ME 391 A – Design, Planning and

Control of Production System

Dr. Kailash Chaudhary

Ph.D. (Mechanical Design), M.E. (P & I), B.E. (Mechanical
Engg)
Assistant Professor
Department of Mechanical Engineering
MBM Engineering College
Production Planning & Control

Operations Scheduling
 Operations Scheduling

Contents
Introduction
Job Shop Scheduling Terminology
Sequencing Rules
Sequencing Theory for a Single Machine
Sequencing Theory for Multiple Machines
Assembly Line Balancing
Advanced Topics for Operations scheduling
 Introduction-What is Operations Scheduling ?
Forecast of future demand
 Implement the production
orders generated in MRP under
given objectives ; Aggregate plan
 Allocate production resources
(machine, workers et al.) to
Master production schedule (MPS)
production orders (jobs or tasks
Schedule of production quantities by
and their due dates) in an
product and time period
optimized manners;
 The results are time allocations
Material Requirement Planning (MRP)
of production resources to
different jobs (job sequences on Generate production orders and
each production resources); purchase order
 All the orders can be completed
while all production resources Operations Scheduling
are utilized with their loads To meet quantities and time
being balanced. requirements for MRP
Scheduling

 Scheduling: The allocation of resources over time to accomplish

specific tasks.
 Demand scheduling: A type of scheduling whereby customers
are assigned to a definite time for order fulfillment.
 Workforce scheduling: A type of scheduling that determines
when employees work.
 Operations scheduling: A type of scheduling in which jobs are
assigned to workstations or employees are assigned to jobs for
specified time periods.
Introduction

Operations scheduling is critical to the success of an

organization; however, it can be a very complicated task.
Effective schedules are needed to meet promised customer
delivery dates or inventory targets.

It covers the following areas in particular:

- assign job to a particular work center/ machine
- time of assignment of job and completion
- allocation of resources like manpower and materials
- time sequence of operations
- feedback and control function to take care of deviations
Objectives of Operations
Scheduling

 Making efficient use of the labour.

 Making best possible use of the equipments that

are available for the use.

 Increasing the profit.

 Increasing the output.

 Improving the service level.

Objectives of Operations
Scheduling

 Maximizing the delivery performance i.e. meeting

the delivery dates.

 Minimizing the inventory.

 Reducing the manufacturing time.

 Minimizing the production costs.

 Minimizing the worker costs.

Functions of Operations
Scheduling

 Allocation of the resources.

 Shop floor control.

 Making maximum use of the plant at minimum

possible cost.

 Ensure that the needs of the manpower are

optimum.

 Determination of the sequence of the jobs.

Functions of Operations
Scheduling

 Specifying the start and the end time for each job
(actively scheduled).

 Getting quick feedback from the shops regarding

the delays and the various interruptions.

 Possess up – to – date information for the

availability of the materials, expected delivery
dates etc.

 Possess up – to – date data on the machine

regarding its breakdown, servicing etc.
Types of Scheduling

Types of Operations Scheduling are as follows:

1. Forward operations scheduling –

 Classified on the basis of the time.
 All the activities are scheduled from the date of the planned
order release.
 First task of the job is scheduled.
 Its subsequent task is scheduled on the scheduled
completion of the first task.
 Like this, accordingly all the tasks of the job are scheduled.
Types of Scheduling

2. Backward operations scheduling –

 Also classified on the basis of the time.

 Activities are scheduled from the date or the planned receipt

date.

 The last activity is scheduled first.

