RB NIE OM Unit 5 2020-21

OPERATIONS MANGEMENT (ME0308)
Unit 5
Scheduling and controlling
Production Activities
Ravikumar Beeranur 1
RB/NIE/Mech
RB/NIE/Mech
RB/NIE/Mech
Unit – 5: ME0308
Scheduling and Controlling Production Activities:

Introduction ,scheduling strategy & guidelines, Scheduling
methodology, concept of single machine scheduling, measure of
performance, SPT, WSPT rule, EDD rule, minimizing nos. of
tardy jobs. flow shop scheduling: Johnson algorithm’s’ jobs on
‘2’ and ’3’ machines, Gantt chart, CDS heuristics. Job shop
scheduling: Scheduling ‘2’ jobs on ‘M’ machines. Numerical
problems.
SLE: Heuristics procedure
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Course outcomes: ME0308
At the end of the course, the student will be able to:
1. Understand role of operation management, the factors affecting productivity
and develop decision support system.
2. Understand the different capacities, facility location and layouts.
3. Analyze different qualitative and quantitative forecasting models.
4. Evaluate different material and capacity requirement planning methods.
5. Create and solve different job scheduling strategies.
6. Understand the Optimisation of time in material logistic process.
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Program Outcomes:
1. Demonstrate engineering knowledge in the four streams of mechanical engineering,
namely, thermal engineering, design engineering, manufacturing engineering and
industrial management.
2. Solve real life problems through the application of engineering knowledge.
3. Design a component, system or process to meet desired needs with realistic
constraints.
4. Formulate mathematical models and conduct experiments to analyze the
complexities of mechanical systems.
5. Provide solutions to varied engineering problems using computational tools.
6. Overcome engineering challenges to cater to the needs of the society.
7. Design and manufacture products which are economically and environmentally
sustainable.
8. Discharge professional and ethical responsibility considering societal health and
safety.
9. Function competently as an individual and as a part of multi-disciplinary teams.
10. Communicate effectively and express ideas with clarity
11. Exhibit professionalism by employing modern project management and financial
tools.
12. Possess the knowledge of contemporary issues and ability to engage in life-long
learning
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Syllabus Flow Chart
• Operations Management concept
Unit 1
• Design and Capacity Planning

Unit 2
• Demand Forecasting
Unit 3
• Aggregate Planning and Master Scheduling

Unit 4
Unit 5
• Scheduling and controlling Production Activities
• Just in Time Manufacturing

Unit 6
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Introductions :
Scheduling is the allocation of start and finish time to each particular order. Therefore
Scheduling can bring productivity in shop floor by providing a calendar for processing
a set of jobs. It is nothing but scheduling various jobs on a set of resources ( machine)
Such that certain performance measures are optimized.
The single machine scheduling problem consists of n jobs with the same single operations
on each of the jobs.
The flow shop scheduling problem consists of n jobs with m operations on each of the jobs.
The job shop scheduling problem contains n jobs with m operations on each of the jobs.
Functions of scheduling are :
1. Release orders
2. Assign jobs
3. Sequencing priorities
4. Manufacturing lead time
5. Status of the jobs
6. Monitor the capacity status of facilities via input/output
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A. Single machine
Concept of single machine scheduling :

The basic single machine scheduling problem is characterized by the following conditions:
1. A set of independent , single- operation jobs is available for processing at time zero.
2. Set-up time of each job is independent of its position in jobs sequence. So, the set-up
time of each job can be included in its processing time.
3. Job descriptors are known in advance.
4. One machine is continuously available and is never kept idle when work is waiting
5. Each job is processed till its completion without break.

Under these conditions, one can see one-to-one correspondence between a sequence
Of the n jobs and a permutation of the job indices 1,2,3……… n . The total number of sequences
In the basic single machine problem in n which is the number of different permutation of
n elements.
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Basic data required to describe jobs in deterministic single machine
scheduling problems
Process time ( tj) . It is the time required to process job j . The processing time tj will
Normally include both actual processing time and set-up time.
Ready time ( rj ) It is the time at which job j is available for processing. The ready time
of a job is the difference between the arrival time of that job and the time at which that
Job is taken for processing. In the basic model, as per condition rj = 0 for all jobs.
Due date (dj ) . It is the time at which the job j is to be completed.
Completion time ( Cj ). It is the time at which the job j is completed in a sequence.

