Professional Documents
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Chapter 16
Process Strategy Process Analysis Process Performance and Quality Constraint Management Process Layout Lean Systems
Supply Chain Strategy Location Inventory Management Forecasting Sales and Operations Planning Resource Planning Scheduling
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.
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Performance Measures
Job flow time: The amount of time a job spends in the
service or manufacturing system. Also referred to as throughput time or time spent in the system, including service.
Total inventory: The sum of scheduled receipts and onhand inventories. Utilization: The percentage of work time that is productively spent by an employee or machine.
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Gantt Charts
Gantt chart: Used as a tool to monitor the
progress of work and to view the load on workstations.
The chart takes two basic forms: (1) the job or activity progress chart, and (2) the workstation chart.
The Gantt progress chart graphically displays the current status of each job or activity relative to its scheduled completion date.
The Gantt workstation chart shows the load on the workstations and the nonproductive time.
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Actual progress
4/17 4/18 4/19 4/20 4/21 4/22 4/23 4/24 4/25 4/26
Plymouth
Pontiac
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Scheduling Employees
Rotating schedule: A schedule that rotates employees through a series of workdays or hours. Fixed schedule: A schedule that calls for each employee to work the same days and hours each week.
Constraints: The technical constraints imposed on the workforce schedule are the resources provided by the staffing plan and the requirements placed on the operating system.
Other constraints, including legal and behavioral considerations, also can be imposed.
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Workforce Scheduling
Example 16.1
The Amalgamated Parcel Service is open 7 days a week. The schedule of requirements is: Required employees
Day
Number of employees
M
6
T
4
W Th F
8 9
S Su
2
10 3
The manager needs a workforce schedule that provides two consecutive days off and minimizes the amount of total slack capacity. To break ties in the selection of off days, the scheduler gives preference to Saturday and Sunday if it is one of the tied pairs. If not, she selects one of the tied pairs arbitrarily.
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Workforce Scheduling
Example 16.1 Steps 1 & 2
Required employees Day Number of employees Employee 1 M 6 X T 4 X W Th F 8 X S Su 2
9 10* 3 X X
Step 1. Find all the pairs of consecutive days that exclude the maximum daily requirements. Select the unique pair that has the lowest total requirements for the 2 days. Friday contains the maximum requirements (10), and the pair SSu has the lowest total requirements. Therefore, Employee 1 is scheduled to work Monday through Friday. Step 2. If a tie occurs, choose one of the tied pairs or ask the employee to make a choice. 2007 Pearson Education
Workforce Scheduling
Example 16.1 Step 3
Required employees
Day
Number of employees Employee 1 Requirements Employee 2
M
6 X 5 X
T
4 X 3 X
W Th F
8 X 7 X
S Su
2
9 10* 3 X X 8 9* 3 X X
Step 3. Subtract the requirements satisfied by the Employee 1 from the net requirements for each day the employee is to work and repeat step one.
Again the pair SSu has the lowest total requirements. Therefore, Employee 2 is scheduled to work Monday through Friday.