 Time of the start of the last task is considered as the time for
the start of the previous activity.
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
Sequencing Jobs

 Operations schedules are short-term

plans designed to implement the sales and
operations plan
 An operation with divergent flows is often
called a job shop
 Low-to medium-volume production
 Utilizes job or batch processes
 The front office would be the equivalent for a
service provider
 Difficult to schedule because of the variability in
job routings and the continual introduction of
new jobs to be processed
Sequencing Jobs

• An operation with line flow is often

called a flow shop
– Medium- to high-volume production
– Utilizes line or continuous flow processes
– The back office would be the equivalent for a
service provider
– Tasks are easier to schedule because the jobs
have a common flow pattern through the
system
 Introduction-Job Shop

A job shop is organized by machines which are grouped

according to their functions.
 Introduction-Job Shop

Job A

Job B

 Not all jobs are assumed to require exactly the same number of operations, and
some jobs may require multiple operations on a single machine (Reentrant
system, Job B twice in work center 3 ).
 Each job may have a different required sequencing of operations.
 No all-purpose solution algorithms for solving general job shop problems ;
 Operations scheduling of shop floor usually means job shop scheduling;
 Job Shop Scheduling Terminology

1. Parallel processing versus sequential processing

 Sequencing Processing: the m machines are distinguishable, and
different operations are performed by different machines.
 Parallel processing: The machines are identical, and any job can be
processed on any machine.
Job A
M1 M2 Job A M1 M2

Job B M3 M4 Job B M3 M4
M , M2, M3, and M4 are different;
1
 Job A has 2 operations which should be
processed on different Machines: M1and  M1, M2, M3, and M4 are
M2; identical;
 Job B has 3 operations which should be  Jobs A and B can be processed
processed on different Machines: M3, M2 on any one of the 4 machines
and M4;
 Job Shop Scheduling Terminology

2 Flow time
 The flow time of job i is the time that elapses from the initiation of
that job on the first machine to the completion of job i.
 The mean flow time, which is a common measure of system
performance, is the arithmetic average of the flow times for all n
jobs

Machines Mean Flow Time=(F1+F2+F3)/3

M1 Job 1 Job 2 Job 3

M2 Job 1 Job 2 Job 3

F1: FT of Job 1 Time

F2: FT of Job 2
F3: FT of Job 3
 Job Shop Scheduling Terminology

3. Make-span
 The make-span is the time required to complete a group of jobs (all n
jobs).
 Minimizing the make-span is a common objective in multiple-machine

sequencing problems.
Machines

M1 Job 1 Job 2 Job 3

M2 Job 1 Job 2 Job 3

F1: FT of Job 1 Time

F2: FT of Job 2
F3: FT of Job 3
Make-span of the 3 jobs
 Job Shop Scheduling Terminology

4. Tardiness and lateness

 Tardiness is the positive difference between the completion time and the
due date of a job.
 Lateness refers to the difference between the job completion time and its
due date and differs from tardiness in that lateness can be either positive or
negative.
 If lateness is positive, it is tardiness; when it is negative, it is earliness
Tardiness Completion
Due date of Job i time of Job i
of Job i Lateness>0---
Tardiness

Completion Due date

Lateness<0---
time of Job i of Job i Earliness

When the completion of Job is earlier than due date, the tardiness is 0
 Sequencing Rules

FCFS (first come-first served)

 Jobs are processed in the sequence in which they entered the shop;
 The simplest and nature way of sequencing as in queuing of a bank

SPT (shortest processing time)

 Jobs are sequenced in increasing order of their processing time;
 The job with shortest processing time is first, the one with the next
shortest processing time is second, and so on;

EDD (earliest due date)

 Jobs are sequenced in increasing order of their due dates;
 The job with earliest due date is first, the one with the next earliest due
date is second, and so on;
 Sequencing Rules

CR (Critical ratio)
 Critical ratio is the remaining time until due date divided by processing

time;
 Scheduling the job with the smallest CR next;

Current time Remaining time of Job i Due date of Job i

Processing time of Job i

CRi=Remaining time of Job i/Processing time of Job i

=(Due date of Job i-current time)/Processing time of Job i
 CR provides the balance between SPT and EDD, such that the task with shorter
remaining time and longer processing time takes higher priority;
 CR will become smaller as the current time approaches due date, and more priority
will given to one with longer processing time;
 For a job, if the numerator of its CR is negative ( the job has been already later), it is
naturally scheduled next;
 If more than one jobs are later, higher priority is given to one that has shorter
processing time (SPT).
 Sequencing Rules

Example 5.1
 A machine center in a job shop for a local fabrication company has five
unprocessed jobs remaining at a particular point in time. The jobs are labeled
1, 2, 3, 4, and 5 in the order that they entered the shop. The respective
processing times and due dates are given in the table below.
 Sequence the 5 jobs by above 4 rules and compare results based on mean

flow time, average tardiness, and number of tardy jobs

Job number Processing Time Due Date

1 11 61
2 29 45
3 31 31
4 1 33
5 2 32
 Mean Flow time=268/5=53.6
Sequencing Rules——FCFS Average tardiness=121/5=24.2
No. of tardy jobs=3.