Performance measures for evaluating schedules are usually function of job completion time.
Some , sample performance measures are flow time, Lateness, Tardiness, etc.
Flow time ( Fj ). It is the amount of time job j spends in the system. Flow time is a
Which indicates the waiting time of jobs in a system . This in turn gives some idea
about in-process inventory due to a schedule. It is the difference between the
Completion time and the ready time of the job j .
( Fj = C j – rj )
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Lateness ( Lj ) . It is the amount of time by which the completion time of job j differs from
The due date ( Lj = Cj – dj ). Lateness is a measure which gives an idea about conformity of
The jobs in a schedule to a given set of due dates of the jobs. Lateness can be either positive
Lateness or negative lateness. Positive lateness of a job means that the job is completed
After its due dates. Negative lateness of a job means that the job is completed before its
Due date. The +ve lateness is a measure of poor service. Tne – ve lateness is a measure
Of better service. In many situations, distinct penalties and other costs are associated
With + ve lateness, but generally, no benefits are associated with –ve lateness. Therefore
It is often desirable to optimize only +ve lateness.
Tardiness ( Tj ). Tardiness is the lateness of job j if it fails to meet its due date, or zero,
Otherwise
Tj = max { O, Cj – dj }
= max { O, Lj }
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Measures of Performance
The different measures of performance which are used in the single machine
Scheduling are listed below with their formulas.
− n
n
Mean flow time: F=1 Fj
j =1
− n Where
n
Mean tardiness : T=1 Tj f (Tj) =1, if Tj > 0, and
j =1 f(Tj) =0, otherwise.
Max flow time : Fmax = max Fj 

1 j  n
Maximum tardiness : Tmax = max T j 

1 j  n
n
Number of tardy jobs : N T

=  f (T j )
j =1
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Objectives of scheduling
1. Providing best customer service possible

2. Making the most efficient use of people, equipment and facilities available
to the organization,
3. Minimum delay and disruption in processing
4. Minimum production cost
5. Preventing unbalanced allocation of time among work centres and thus
reducing idle time.
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Scheduling strategies : RB/NIE/Mech
1. Detailed scheduling : In manufacturing system, it is very common to expect change
in orders, breakdown of machines, slippage and unexpected events taking place in
the work centres. A detailed scheduling of any job at the initial stage is hence highly
impractical due to these changes.
2. Cumulative scheduling of total work load : In all types of orders from a customer
are added together to get cumulative work load. However this may result in
overloading of current periods and under loading of future periods. It doesn’t
give any idea about which job to do when and also it doesn’t have any control
about which orders are being worked on.
3. Combination of detailed and cumulative scheduling ; In this case, cumulative

workload is calculated as jobs arrive and used to plan for approximate capacity
needs. A broad based capacity planning is done in terms of total labour and
Machine hour requirements per week at key workcentres. If any changes occur
during the week prior to manufacturing, the computer updates the MRP and CRP
automatically. Capacity to some specific jobs can be assigned at a later date.
4. Priority decision rules : Scheduling based on priority decision rules can be either used
independently or in conjunction with the above rules. When used independently these
rules could either results in high inventory ( work-in-process ) or reduced service time to some
customers, When used in conjunction with cumulative and detailed scheduling it could
Ravikumar Beeranur
be more effective, Priority decision rules includes FCFS, LPT, SPT, EDD, PCO, RS15etc.
Scheduling guidelines :
If a system were to be credible, a realistic scheduling is a must. For a firm to be successful,
The following guidelines for job scheduling and loading workcentres are essential.
1. Provide a realistic schedule considering practical possibilities.
2. Allow adequate time for operations.
3. Allow adequate time before in between and after
4. Don’t release all available jobs to workshop which may overload the capacity
5. Don’t schedule all available capacity
6. Load only selected work centres
7. Allow for necessary changes
8. Gear-up the entire shop

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Forward V/s Backward Scheduling
Forward scheduling is the method of releasing all available jobs to the shop in that it
begins as soon as the requirements are known. This immediate release can result in early
Completion of a job at a possible cost of more work in process and in higher inventory
Carrying costs than necessary.
Backward scheduling is that method which uses the same lead-time offset logic as MRP.
Here the customer orders for a job as late as possible but expects it to be delivered in
time or on due date. Components are delivered when needed rather than “ as soon
as possible” Forward Operation time
Obtain raw Operation Operation Final
1
Material 2 Assembly
Time period 1 2 3 4 5 6 7 8 9 10 11
Obtain raw Operation Operation Final

Material 1 2 Assembly
Backward
Today’s date
Transit or queueRavikumar
time Beeranur 17
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Sequencing n jobs on 1 machine for job shop
Often facing the problem of sequencing a number of jobs on one machine in practice,
Example.
1. A number of patients to be treated by a doctor,

2. A number of cars to be survived at a service station
3. A number of broken-down machines to be repaired by a service mechanics
Each job governed by its unique technological requirement demands processing on

machine in a certain order in order to minimize mean flow time, mean in process in
inventory, and mean waiting time etc.
FCFS, SPT, WMFT, EDD , Tardy jobs algorithm.

