Dt, q Ahtu, AAhtot E6in

Chapt€r l7
Operations Scheduling
Dr. M. Ahsn Akhar Hasin
BUET

lntroductiotr to Operations Scheduling

h is ihe pmcos ol orsanizing. choosing and liming resource usage lo carry our atl ihc
adivitics nccesary ro pmducc rhe desire! ourpuls ar the desircd tiDes, while satisfying a
l.reo nunber orti'ne antl relationship con$minr anongthe Nli,itics and the.esources.

In brcad, the funcrio.s orOpentions Scheduline aretoderennine rheliminss Grdr lifre and
.ompl.lion ritoe ol each activlB/opemtion) and sequence ol opcmriors (orderins or
operarioisor job, rt h a prcduction conror runcrion.

In opeBtions schedtrling, a cunomer oder or producion order is knoyn as a Job, Once lhe
jobs are itr hand, those need schenulins. aspcrprioriry A busy shop noor(poduclion nooo
may have manyiobs under pm.essing sintrltaneoury.

Prcduclion conrol (in Poducrion Plannirg md Conlst) fundion includes acri!iries like
Opemtions sch edu 1ing.
asigning rvorkc6 to na.hines/opentioDs.
Bsimins lobs (ordere) lo sork cente6.
- monitorinCondconrollingpmgrc$of orde6,
expediling cririol ordeE

Proddction conrrcl is ako known as Shop Floor Conrot (SFC), or prcducti.n Acriliry

A wol,k Cenrer h an area in poduclion siere one or mo.e produclive rcs.uces

(macnines, c{tuipne.! manpo\re, are srouped rocerher lo p$lom a panicutar
opcmtionc). The $ork cenler mar bc a single machlne, a s6up ormachines, or an area
wheE a paniculartype of*ork is done. The work.cnrc6 may be organizcd (i.e. tayout
ofde Nork cente^) in many Bays, dependins upon lwe ofproducls, requiremenrs for
pm.csing and cunomer..der techniquc.

Shop Routingrob Routing

It is rhc pa(em or parh of flow of msleisls. sequenced thrcugh *!.k centers. Hoc, scrie!
olopqarional sleps that are canied o[ succe$ively to prcducc an itch is defined. The
oDeraions are identified by serialnumbsr, as perdesisn and pmses plan, which indicales
sequence of operalions lor the asociared nrnuladuring proccs
For instance,lels assumc Nojobs ryirh the follo*ing routnlgs:
D., M. ah\anAlhtut ltatin

Inlinile Vs. Finitc Loading

The characie sticrh.r disiineu is hes onc schedu ting syscn trom anolher h how capacirl
is considered in dcreminingschedute. Ihe scheduling synem can considereirher tiniEd
capacity or open capacny.

lnfinite l.adiigoccu6 rheh Nork i! a$igned to r sork ccntsr b.sed on *hai n needed
as per ma*et dcmand. No consideration h given dtrec y whdher rhere is suficienl
c.pacily to complete rhe scheduled oidc6 or nol, Capacir) timitario connrainr is tgnored
here. MRPusynem,ltr ils cuiienr fom, is an Infinile Loadtnc s)$em br- dehuh, Tirere k
a high ch.nce that rhe schedulc maybecome inftasibte.

Llo\.ver, the Ealiiy h lhd an, shop has limned capacirJ,. in rcms otboth hanpoweraDd
machi.e es. Finne bading ukes in ro accounr avaitabte capacity ofcach resource. and
relkstheplan ro firin the availablE.apacjly. tr esence,lhe s)stcm deremines exsrly
rvhat will bc done byeach resou.cear everynomenr,luinsrhe opemtjonal time.

Ioturd $. Back*,.d S.hcdulins

Anolhsr chaacrerhtic thar dndnguhhes schedtrting syjems h sherher lhe schcdute is

prc*nted loN€rd or backuard in tih. It G lareely dependingon
Opeofmanutacturing

Fo ard scheduling sy$em rakes an or'ler rhen detemines iG nan tine end rhcn
calculares the possiblc fi.hh rime byadding nanufacturing Icad rime. Genently, Make-
ro{ro.k items decides $an dme and lhen find $e probabte cohpletion time by addi.g
pm.essing time in rhe foNard direcrion in time line. A s,$em thal toNard $hcdutes ca;
relllheearlicn date rhal on onler c& be conpleted.

Coive6ely, Back*ard scheduling delemines rhe o.der due dric, and then back racks to
find polsibLe ordcr rclerse date. fte ba.kRard schedulc rcls rvhen an ord* mun be
nrfred ir orderro compleie rvithout dela]. This sysrcm is Neltsuited lo Make{o-ord
systems, or Job shop. An MRP synem is by dctauk a ba.kNtrd schedutjig slstem,
Bhich can calculale order release dates by oil{criig manuladxrins lead rime fiom
Dt M, Ahtuh Akhtot llasin NE, BUEf

In rhis peryrectlve. il has ro be nole'l lhat lhe mo$ connoi is lonvard schedu Lina.