Job number Processing Time Due Date

1 11 61
2 29 45
3 31 31
4 1 33
5 2 32

Job Completion Time Due Date Tardiness

1 11 61 0
2 40 45 0
3 71 31 40
4 72 33 39
5 74 32 42
Totals 268 121
 Mean Flow time=135/5=27.0
Sequencing Rules——SPT Average tardiness=43/5=8.6
No. of tardy jobs=1.
Job number Processing Time Due Date

1 11 61
2 29 45
3 31 31
4 1 33
5 2 32

Job Processing Time Completion Time Due Date Tardiness

4 1 1 33 0
5 2 3 32 0
1 11 14 61 0
2 29 43 45 0
3 31 74 31 43
Totals 135 43
 Mean Flow time=235/5=47.0
Sequencing Rules——EDD Average tardiness=33/5=6.6
No. of tardy jobs=4.

Job number Processing Time Due Date

1 11 61
2 29 45
3 31 31
4 1 33
5 2 32

Job Processing Time Completion Time Due Date Tardiness

3 31 31 31 0
5 2 33 32 1
4 1 34 33 1
2 29 63 45 18
1 11 74 61 13
Totals 235 33
 Sequencing Rules——CR

Current time: t=0

Job number Processing Time Due Date Critical Ratio
1 11 61 61/11(5.545)
2 29 45 45/29(1.552)
3 31 31 31/31(1.000)
4 1 33 33/1 (33.00)
5 2 32 32/2 (16.00)

Current time should be reset after scheduling one job

Current time: t=31
Job number Processing Time Due Date-Current Time Critical Ratio
1 11 30 30/11(2.727)
2 29 14 14/29(0.483)
4 1 2 2/1 (2.000)
5 2 1 1/2 (0.500)
 Mean Flow time=289/5=57.8
Sequencing Rules——CR Average tardiness=87/5=17.4
No. of tardy jobs=4.
Current time=60
Job number Processing Time Due Date- Critical Ratio
Current Time
1 11 1 1/11(0.0909)
4 1 -27 -27/1<0
5 2 -28 -28/2<0

Both Jobs 4 and 5 are later, however Job 4 has shorter processing time
and thus is scheduled first; Finally, job 1 is scheduled last.
Job number Processing Time Completion Time Tardiness
3 31 31 0
2 29 60 15
4 1 61 28
5 2 63 31
1 11 74 13
Totals 289 87
 Sequencing Rules——Summary

Rule Mean Flow Time Average Number of

Tardiness Tardy Jobs

FCFS 53.6 24.2 3

SPT 27.0 8.6 1
EDD 47.0 6.6 4
CR 57.8 17.4 4

Discussions
 SPT results in smallest mean flow time;
 EDD yields the minimum maximum tardiness (42, 43, 18, and 31 for the 4
different rules);
 Always true? Yes!
 Sequencing Theory for A Single Machines

Assuming that n jobs are to be processed through one machine.

For each job i, define the following quantities:
 ti=Processing time for job i, constant for job i;
 di=Due date for job i, constant for job i;
 Wi=Waiting time for job i, the amount of time that the job must wait before its
processing can begin.
 When all the jobs are processed continuously, W is the sum of the
i
processing times for all of the preceding jobs;
t1 t2 t3 t4

W4=t1+t2+t3 F4=W4+t4
 F =Flow time for job i, the waiting time plus the processing time: F = W + t ;
i i i i

 Li=Lateness of job i , Li= Fi- di, either positive or negative;

 Ti=Tardiness of job i, the positive part of Li, Ti=max[Li,0] ;

 Sequencing Theory for A Single Machines

 Maximum Tardiness T max

= max{ T ,T 1 2
,...,T n}
n
1
∑
'
 Mean Flow Time F =
n F
i=1
i

 Suppose that 4 jobs J1, J2, J3, J4 need to be scheduled

 For example a schedule  Considered as a permutation of

is J3-J2-J1-J4 integers 1, 2, 3, 4: 3, 2, 1, 4.