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FCFS - First Come First Served.
Priority is given to the job which arrives earliest. It is used in service industries .
Ex. Bank , Post office. Etc.
Ex. Job 1 2 3 4 5
Due date 8 3 7 9 6
Process Time 7 4 5 2 6
Job 1 2 3 4 5
Process time 7 4 5 2 6
Flow time 7 11 16 18 24
Due Date 8 3 7 9 6
Diff ( Fj –Dj) 0 8 9 9 14
Average completion time = ∑ Fj /N = 76 /5 = 15.2 days
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Shortest Processing Time (SPT) Rule to Minimize Mean Flow Time.
In single machine scheduling problem, sequencing the jobs in increasing order of
Processing time is known as the shortest processing time ( SPT) sequencing.
Sometimes we may be interested in minimizing the time spent by jobs in the system.
This in turn, will minimize the in-process inventory, Also we may be interested in rapid
turnaround /throughput times of the jobs.
The time spent by a job in the system is nothing but its flow time, and the
‘ rapid turnaround time ‘ is its mean flow ( F ) . Job shop
Short processing time (SPT) rule minimize the mean flow time.
Problem. Consider the following single machine scheduling system

Jobs 1 2 3 4 5
Processing 15 4 5 14 8
time (tj) hrs.
Find the optimal sequence which will minimize the mean flow time and also obtain
the minimum mean flow time.
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Solution :
No. of jobs = 5
Arrange the jobs as per the SPT ordering as shown below.
− 5
5
Jobs 2 3 5 4 1 F=1 Fj
Processing 4 5 8 14 15 j =1
time (tj) hrs.

Therefore the job sequence which will minimize the mean flow time is
2-3-5-4-1
Computation of
Fmin
Jobs (j) 2 3 5 4 1
Processing 4 5 8 14 15
Time (tj)
Completion time 4 9 17 31 46
(Cj) (Fj)
Since ready time rj = 0 for all j, the flow time (Fj) is equal to Cj for all j.
− 5
5
F=1 Fj = (1/5) / ( 4+9+17+31+46) = 1/5 X (107) = 21.4 hours
j =1
Therefore the optimal
Ravikumarmean
Beeranurflow time = 21.4 hours. 21
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Prob. Consider the following single machine scheduling problem.
Job J 1 2 3 4 5
Processing time 20 8 7 10 9
(tj) ( hrs)
Find the optimal sequence which will minimize the mean flow time and also obtain
the minimum mean flow time.
Ans: 3-2-5-4-1, F minimum mean flow time.= 26.8
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Weighted mean flow time
Sometimes, the jobs in a single machine scheduling problem will not have equal importance,
Under such situation, each job is assigned a weight Wj, The mean flow time which is
Computed after considering Wj is called weighted mean flow time which is shown below.
n
−
W F
j =1
j j
Fw = n
W
j =1
j
WSPT rule In single machine scheduling problem, sequencing the jobs in increasing order
of weighted processing time is known as weighed shortest processing time ( WSPT)
sequencing. The weighted processing time of a job is obtained by dividing is processing
time by its weight.
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Problem. Consider the following single machine scheduling problem with weight.
Job j 1 2 3 4 5
Processing time (tj) 15 4 5 14 8
Weight Wj 1 2 1 2 3
Determine the sequence which will minimize the weighted mean flowtime of the above problem.
Solution :
Job j 1 2 3 4 5
Weight Wj 1 2 1 2 3
tj/Wj 15 2 5 7 2.67
Arrange the jobs in the increasing order of tj/Wj (i.e. WSPT ordering). From the above
Table. We get the following relation.
t2/W2 ≤ t5/W5 ≤ t3/W3 ≤t4/W4 ≤ t1/W1
Therefore optimal sequence which will minimize the weighted mean flow time is
2-5-3-4-1 n
Job j 2 5 3 4 1 −
 W j Fj
tj 4 8 5 14 15 Fw = j =1n
Cj ( Fj ) 4 12 17 31 46 j =1
Wj
Wj 2 3 1 2 1
Fj * Wj 8 36 17 62 46
−
= (8+36+17+62+46)/( 2+3+1+2++1) = 18.78 hours.
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F w Ravikumar Beeranur 24
Prob. Consider the following single machine scheduling problem with weights. Determine
the sequence which will minimize the weighted mean flow of the problem. Also find the
weighted mean flow time.
Job J 1 2 3 4 5
Weight ( wj ) 1 2 1 2 3
Ans : 2-5-3-4-1 , WMFT : 18.78
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Earliest Due Date (EDD) Rule To Minimize Maximum Lateness
The lateness ( Lj) of a job is defined as the difference between the completion time and
the due date of that job. Lj can be either positive or negative value.
Lj=Cj–dj
The maximum job lateness ( L max) and the maximum job tardiness ( T max ) are
minimized by Earliest Due Date (EDD) sequencing.
In single machine scheduling problem, sequencing of jobs in increasing order of due date
Is known as “ Earliest Due Date “ rule.
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Lateness ( Lj ) . It is the amount of time by which the completion time of job j differs from
The due date ( Lj = Cj – dj ). Lateness is a measure which gives an idea about conformity of
The jobs in a schedule to a given set of due dates of the jobs. Lateness can be either positive
Lateness or negative lateness. Positive lateness of a job means that the job is completed
After its due dates. Negative lateness of a job means that the job is completed before its
Due date. The +ve lateness is a measure of poor service. Tne – ve lateness is a measure
Of better service. In many situations, distinct penalties and other costs are associated
With + ve lateness, but generally, no benefits are associated with –ve lateness. Therefore
It is often desirable to optimize only +ve lateness.
Tardiness ( Tj ). Tardiness is the lateness of job j if it fails to meet its due date, or zero,
Otherwise
Tj = max { O, Cj – dj }
= max { O, Lj }
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Problem. Consider the following single machine scheduling problem.
Job j 1 2 3 4 5 6
Processing time (tj) 10 8 8 7 12 15
Due date ( dj) 15 10 12 11 18 25
Determine the sequence which will minimize the maximum lateness ( L max). Also,
Determine the L max with respect to the optimal sequence.
Solution . Arrange the jobs as per EDD ( i.e. in the increasing order of their due dates).
The EDD sequence is 2-4-3-1-5-6
Computation of L max
Job j 2 4 3 1 5 6
Completion time (Cj) 8 (8+7)=15 23 33 45 60
Due date ( dj) 10 11 12 15 18 25
Lateness ( Lj) (Cj-dj)=-2 4 11 18 27 35
From the above table, the maximum Lj is 35. This is the optimized (minimized) value
For L max. The L max of any other non-EDD sequence will not be less than 35.
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Prob. Consider the following single machine scheduling problems
Job j 1 2 3 4 5 6
Due date ( dj) 14 12 10 14 20 28
Determine the sequence which will minimize the maximum lateness