M!.hinevs. Lahor Limitod Proc.$

Resou rc es and hei r c.paciries a.e impodanr in pLanni.g and scheduli.g.Ir is impona to
r

knos ihich resource Lhima(ely Covems the capacirlr ofr \ork center snd thus. Nhjch
rslurce needs to be scheduled. onen it happ*, $ar a *ork ccntcr k equipped *i$ a
ma.hine as Ncll as xn opeiaror (m,npoler. rhen. it is ifrpoda.t ro kno* rvhici one
(nachineor manpo$or) h uhimarel! playingthe nain role in rhe opdBrion.

lh case ol Machine Limited process, lho kno*nas Machine Con$rained pros.s.

toachine is the critical resourcc rhal is scheduled. a Eork cenier Nirh a .onputer
cortrollcd CNC m.chine is xnerampleolmachi.e limited prcccss, where mmposq hs
frinor mle who does notgovem thecoplcily.

On lhe other hand, Labor Limitcd pmcc$. also known as Labor C.nnraiisd proce$j is
the otre $lEre labor h rhe ffirical rcsource thal is schoduled. Ceieftllrr, in a lahoL
orienred operation. ie.nxnual operation. itislhe laborshich governs the copacily eol

Iniriaring perlomdce ol rhe s.heduled Bork h conmoilt renned I

DXttdtchiry al
ordeE. *hi.h musl be *iihin the limited capacity.frhe prcduction rcsources. Capacnl
plannine ndncussed below.

Capaciry Phnning

It is hasically a pl.nning ruicrion resadine

a comparkon of horv much capocily is requircd
ro n*r planned ouQut, sgainst how much capacily is aroiLable ir the floor. i.c. capaciry
required vs. capaciry available.

tn the coniext ofcapacity planninE. anorher inpona issue regarding capa.ir, avaitabte. is
-Dcsign capacity" ,gain$ " Efect ive caprciq Design capacity h rhc ndi'num
', mountof
work that an organizrtion is copoble ofcompleling in a givei period. EiGciire copaciry is rhe
maximum mounl ofsork that an oreanianion is capable of completing in a given pe od
duc to consrainh such .s qurliiy p6blcms, delars. malerial handlins, etc.
DL M. Ahsa, Akhtot llasin

Irofr a scheduling pospcctive ir is imponant ro deremtne hoY much

*ill be requircd lo manufaotuF a quanlity of prns. Sinpty mutripll
ilme by lhe number ol pans and dilide btr the pan or process
I quipn.nr I 'fi.'er.J. or O\ea 'l qu pl.r' I fiec..vcre+ .

llproduction is scheduled to pioduce 500 pieccs ol prcducr A on a mi.nine halins a

crle rime of30 seconds and rhe OEE for rhe pDccs h 35%, rhcn rhe lime lo pmduce rhe
pans rluld be caicularcd as follows:

r 30 secoDdn / 35% = 17647.1 seconds The OEE iidex Dake\ ir easv r.

(500 pans
d e-'ne *Ther ve h.\e a,ph c"p:..) .o 1.'.e reqL. d prco..rion. t.ih,
sxanple 4.2 hou6 at smddd versus.l.9 hou6 based on rhe OEE indcx.

By rcpeainglhis pmcess lor all lhe pans fiar rur lhrcueh a give. machine, il is posible
lo der.mine the rotal capacity req u jred ro rm prcduction.

Whcn coisidering new Nork lor a pie* ofequipmeni or hachinery. knowing how much
capaciry h available lo fln rhs uoit will evertually become pan ofthe orenlLproces.
Trcically, an annual forccai h used ro derennine how nany hou6 per t.ar are requned.
Ir h ,l5o possible thar seasonaL innuences exk wirhin lhe machinc requirement. so a
quanerly or elen h.nrhly capacity rcpon may be equircd.

Io calculate the total opaciry xvailabk,lhe rolume k adju(cd acconlin8 ro ihe period
being cons ide red. Ire available cap&ity ca. be i.creassd bv
a) eiv ins ovcn ine (shon tem $ep),
b) addinshew shifts (shon ro mid tem nep)
c) buyingmschine (nld to long tem step).
d) hnins morenaipower(mid to lonE rern ncD). dd
e) cxpandi.s the p.oducdon planr (lonstem $ep)

!
Now-a-dars. ousourcirg k aho considerd as shor rem measuft of capacir, deticir.
Se vera I compor ies in Baneladcsh oucou(e a
,an oflheirtargd produclion volumc ro orher

A diss.pancy be$en the capaciry ol rn orsaniation dd rhe dedands of ils cunomen

(apaciry required) renrlG in inemciencl. either in under utilized resources or unfulfilled
cu$one6. The soal oiobjecrive ofcapacily planning is to minimizethisdkcrepancy.