 For only a single machine, every schedule can be represented by a

permutation (ordering) of the integers 1, 2, 3, …, n.
 There are totally n! (the factorial of n) different permutations.
 A permutation of integers 1, 2, …, n is expressed by [1], [2], …, [n],
which represents a schedule;
 [i] denotes the integer that put in the ith place in the permutation;

 In case of a schedule 3, 2, 1, 4, [1]=3, [2]=2, [3]=1, and [4]=4;

 Sequencing Theory for A Single Machines

1.Shortest-Processing-Time Scheduling
Theorem 8.1 The scheduling rule that minimizes the mean flow
time F’ is SPT.
k
 Suppose a schedule is [1], [2], … [k], [k+1], … F =∑t[i ]
[k ]
[n], the flow time of the job that is scheduled in i=
1

position k is given by, say job in position 3:

t[1] (t2) t[2] (t1) t[3] (t4) t[4] (t3)

F[2]=t[1]+t[2]=t2+t1

The mean flow time of all jobs on 1 n

1 n k

∑ ∑∑
'
F =
n F [k ]
=
n t [i ]
the schedule is given by i=1 k=1 i=1
 Sequencing Theory for A Single Machines
1.Shortest-Processing-Time Scheduling
Theorem 8.1 The scheduling rule that minimizes the mean flow
time F’ is SPT
n n k
1 1
∑ ∑∑
'
The mean flow time is given by F =
n F
i=1
[k ]
=
n k=
t
1 i=1
[i ]

 The double summation term may By summing down the column rather
be written in a different form. than across the row, we may rewrite F’
Expanding the double summation, in the form
we obtain
k=1:t[1] ; nt[1]+(n-1)t[2]+…+t[n]
k=2:t[1]+ t[2];
…;
Clearly, it is minimized by setting
k=n:t[1]+ t[2 +…t[n]
t [1]
≤ t [2] ≤ ... ≤ t [ n ]

SPT sequencing rule: the job with shortest processing time t is set first
 Sequencing Theory for A Single Machines

1. Shortest-Processing-Time Scheduling (Cont.)

Corollary 8.1 The following measures are equivalent:
 Mean flow time
 Mean waiting time
 Mean lateness
SPT minimizes mean flow time, mean waiting time, and
mean lateness for single machine sequencing.
2. Earliest-Due-Date Scheduling: If the objective is to
minimize the maximum lateness, then the jobs should be
sequenced according to their due dates. That is, d[1]≤ d[2]≤…
d[n].
 Sequencing Theory for A Single Machine

3. Minimizing the number of Tardy Jobs: An algorithm from

Moore(1968) that minimizes the number of tardy jobs for the
single machine problem.
 Step1. Sequence the jobs according to the earliest due date to obtain the
initial solution. That is d[1]≤ d[2]≤,…, ≤ d[n];
 Step2. Find the first tardy job in the current sequence, say job [i]. If none
exists go to step 4.
 Step3. Consider jobs [1], [2], …, [i]. Reject the job with the largest
processing time. Return to step2. (Why ?)
 Reason: It has the largest effect on the tardiness of the Job [i].
 Step4. Form an optimal sequence by taking the current sequence and
appending to it the rejected jobs. (Can be appended in any order?)
 Yes, because we only consider the number of tardiness jobs rather than
tardiness.
 Sequencing Theory for A Single Machine

Example 8.3
Job 1 2 3 4 5 6
Due date 15 6 9 23 20 30
Processing time 10 3 4 8 10 6

Solution Longest processing time

Job 2 3 1 5 4 6
Due date 6 9 15 20 23 30
Processing time 3 4 10 10 8 6
Completion 3 7 17 27 35 41
time
 Sequencing Theory for A Single Machine