(Lmax) Also, determine the Lmax with respect to the optimal sequence.
Ans. 3-2-1-4-5-6 L max = 28
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Prob. Consider the following problem in single machine scheduling with independent
jobs.
Jobs j 1 2 3 4 5 6 7 8
tj 5 12 8 10 3 15 8 6
dj 10 16 11 16 6 25 12 14
wj 2 1 1 2 3 4 2 3
Obtain the optimal schedule for each of the following performance measures:
a) To minimize mean flow time.
b) To minimize the maximum lateness.
c) To minimize weighted mean flow time.
Ans :
a) 5-1-8-3-7-4-2-6
b) 5-1-3-7-8-2-4-6
c) 5-8-1-6-7-4-3-2
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Minimizing the number of tardy jobs
If a job is completed beyond its due date, then it is called tardy job otherwise it is called
Non-tardy job.
In many organization, the objective may be to minimize the total number of tardy jobs,
If the EDD sequence yields zero tardy, or its yields exactly one tardy job, then it is an
optimal sequence for minimizing the total number of tardy jobs (NT ). If it yields more
than one tardy job, the EDD sequence may not yield the optimal solution. An exact
algorithm for the general case is given below. The final sequence consists of two
streams of jobs as given below.
( a) First, a set (E) of early jobs, in EDD order

(b) Then, a set ( L) of late jobs, in any order
This algorithm gives optimal sequence which will result in minimum number of
Tardy jobs ( NT ) .
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Hodgson’s Algorithm to Minimize NT
Step 1. Arrange the jobs in EDD order and assume this as set E. Let set L be empty.
Step 2. If no jobs in E are late, them stop. Find the union of E and L ( Note : the remaining
jobs in E should be in EDD order, But the jobs in L can be in any order);
Otherwise, identify the first late job in E. Let it be job K.
Step 3. Identify the longest job, among the first K jobs in the sequence . Remove this job
From E and place it in L. Revise the completion times of the jobs remaining in E and
Return to step 2.
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Problem : A computer systems consulting company is under contract to carry out seven
Projects, all with deadlines assured in days from now. The consultants are a small group
and they work together on each project, so that the project will be started and completed
sequentially. Under the terms of contract, the consultants will receive Rs 24,000 for each
project completed on time, but they will incur Rs. 40,000 in penalties for each project
completed late. Each project has an associated duration, which is the anticipated number of
Days required to carry out the project as shown below.
How should the projects be sequenced in order to maximize net revenues ?
Project ID 1 2 3 4 5 6 7
Duration (tj) 2 4 6 8 10 12 14
Deadlines (dj) 6 12 30 19 12 18 24
Solution : From the statement of the problem, one can identify that the objective is to
Maximize net revenues. This can be achieved by simply obtaining a sequence which
Will minimize the number of tardy jobs ( NT).
Hence, apply Hodgson’s algorithm to minimize NT
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dj Arrange in ascending order
Step 1. The earliest due date order is shown below.
dj 6 12 12 18 19 24 30
Project ( j) 1 2 5 6 4 7 3
Place the above sequence of projects which is in EDD order in set E. Therefore,
Set E = (1,2,5,6,4,7,3)
Set L = ( Empty) Due dates are low hence tardy
Step 2. The lateness of the projects are checked as shown below.
Project ( j) 1 2 5 6 4 7 3
Duration ( tj) 2 4 10 12 8 14 6
Completion time (Cj) 2 6 16 28 36 50 56
Due date ( dj) 6 12 12 18 19 24 30
Tardy/non tardy (1/0) 0 0 1 1 1 1 1
Due date are more hence no tardy