Capacily plaiiing is a par0lleLfunction olschcduling A good schedute in frcr manages rhe

resourccs tr€ll. which eisures elleclive uscolcrpacity.
Dr M. Ahe" A\hrar Easin

Objectives of Scheduling

The obj@rive5 orscheduhfs are

3 Minihizenorytimeoljobs
4. Minimize Wo& ln Proces i.lent ry.
5. Increase urilizalion.lresoures,.r minimize thc idle iimcsofresources. dc.

when noft than onejob remains for proce$ins ih oie muchine or wortr centerj rhe operator
needs ro kno{ the oider in *hich ro proce$ the jobs, litemlly kno\r as a Sequencc. The
pDce$ oi detemining a seqtrence of orde6 h kno*n as .lob Se'iuenci.s. h heans
deteminarion orNhichjobs to siart nrst thc noxr, erc. on amacnine, or work.enler.

Thh is done usinC some rules known as .iPiorily Rule',, *hich is judSed aSains some
perfonnance crileria, such as minimizarioi olflo* time. These are simple, requirin8ontyrhar
jobs be sequenccd according to rhe ruLe described, sith one pleoe ordara such as proce$ins
lime, duc date, order ariival date, etc. ThG h speciaLty usetul in case ot oderbased
.ofrpaniesj e,g. makeio-odcr. ll no panicular ord h specificd. rhe op€raior Notrld
probably prccess ths job ihat arived firr. This delaulr scquence is called ftst-come, fi^!
seNed (FCFS). Hoiever, in now shop envircnDeni. Shonen Prccessjns lime wilt anvayj

Some cohmonlyused prio.ir, rules 3re :

l. Firsl Come FiIn Sene (FCFS) Jobsorordesderunintheorderlheyanivc.

2. Lasl Cone FiNt Scrvc (LcFs) what ererjob aftives the lan is pDcesed fitsr
Alrhough this is not .omhon. but found in many p.acrical siluatiotrs, such as in a
*tail supemarke/oullet, warehousc, ctc. As the producls/moreriah ad!e. rhey are
placed on lhe lronr side ofshelves. When cu{ome6 visil. the, picktrp foh rhe lront
side. alrhough PUr the la$.

3. shone$ opemtion Tlme (SoT), or sh.ne$ Prcce$ine |ime (SPT) - Run rhc j.b
virh rhe shone$ com plerion tine fimt, next sh onest second, and so on.

4, EarliestDueDateIEDD) Runthe jobwithrhsearlienduedate fi6t.

5. Crilicat Ratio (cR) -Thh is calculatcd as ihe dilierence benreen tie due dare and the
cuftcnr ddc divided by rhe number ol *!rk d!)s remaininS order rith rhe smallest

DLe ddte turrz* adb

no.of \-nk dats remdini4

6. Slack Tine renaining (STR) Ihis h calculaled aslhe difcrcnce bctwccn rhc rinc
rcfrainihg bcforc rho duc datc minus rh. proccssing rinc rcnainihg. Onlo with rhc
shone{ sTR is seleclcd fisr.

In addni.i ro the ah.!e rules. rhere are miny orher priorill rules, lvhich m!1, be used
DL M, Ahsa, .lkhti Eati,

Out ofsevemL priorii, rules, used de FIFO. ADD md SPT ler. we

demonsr'ate an example with

Tohlllo* line = 3 + 7+9 +

S., mean no*lime = s0/5 =

S?T

TolalFlowtime= I +l+6+ l0+ 16=16days

So, mean flowtihe:16 / 5 = 7,2 days

Procesins tine (day, Due date (day, I Flow dfre (davs

ToralFlowtime= I +,1+8+ t0+ t6=39days

So, nca. flow time =39/ 5 =7.3 days

\ summary olrhe obo!e.r.uld ons i5 given belou:

So, SPTei\es minih!m me fowtime.

Dt M. Ahtua athtat Easi,

.rohnson's rule h a herhod of schedulinc many jobs (n jobs) in lwo sork ceires (or,
machines). This is speclall) applicable to flow shop case. !s pinory objscrive h to find !n
optim,lsequence oljobs to rcduce flow tihe or makespan (the tolalamoum oftime it takes
lo complete alljob9. L aho ieduces rhe mount ofidle line in $e system. rn brjei rhis h a
melhod for"Scheduling n Jobs on 2 machinet', which is Nrirlen as n/2 floF shop prcbleb.

lr hasthe lollowing alCorithn:

l. Listthcopaation rines foreachjob on both machines

2. Selecr the shonen operation time
r. Irlne shonesr rime is lor lhe lsl nachinc, $hedule the job fiEi ifii is ror rhe 2nd
mach ine. schedu le the job lasr.

4. Repeat Steps 2 and s lor each remaininsjob untilalljobsarc scheduled.

rou' Job. Tq.ireopeErion, in nton&\inc..Ooe.d'o.'ire. dE gi\en

l
6 8
c 5

Tne follos ne(hedu e isgeneft'ed:

0 5 ll l3 2l
B

c B D
05It192325
cuhulativedays

Here,lhe flow time (mokespan) lbrlourjobs. Nonachines is 25 days, Nhich k ninimum.

Johnson\ rulc Nas oiiginrlly dcvoloped for two machines, allhough h can be *rended for3