Example 8.3 :Solution (Cont.) Longest processing time

Job 2 3 5 4 6
Due date 6 9 20 23 30
Processing time 3 4 10 8 6
Completion time 3 7 17 25 31

Job 2 3 4 6
Due date 6 9 23 30
Processing time 3 4 8 6
Completion time 3 7 15 21

The optimal sequence: 2, 3, 4, 6, 5, 1 or 2, 3, 4, 6, 1, 5. In each case the

number of tardy jobs is exactly 2.
 Sequencing Theory for A Single Machines
Precedence constraints: Lawler’s Algorithm
g i ( Fi ) = Fi − d i = Li Minimizing maximum
lateness
Objective min max g ( F ) i i
Function 1≤ i ≤ n

g i ( Fi ) = max( Fi − d i ,0) Minimizing maximum

tardiness
gi is any non-decreasing function of the flow time Fi

The Algorithm
First schedules the job to be completed last, then the job to be completed
next to last, and so on. At each stage one determines the set of jobs not
required to precede any other. Call this set V. among the set V, choose the
job k that satisfies
g k (τ ) = min ( g i (τ )) e.g.: the job among V that has smallest tardiness,
i∈v if arranged on position [n].
τ = ∑i =1 t i
n
The processing time of the current sequence
 Sequencing Theory for A Single Machines

The Algorithm (Cont.)

 Consider the remaining jobs and again determine the set of
jobs that are not required to precede any other remaining job.

 The value of τ is then reduced by tk and the job scheduled next

to last is now determined.
 The process is continued until all jobs are scheduled.

Note: As jobs are scheduled, some of the precedence

constraints may be relaxed, so the set V is likely to change at
each iteration.
 Sequencing Theory for A Single Machines
Example 8.4

Job 1 2 3 4 5 6
Processing time 2 3 4 3 2 1
Due date 3 6 9 7 11 7
 Sequencing Theory for A Single Machines
Example 8.4
Not predecessor
Step1: find the job scheduled last(sixth)

Job 1 2 3 4 5 6
Processing time 2 3 4 3 2 1
Due date 3 6 9 7 11 7

3 5 6
τ =2+3+4+3+2+1=15
Tardiness 15-9=6 15-11=4 15-7=8
Step2: find the job scheduled fifth
Not predecessor
Job 1 2 3 4 6
Processing time 2 3 4 3 1
Due date 3 6 9 7 7

3 6
τ =15-2=13 Tardines 13-9=4 13-7=6
 Sequencing Theory for A Single Machines

Example 8.4
Not predecessor
Step3: find the job scheduled fourth

Job 1 2 4 6
Because job3 is no
Processing time 2 3 3 1 longer on the list,
Job 2 now because
Due date 3 6 7 7 a candidate.

2 6
τ =13-4=9
Tardiness 9-6=3 9-7=2
Step4: find the job scheduled third
Not predecessor
Job 1 2 4
Because job6 has been
Processing time 2 3 3 scheduled, Job 4 now
because a candidate along
Due date 3 6 7 with Job 2.

2 4
τ =9-1=8 Tardiness 8-6=2 8-7=1
 Sequencing Theory for A Single Machines

Example 8.4
Not predecessor
Step5: find the job scheduled second

Job 1 2
Processing 2 3 The optimal sequence: 1-2-4-6-3-5
time
Due date 3 6

Job Processing Flow Due date Tardiness

time time
1 2 2 3 0
2 3 5 6 0
4 3 8 7 1
6 1 9 7 2
3 4 13 9 4
5 2 15 11 4 Maximum tardiness
 Sequencing Theory for Multiple Machines

Assume that n jobs are to be processed through m

machines. The number of possible schedules is
astonishing, even for moderate values of both n and m.
For each machine, there is n! different ordering of
the jobs; if the jobs may be processed on the machines
in any order, there are totally (n!)m possible schedules.
(n=5, m=5, 25 billion possible schedules)
Even with the availability of inexpensive computing
today, enumerating all feasible schedules for even
moderate-sized problems is impossible or, at best,
impractical.
 Sequencing Theory for Multiple Machines