In the above table, in the last row, 0 means that the project is non-tardy and 1 means
That the project is tardy.
As per the sequence in the set E, there are five tardy projects. The first tardy project is
5 which is in the third position [3]
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Step 3. The project with the largest duration among the first three projects in the
Sequence is 5. Remove this project and append it to L therefore.
L = { 5}
E = { 1,2,6,4,7,3}
The completion times of the projects in the set E are revised as shown below.
Project ( j) 1 2 6 4 7 3
Duration ( tj) 2 4 12 8 14 6
Completion time (Cj) 2 6 18 26 40 46
Due date ( dj) 6 12 18 19 24 30
Tardy/non tardy 0 0 0 1 1 1
Step 2. From Step 3, it is clear that there are three tardy projects. The first tardy project
Is 4 which is in the fourth position of the sequence in the set E.
Step 3. The Project with the longest duration among the first four projects is 6. Remove
The project 6 from the set E and append it to the set L. Therefore,
E = { 1,2,4, 7, 3}
L = { 5,6}
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The completion times of the projects in the set E are revised as shown:
Project ( j) 1 2 4 7 3
Duration ( tj) 2 4 8 14 6
Completion time (Cj) 2 6 14 28 34
Due date ( dj) 6 12 19 24 30
Tardy/non tardy 0 0 0 1 1
Step 2. From the table shown in step 3 it is known that are two tardy projects. The first
Tardy project is 7 which is at the fourth position in the set E.
Step 3. The project with the longest duration among the first four projects in the
Set E is 7. Remove this job from the set E and append it to be set L.
E = { 1,2,4,3}
L = { 5,6,7 }
The completion times of the projects are revised as shown below :
Project ( j) 1 2 4 3
Duration ( tj) 2 4 8 6
Completion time (Cj) 2 6 14 20
Due date ( dj) 6 12 19 30
Tardy/non tardy 0 0 0 0
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Step 2. From the table in the previous step, it is clear that all the projects are non-tardy.
Hence, we reached the optimal sequence in E.
Now merge E and L to get the complete sequence.
Final sequence = E  L = { 1,2,4,3,5,6,7}
In the above optimal sequence, total number of tardy projects is 3 which is the minimum value
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Prob. A paint shop with an automatic spray paint facility has 8 jobs on hand with
estimated processing times and due dates as show below:
Job 1 2 3 4 5 6 7 8
Processing time 5 8 6 3 10 14 7 3
(days)
Due date ( days) 15 10 15 25 20 40 45 50
The manager is convinced that the shortest processing time rule is the best to develop a
job processing schedule especially because of the fact that a flat penalty of Rs. 500 is to
be paid for each job completed after due date.
a) Compute the SPT sequence and the penalty to be paid.

b) Can you suggest a better sequence ? If so, what is the penalty for the suggested
sequence?
Ans : SPT rule. Sequence. 4-8-1-3-7-2-5-6 ; 4 tardy jobs; Penalty = Rs. 2000
???????????
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B. Jobs Shop Scheduling ( Flow Shop Scheduling)
In flow shop scheduling problem, there are n jobs; each requires processing on m different
Machines. The order in which the machines are required to process a job is called process
Sequence of that job. The process sequence of all the jobs are the same. But the
Processing times for various jobs on a machine may differ. If an operation is absent in a
Job , then the processing time of the operation of that job is assumed or zero.
The flow –shop scheduling problem can be characterized as given below;

1. A set of multiple –operation jobs is available for processing at time zero ( Each job
requires m operations and each operation requires a different machine)
2. Set-up times for the operations are sequence independent, and are include in
Processing times.
3. Job descriptors are known in advance.
4. m different machines are continuously available.
5. Each individual operation of jobs is processed till its completion without break.
Advantage over single machine scheduling is that the inserted idle time
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Example. Job Machine 1(time) Machine 2 (time)
1 5 4
2 3 1 Try : 4132
3 6 2
3+5=8 4 7 8
If the sequence of the job is 2-1-4-3. then the corresponding makespan is computed
Makespan = 29
Machine 1 2 1 3 4
3 8 14 21
Sequence 2-1-3-4 and 3-4-1-2
Machine 2 idle
2 idle
1 idle
3 idel 4 Makespan (29)  Makespan (26)
3 4 8 12 14 16 29
Fig Gantt chart for sequence 2-1-3-4

