantt Chart
Job 32B
Behind schedule
Facility
3
Job 23C
Ahead of schedule
2
Job 11C
Job 12A
On schedule
Key:
6
8
Todays Date
10
11
12
Days
Planned activity
Completed activity
17-31
PERIOD
Planned input
Actual input
Deviation
Planned output
Actual output
Deviation
Backlog
30
TOTAL
65
65
70
70
75
75
75
75
20
10
270
0
0
300
0
0
17-32
PERIOD
Planned input
Actual input
Deviation
Planned output
Actual output
Deviation
Backlog
30
65
60
-5
75
75
-0
15
65
60
-5
75
75
-0
0
70
65
-5
75
65
-10
0
70
65
-5
75
65
-10
0
TOTAL
270
250
-20
300
280
-20
17-33
Excel for Input/Output Control
User inputs
planned and
actual values
Excel calculates deviations

and backlog
17-34
Advanced Planning and Scheduling

Systems
Infinite scheduling - assumes infinite capacity
Loads without regard to capacity
Then levels the load and sequences jobs
Finite scheduling - assumes finite (limited)

capacity
Sequences jobs as part of the loading decision
Resources are never loaded beyond capacity
17-35

Systems
Advanced planning and scheduling (APS)
Add-ins to ERP systems
Constraint-based programming (CBP) identifies a
solution space and evaluates alternatives
Genetic algorithms based on natural selection
properties of genetics
Manufacturing execution system (MES) monitors
status, usage, availability, quality
17-36
17-37
Theory of Constraints
Not all resources are used evenly

Finite scheduling approach
Concentrate on the bottleneck resource
Synchronize flow through the bottleneck
Use process and transfer batch sizes to move
product through facility
17-38
Drum-Buffer-Rope
Drum
Bottleneck, beating to set the pace of production for
the rest of the system
Buffer
Inventory placed in front of the bottleneck to ensure it
is always kept busy
Determines output or throughput of the system
Rope
Communication signal; tells processes upstream
when they should begin production
17-39
TOC Scheduling Procedure

Identify bottleneck
Schedule job first whose lead time to bottleneck is
less than or equal to bottleneck processing time
Forward schedule bottleneck machine
Backward schedule other machines to sustain
bottleneck schedule
Transfer in batch sizes smaller than process batch
size
17-40
Synchronous Manufacturing
A
B3 1 7
C3 2 15
D3 3 5
B2 2 3
C2 1 10
D2 2 8
B1 1 5
C1 3 2
D1 3 10
Key:
Ij k l
Item i
Operation j of item i performed at
machine center k takes l minutes
to process
17-41
Demand = 100 As
Machine setup time = 60 minutes
MACHINE 1 MACHINE 2 MACHINE 3
B1
B3
C2
Sum
5
7
10
22
B2
C3
D2
3
15
8
26*
C1
D3
D1
2
5
10
17
* Bottleneck
17-42
Setup
Machine 1
C2
Setup
B1
B3
1002
1562
2322
Idle
Setup
Machine 2
C3
B2
12
1512
Machine 3
Setup
C1
Setup
D2
1872
2732
Setup
D1
0 200
Idle
1260
D3
1940
Completion
time
2737
17-43
Employee Scheduling
Labor is very flexible resource
Scheduling workforce is complicated, repetitive
task
Assignment method can be used
Heuristics are commonly used
Copyright 2011
John Wiley
& Sons,
Inc.& Sons, Inc.
Copyright
2011 John
Wiley
17-44
Employee Scheduling Heuristic

1. Let N = no. of workers available
Di = demand for workers on day i
X = day working
O = day off
2. Assign the first N - D1 workers day 1 off. Assign the next N - D2
workers day 2 off. Continue in a similar manner until all days are
have been scheduled
3. If number of workdays for full time employee < 5, assign
remaining workdays so consecutive days off are possible
4. Assign any remaining work to part-time employees
5. If consecutive days off are desired, consider switching schedules
among days with the same demand requirements
17-45
Employee Scheduling
DAY OF WEEK
MIN NO. OF
WORKERS REQUIRED
TH
SA
SU
Taylor
Smith
Simpson
Allen
Dickerson
17-46
Employee Scheduling
DAY OF WEEK
MIN NO. OF
WORKERS REQUIRED
Taylor
Smith
Simpson
Allen
Dickerson
TH
SA
SU
O
O
X
X
X
X
X
O
O
X
X
X
X
X
O
O
O
X
X
X
X
X
O
X
X
X
X
X
X
X
X
X
X
O
O
Completed schedule satisfies requirements but has no

consecutive days off
17-47
Employee Scheduling
DAY OF WEEK
MIN NO. OF
WORKERS REQUIRED
Taylor
Smith
Simpson
Allen
Dickerson
TH
SA
SU
O
O
X
X
X
O
O
X
X
X
X
X
O
X
X
X
X
O
O
X
X
X
X
X
O
X
X
X
X
X
X
X
X
O
O
Revised schedule satisfies requirements with consecutive

days off for most employees
17-48
Automated Scheduling Systems

Staff Scheduling
Assign workers to standardize shift patterns
Schedule Bidding
Workers bid for certain shift positions or schedules
Schedule Optimization
Creates demand-driven forecast of labor needs
Assigns workers to variable schedules
Uses mathematical programming and artificial
intelligence techniques
17-49

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17-50

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Chapter 17

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Meet customer due dates

Copyright 2011 John Wiley & Sons, Inc.

Shop Floor Control (SFC)

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

1. Perform row reductions

subtract minimum value in each

3. Cross out all zeros in matrix

use minimum number of

Else modify matrix:

5. Repeat steps 3 and 4 until

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Cover all zeros

Number lines number of rows so modify matrix

Cover all zeros

Number of lines = number of rows so at optimal solution

Project Cost = (5 + 6 + 4 + 6) X $100 = $2,100

Assignment Method - Setup

Click Solve for

Sum of all rows and

Assignment Method - Solution

FCFS - first-come, first-served

Copyright 2011 John Wiley & Sons, Inc.

Minimum Slack & Smallest Critical Ratio

CR recalculates sequence as processing

due date - todays date

If CR > 1, job ahead of schedule

Copyright 2011 John Wiley & Sons, Inc.

Sequencing Jobs Through One Process

Copyright 2011 John Wiley & Sons, Inc.

Simple Sequencing Rules

Copyright 2011 John Wiley & Sons, Inc.

Simple Sequencing Rules: FCFS

PROCESSING COMPLETION DUE

Copyright 2011 John Wiley & Sons, Inc.

Simple Sequencing Rules: DDATE

PROCESSING COMPLETION DUE

Copyright 2011 John Wiley & Sons, Inc.

PROCESSING COMPLETION DUE

Copyright 2011 John Wiley & Sons, Inc.

Simple Sequencing Rules: SPT

PROCESSING COMPLETION DUE

Copyright 2011 John Wiley & Sons, Inc.

Simple Sequencing Rules: Summary

Copyright 2011 John Wiley & Sons, Inc.

Sequencing Jobs Through

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Excel for Johnsons Rule

User inputs processing

When the set of

Guidelines for Selecting a

SPT most useful when shop is highly congested

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.

Copyright 2011 John Wiley & Sons, Inc.