Gantt chart
Suppose that two jobs, I and J, are to be scheduled on two
machines, 1 and 2, the processing times are

Machine 1 Machine 2
Job I 4 1
Job J 1 4

 Assume that both jobs must be processed first on machine 1

and then on machine 2. There are four possible schedules.
Sequencing Theory for Multiple Machines
Schedule Total flow time Mean flow time Mean idle time
1 9 (5+9)/2=7 (4+4)/2=4
2 6 5.5 1
3 10 8 5
4 10 9.5 5
 Sequencing Theory for Multiple Machines

1. Scheduling n Jobs on Two Machines

Theorem 8.2 The optimal solution for scheduling n jobs on two machines
is always a permutation schedule.
A very efficient algorithm for solving the two-machine problem was
discovered by Johnson(1954).
 Denote the machines by A and B
 The jobs must be processed first on machine A and then on machine B.
 Define
 Ai=Processing time of job i on machine A
 Bi=Processing time of job i on machine B
 Rule: Job i precedes job i+1 if min(Ai, Bi-1)<min(Ai+1,Bi)
 List the values of Ai and Bi in two columns.
 Find the smallest remaining element in the two columns. If it
appears in column A, then schedule that job next. If it appears in
column B, then schedule that job last.
 Cross off the jobs as they are scheduled. Stop when all jobs have
 Sequencing Theory for Multiple Machines
Job Machine A Machine B
Example 8.5 1 5 2
2 1 6
3 9 7
4 3 8
5 10 4

Optimal sequence : 2 4 3 5 1
 Sequencing Theory for Multiple Machines

2. Extension to Three Machines

 The three-machine problem can be reduced to a two-machine problem if
the following condition is satisfied
min Ai≥ max Bi or min Ci≥ max Bi
It is only necessary that either one of these conditions be satisfied. If that is the
case, then the problem is reduced to a two-machine problem
 Define Ai’=Ai+Bi, Bi’=Bi+Ci
 Solve the problem using the rules described above for two-machines, treating
Ai’ and Bi’ as the processing times.
 The resulting permutation schedule will be optimal for the three-machine
problem.
 If the condition are not satisfied, this method will usually give reasonable,
but possibly sub-optimal results.
 Sequencing Theory for Multiple Machines

3. 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.
 Draw a Cartesian coordinate system with the processing times
corresponding to the first job on the horizontal axis and the processing
times corresponding to the second job on the vertical axis.
 Block out areas corresponding to each machine at the intersection of the
intervals marked for that machine on the two axes.
 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
45-degree diagonal. The path with minimum vertical distance
corresponds to the optimal solution.
 Sequencing Theory for Multiple Machines

Example 8.7
A regional manufacturing firm produces a variety of household products. One
is a wooden desk lamp. Prior to packing, the lamps must be sanded, lacquered,
and polished. Each operation requires a different machine. There are currently
shipments of two models awaiting processing. The times required for the three
operations for each of the two shipments are

Job 1 Job2
Operation Time Operation Time
Sanding (A) 3 A 2
Lacquering (B) 4 B 5
Polishing( C ) 5 C 3
 Minimizing the flow time is the same as maximizing the time that both jobs are
being processed. That is equivalent to finding the path from the origin to the end of
block C that maximizes the diagonal movement and therefore minimizes either the
horizontal or the vertical movement.

or 10+6=16

or 10+(3+2)=15
 Assembly Line Balancing

 The problem of balancing an assembly line is a classic

industrial engineering problem.
 The problem is characterized by a set of n distinct tasks that must be completed
on each item.
 The time required to complete task i is a known constant ti.
 The goal is to organize the tasks into groups, with each group of tasks being
performed at a single workstation.
 In most cases, the amount of time allotted to each workstation is determined in
advance, based on the desired rate of production of the assembly line.
 Assembly Line Balancing