Makespan =Making time
Machine 1 3 4 1 2
21 Makespan for the
6 13 18
Schedule is = 26
Machine 2 idle 3 4
idle 1 2
6 8 13 21 25 26
RB/NIE/Mech Gantt chart for sequence 3-4-1-2
Johnson’s problem 2 machine and n jobs
The time complexity function for a general flow-shop problem is exponential in nature. This
means, the functions grows exponentially with an increase in the problem size. But for a
problem with 2 machine and n jobs, Johnson had developed a polynomial algorithm to
Get optimal solution, i.e, in a definite time, one can get the optimal solution.
Johnson’s Algorithm
Step 1. Find the minimum among various ti1 and ti2

Step 2a. If the minimum processing time requires machine 1, place the associated job in
the first available position in sequence. Go to step 3
Step 2b. If the minimum processing time requires machine 2, place the associated job
in the last available position in sequence. Go to step 3
Step 3. Remove the assigned job from consideration and return to step 1 unit all
position in sequence are filled. (Ties may be broken randomly)
tij , Represent the processing time of the job i

on the machine j
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Problem. Consider the following two (2)machines and six(6) jobs flow shop scheduling problem.
Using Johnson’s algorithm, obtain the optimal sequence which will minimize the
Makespan. Job i Machine 1 Machine2
1 5 4
2 2 3
3 13 14
4 10 1
5 8 9
6 12 11
Solution : The working of the algorithm are summarized in the form of a table which is
Shown below.
Stage Unscheduled Jobs Minimum t ij Assignment Partial sequence
1 1, 2, 3, 4, 5, 6 t 42 4 = [6] Position X X X X X 4
2 1, 2, 3, 5, 6 t 21 2 = [1] 2 X X X X 4
3 1, 3, 5, 6 t12 1 = [5] 2 X X X1 4
4 3, 5, 6 t51 5 = [2] 2 5 X X 1 4
5 3, 6 t 62 6 = [4] 2 5 X 6 1 4
6 3 t 31 3 = [3] 2 536 14
The optimal sequence is 2-5-3-6-1-4

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The makespan is determined as shown below, in the table.
Processing Time
Machine 1 Machine 2 Idle time on machine 2
Job j Time - in Time- out Time - in Time-out
2 0 2 2 5 2
5 2 10 10 19 10-5 =5
3 10 23 23 37 23-19=4
6 23 35 37 48 48-48=0
1 35 40 48 52 0
4 40 50 52 53 0
The makespan for this schedule is 53. The makespan can also be obtained using
Gantt chart.
Machine 1 2 5 3 6 1 4
2 10 23 35 40 50
Machine 2
2 5 3 6 1 4
2 5 10 19 23 37 48 52 53
idle Ravikumar Beeranur 43

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Extension of Johnson’s rule. n jobs and 3 machines
Consider a ‘ three machine and n jobs’ flow shop scheduling problem

(3 machine and n jobs)
Processing time.
Job i Machine 1 Machine 2 Machine3 Processing Time
1 t 11 t 12 t 13 Job i Machine A Machine B Machine3
2 t 21 t 22 t 23 1 t 11+ t 12 t 12+ t 13 t 13
2 t 21+ t 22 t 22+ t23 t 23
3 t 31 t 32 t 33
3 t 31+ t 32 t 32+ t33 t 33
4 t 41 t 42 t 43 4 t 41+ t 42 t 42+ t 43 t 43
- - - - 5 t i1+ t i2 t i2+ t i3 -
n t n1 t n2 t n3 6 t n1+ t 12 t n2+ t n3 t n3
If min t i1  max t i2
OR i i
If min t i3  max t i2 Extending Johnson’s algorithem
i i
If any one of the above conditions is satisfied
Then extend the johnson’s algorithm. Ravikumar Beeranur 44
RB/NIE/Mech
Problem. Consider the following 3 machine and 5 jobs flow shop problems.
Processing Time
Job i Machine 1 Machine 2 Machine3
1 8 5 4
2 10 6 9
3 6 2 8
4 7 3 6
5 11 4 5
In the above table. Min ( ti1) = 6 Find optimum sequence ?

Max (ti2) = 6
Since the condition min ( ti1)  max ( ti2) is satisfied, we can extend the johnson’s algorithm
To this problem. So modified problem may be given as follows.
Processing Time Optimum sequence
Job i Machine A MachineB 3-2-5-1-4
1 8+5= 13 5+4 =9
2 10+6 =16 6+9 = 15
3 8 10
4 10 9 Use johnson’s
5 15 9 Rule to get optimum
sequence
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The makespan of the sequence is determine as shown below.
Processing Time
Machine 1 Machine 2 Machine 3 Idle time on Idle time on
Job Time - in Time- out Time - in Time- time- Time- machine 2 machine 3
out in out
3 0 6 6 6+2=8 8 16 6-0=6 8
2 6 6+10=16 16 16+6=22 22 31 16-8=8 22-16=6
5 16 16+11=27 27 31 31 36 27-22=5 31-31=0
1 27 35 35 40 40 44 35-31=4 40-36=4
4 35 42 42 45 45 51 42-40=2 45-44=1
The makespan for this problem is 51 units of time.
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CDS HEURISTIC
For large size problems, it would be difficult to get optimum solution in finite time. Since
the flow shop scheduling is a combinatorial problem. This means the time complexity function
of flow shop problem is exponential in nature, Hence, to use efficient heuristics for large
size problems.
CDS ( Campbell, Dudck and Smith )

Te CDS heuristic corresponds to multistage use of Johnson’s rule applied to a new problem
Formed from the original with processing times
At stage 1 t1j1 = tj1 and t2j1 = tjm

In other words, Johnson’s rule is applied to the first and mth operation and intermediate
Operations are ignored.
t2 j1 = tj1 + t j2, t2 j2 = tjm + tj, m-1
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This is, Johnson’s rule is applied to the sum of the first two and the last two operation
Processing times. In general at stage i
j1 =  t jk
i
t i j 2 =  t j ,m−k +1
i
t and
k =1 k =1
For each stage i ( I = 1,2-------m-1 ), the job order obtained is used to calculate a
Makespan for the original problem. After m-1 , stage, the best makespan among
The m-1 schedule is identified. ( some of the m-1 sequences may be identical).
RB/NIE/Mech
Problem. Find the makespan using CDS heuristic for the following flow shop problem.
Job j t j1 t j2 t j3 t j4
1 4 3 7 8
2 3 7 2 5
3 1 2 4 7
4 3 4 3 2
Solution :
Stage. 1 Processing Time
Job i Machine 1 Machine2
t j1 t j4
1 4 8
2 3 5
3 1 7
4 3 2
The optimal sequence for the above problem is

3-2-1-4
****Apply johnson’s rule n jobs and 2 machine
and find outRavikumar
optimalBeeranur
sequence 49
RB/NIE/Mech
The makespan calculation for the 3-2-1-4
Processing Time
Machine 1 Machine 2 Machine 3 Machine 4
Job time - in time- out time - in time-out time-in time-out time-in time-out
3 0 1 1 3 3 7 7 14
2 1 4 4 11 11 13 14 19
1 4 8 11 14 14 21 21 29
4 8 11 14 18 21 24 29 31
Makespan of this problem = 31
Stage 2. Processing Time

T1+ T2 t3 + t4
1 4+3 =7 7+8 =15
From the problem table. 2 10 7
3 3 11
4 7 5
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***After applying johnson’s algorithm to the above problem, we get the sequence 3-1-2-4
Makespan calculation is summarized in the following table.
Processing Time ( in hour )
3 0 1 1 3 3 7 7 14
1 1 5 5 8 8 15 15 23
2 5 8 8 15 15 17 23 28
4 8 11 15 19 19 22 28 30
The makespan for the sequence 3-1-2-4 is 30
Stage 2. Processing Time

tj1 t j2
1 4+3 =7 7+8 =15
From problem table. 2 10 7
3 3 11
4 7 5
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Processing Time
Stage 3. Job i Machine 1 Machine2
tj1 t j2
Machine 1+machine2+machine 3 1 4+3+7=14 3+7+8=18
2 12 14
Machine 2+machine3+machine 4 3 7 13
4 10 9
The application of johnson’s algorithm to the above data yields the sequence 3-2-1-4
The determination of the corresponding makespan is shown below.
Processing Time ( in hour )
3 0 1 1 3 3 7 7 14
2 1 4 4 11 11 13 14 19
1 4 8 11 14 14 21 21 29
4 8 11 14 18 21 24 29 31
Summary Stage Sequence Makespan