 Assembly line balancing is traditionally thought of as a

facilities design and layout problem.
 There are a variety of factors that contribute to the
difficulty of the problem.
 Precedence constrains: some tasks may have to be
completed in a particular sequence.
 Zoning restriction: Some tasks cannot be performed at
the same workstation.
 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 n
T =∑ti i=
1
 Assembly Line Balancing

For a cycle time of C, the minimum number of

workstations possible is [T/C], where the brackets
indicate that the value of T/C is to be rounded to the
next larger integer.
Ranked positional weight technique:
Places a weight on each task based on the total
time required by this task and all of the
succeeding tasks;
Tasks are assigned sequentially to stations
based on these weights-the bigger the weight is,
the higher the priority is.
 Assembly Line Balancing

Example 8.11
The Final assembly of Noname personal computers, a generic mail-order PC
clone, requires a total of 12 tasks. The assembly is done at the Lubbock, Texas,
plant using various components imported from the Far East. The network
representation of this particular problem is given in the following figure.
 Assembly Line Balancing
∑ti=70, and the production rate is a unit /15 minutes;
Precondition The minimum number of workstations = [70/15]=5
The job times and precedence relationships for this problem are summarized
in the table below.

Task Immediate Predecessors Time

1 _ 12
2 1 6
3 2 6
4 2 2
5 2 2
6 2 12
7 3, 4 7
8 7 5
9 5 1
10 9, 6 4
11 8, 10 6
12 11 7
 Assembly Line Balancing

The solution precedence requires determining the positional

weight of each task. The positional weight of task i is defined as
the time required to perform task i plus the times required to
perform all tasks having task i as a predecessor.
t3+t7+t8+t11+t12=31 Task Positional Weight
1 70
2 58
3 31
4 27
5 20
6 29
7 25
8 18
9 18
10 17
The ranking
11 13
1, 2, 3, 6, 4, 7, 5, 8, 9, 10, 11, 12 7
12
 Assembly Line Balancing
Profile 1 C=15
Station 1 2 3 4 5 6
Tasks 1 2, 3, 4 5, 6, 9 7, 8 10, 11 12
Processing time 12 14 15 12 10 7
Idle time 3 1 0 3 5 8

Task Immediate Time

Predecessors
1 _ 12
2 1 6
3 2 6
4 2 2
5 2 2
6 2 12
7 3, 4 7
8 7 5 The ranking
9 5 1
10 9, 6 4 1, 2, 3, 6, 4, 7, 5, 8, 9, 10, 11,
11 8, 10 6 12
12 11 7
 Assembly Line Balancing
Profile 1 C=15
Station 1 2 3 4 5 6
Tasks 1 2,3,4 5,6,9 7,8 10,11 12
Processing time 12 14 15 2 10 7
Idle time 3 1 0 3 5 8
15 The ranking
1, 2, 3, 6, 4, 7, 5, 8, 9, 10, 11,
Cycle Time=15 12
T1=12 T2=6
T2=6 T3=6 T4=2 T5=2 Evaluate the
T5=2 T6=12 T9=1 balancing results by
the efficiency
T7=7 T8=5 T10=4
∑ti/NC;
T10=4 T11=6 T12=7
The efficiencies for
T12=7 Profiles 1 is 77.7%.
 Assembly Line Balancing

Alternative 1: Change cycle time to ensure 5 station balance

Profile 2: Increasing cycle time from 15 to 16

Station 1 2 3 4 5
Tasks 1 2,3,4,5 6,9 7,8,10 11,12
Idle time 4 0 3 0 3

Increasing the cycle time from 15 to 16, the total idle time
has been cut down from 20 min/units to 10; resulting in a
substantial improvement in balancing rate.
 However, the production rate has to be reduced from one
unit/15 minutes to one unit/16minute;
 Assembly Line Balancing

Alternative 2: Staying with 6 stations, see if a six-station

balance could be obtained by cycle time less that 15 minutes
The efficiencies for profile 1~ 3 are 77.7%,
Profile 2 C=13 87.5%, and 89.7%. Thus the profile 3 is the
best one.
Station 1 2 3 4 5 6
Tasks 1 2,3 6 4,5,7,9 8,10 11,12
Idle time 1 1 1 1 4 0

 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;
The End !