1 3-2-1-4 31 The best sequence
2 3-1-2-4 30 Is 3-1-2-4 which
3 3-2-1-4 31 has makespan of 30
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Job Shop Scheduling
job shop scheduling: Types of scheduling heuristics procedure,
priority dispatching rules, Scheduling ‘2’ jobs on ‘M’ machines.
In job shop problem, each job has m different operations. If some of the jobs are having
less than m operations, required number of dummy operations with zero process times
are assumed. By this assumption, the condition of equal number of operations for all
the jobs is ensured.
In job scheduling problem, the process sequence of the jobs are not the same. Hence,
heuristics approaches are popular in this area.
RB/NIE/Mech
TWO JOBS AND M MACHINES SCHEDULING
Two jobs and M machines scheduling is a special problem under job shop scheduling. The
problem consists of 2 jobs which require processing on M machines. The processing
sequences of the jobs are not the same. Since, this is a special king under the job shop
scheduling like, Johnson’s problem ( n jobs and 2 machines) under flow shop scheduling,
The graphical procedures consists of the following steps:
Step1. Construct a two dimensional graph in which x-axis represents the job 1, its sequence
of operations and their processing times, and y-axis represents the jobs 2, its sequence of
operations and their processing times ( use the same scale for x-axis and y-axis).
Step 2. Shade each region where a machine would be occupied by the two jobs
simultaneously.
Step 3. The processing of both jobs can be shown by a continuous line consisting of
horizontal, vertical and 45 degree diagonal lines. The line is drawn from the origin and
continued to the upper right corner by avoiding the regions. A diagonal line means that
both jobs can be performed simultaneously. So, while drawing the line from the origin
to the top right corner, we should try to maximize the length of diagonal travel ( sum of the
lengths of 45 degree lines ) which will minimize the makespan of the problems.
Using trial and error method, one can draw the final line which has the maximum
diagonal portion, Ravikumar Beeranur 54
RB/NIE/Mech
RB/NIE/Mech
RB/NIE/Mech
Problem. Use graphical method to minimize the time needed to process the
following jobs on the machines shown (i.e. for each machine, find the jobs which
should be scheduled first). Also, calculate the total time elapsed to complete both
jobs.
Sequence A B C D E
Job 1 Time
2 3 4 6 2
(Hrs)
Sequence C A D E B
Job 2 Time
4 5 3 2 6
(Hrs)
RB/NIE/Mech
Problem. Use graphical method to minimize the time needed to process the
following jobs on the machines shown (i.e. for each machine, find the jobs which
should be scheduled first). Also, calculate the total time elapsed to complete both
jobs.
Sequence A B C D E
Job 1
Time (Hrs) 2 6 5 4 7
Sequence C B D A E
Job 2
Time (Hrs) 6 5 7 4 8
RB/NIE/Mech
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RB/NIE/Mech
RB/NIE/Mech
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Choice is yours
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OPERATIONS MANGEMENT (ME0308)

Scheduling and Controlling Production Activities:

2. Understand the different capacities, facility location and layouts.

3. Analyze different qualitative and quantitative forecasting models.

4. Evaluate different material and capacity requirement planning methods.

5. Create and solve different job scheduling strategies.

6. Understand the Optimisation of time in material logistic process.

• Design and Capacity Planning

• Aggregate Planning and Master Scheduling

• Just in Time Manufacturing

Concept of single machine scheduling :

Due date (dj ) . It is the time at which the job j is to be completed.

Completion time ( Cj ). It is the time at which the job j is completed in a sequence.

Max flow time : Fmax = max Fj 

Maximum tardiness : Tmax = max T j 

Number of tardy jobs : N T

1. Providing best customer service possible

3. Combination of detailed and cumulative scheduling ; In this case, cumulative

1. Provide a realistic schedule considering practical possibilities.

2. Allow adequate time for operations.

3. Allow adequate time before in between and after

5. Don’t schedule all available capacity

6. Load only selected work centres

7. Allow for necessary changes

8. Gear-up the entire shop

Obtain raw Operation Operation Final

1. A number of patients to be treated by a doctor,

Each job governed by its unique technological requirement demands processing on

FCFS, SPT, WMFT, EDD , Tardy jobs algorithm.

Average completion time = ∑ Fj /N = 76 /5 = 15.2 days

Problem. Consider the following single machine scheduling system

time (tj) hrs.

Ans: 3-2-5-4-1, F minimum mean flow time.= 26.8

Ans : 2-5-3-4-1 , WMFT : 18.78

Determine the sequence which will minimize the maximum lateness

Ans. 3-2-1-4-5-6 L max = 28

( a) First, a set (E) of early jobs, in EDD order

How should the projects be sequenced in order to maximize net revenues ?

Hence, apply Hodgson’s algorithm to minimize NT

Due date are more hence no tardy

Now merge E and L to get the complete sequence.

Final sequence = E  L = { 1,2,4,3,5,6,7}

a) Compute the SPT sequence and the penalty to be paid.

The flow –shop scheduling problem can be characterized as given below;

Fig Gantt chart for sequence 2-1-3-4

Step 1. Find the minimum among various ti1 and ti2

tij , Represent the processing time of the job i

The optimal sequence is 2-5-3-6-1-4

idle Ravikumar Beeranur 43

Consider a ‘ three machine and n jobs’ flow shop scheduling problem

In the above table. Min ( ti1) = 6 Find optimum sequence ?

The makespan for this problem is 51 units of time.

CDS ( Campbell, Dudck and Smith )

At stage 1 t1j1 = tj1 and t2j1 = tjm

The optimal sequence for the above problem is

Makespan of this problem = 31

Stage 2. Processing Time