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Workforce Scheduling
Example 16.1 Step 4
Required employees Day Number of employees Employee 1 Requirement Employee 2 Requirement Employee 3 Requirement M 6 X 5 X 4 X 3 T 4 X 3 X 2 X 1 W Th F 8 X 7 X 6 X 5 S Su 2 2
9 10* 3 X X 8 9* 3 X X 7 8* 3 X X 6 7* 3
2
2
Step 4. Repeat steps 1 through 3 until all the requirements have been satisfied. After Employees 1, 2, and 3 have reduced the requirements, the pair with the lowest requirements changes, and Employee 4 will be scheduled for Wednesday through Sunday. 2007 Pearson Education
Workforce Scheduling
Example 16.1 Step 4 continued
Required employees Day Number of employees Employee 1 Requirement Employee 2 Requirement Employee 3 Requirement Employee 4 Requirement Employee 5
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M 6 X 5 X 4 X 3 3 X
T 4 X 3 X 2 X 1 1 X
W Th F 8 X 7 X 6 X 5 X 4 X
S Su 2 2 2 2 X 1
9 10* 3 X X 8 9* 3 X X 7 8* 3 X X 6 7* 3 X X X 5 6* 2 X X
Workforce Scheduling
Example 16.1 Step 4
Required employees Day Requirement Employee 6 Requirement Employee 7 Requirement Employee 8 Requirement Employee 9 Requirement Employee 10
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continued
M 2 2 X 1 X 0 0 X
T 0 0 X 0 X 0 X 0 X
W Th F 3 X 2 X 1 X 0 X 0 X 4 X 3 X 2 X 1 X 0 X 5* X 4* X 3* X 2* X 1* X
S Su 2 X 1 1 1 X 0 1 X 0 0 0 0
Workforce Scheduling
Example 16.1
Final Schedule Day Employee 1 Employee 2 Employee 3 Employee 4 Employee 5 Employee 6 Employee 7 Employee 8 Employee 9 Employee 10
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M X X X
off
T X X X
off
W Th F X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
S Su
off off off off off off
X
off
X
off
X
off
X
off
X
off off
X
off off off off
X X
off
X X X X
X
off
Workforce Scheduling
Example 16.1 Final Schedule
Final Schedule M T W Th F S
off
off off
Su
off
off off
Employee Employee Employee Employee Employee Employee Employee Employee Employee Employee
1 2 3 4 5 6 7 8 9 10
X X X
off
X X X
off
X
off
X
off
X X
off
X 7 6 1
X X X X 8 4 4
X X X X X X X X X X
10 8 2
X X X X X X X X X X
10 9 1
X X X X X X X X X X
10 10 0
X
off
X
off
X
off off
X
off off off off
X
off
Total
3 3 0
2 2 0
50 42 8
Operations Scheduling
Operations schedules are short-term plans designed to implement the master production schedule.
Operations scheduling focuses on how best to use existing capacity. Often, several jobs must be processed at one or more workstations. Typically, a variety of tasks can be performed at each workstation.
Job shop: A firm that specializes in low- to medium-volume production and utilizes job or batch processes. Flow shop: A firm that specializes in medium- to high-volume production and utilizes line or continuous processes.
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Manufacturing Process
Shipping Department
Raw Materials
the time remaining until a jobs due date by the total shop time remaining for the job. CR = (Due date Todays date)/Total shop time remaining
Total Shop Time = Setup, processing, move, and expected waiting times of all remaining operations, including the operation being scheduled.
Priority rules, such as CR and S/RO, incorporate information about the remaining workstations at which the job must be processed. We call these rules multiple-dimension rules.
Multiple-dimension rules: A set of rules that apply to more than one aspect of a job.
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Example 16.2
Single-Dimension Rule Sequencing
Five engine blocks are waiting for processing. The processing times have been estimated. Expected completion times have been agreed. The table shows the situation as of Monday morning. Customer pickup times are measured in business hours from Monday morning. Determine the schedule by using the EDD rule and then the SPT rule. Calculate the average hours early, hours past due, WIP inventory, and total inventory for each method.
If low job flow times and WIP inventories are critical, which rule should be chosen?
Example 16.2
Single-Dimension Rule EDD
Engine Block Sequence
Ranger Explorer Econoline 150 Bronco
Thunderbird
0 8 14 17 32
+ + + + +
8 6 3 15 12
= = = = =
8 14 17 32 44
10 12 18 20 22
10 14 18 32 44
2 2 1 12 22
Average job flow time = 23 hours Average hours past due = 7.2 hours
Average WIP = 2.61 blocks 8 18 + 14 17 32 + 44 10 + 14 + ++ 32 ++44 Average total inventory = 2.68 engine blocks 44 44 2007 Pearson Education
Example 16.2
Single-Dimension Rule SPT
Engine Block Sequence
Ranger Econoline 150 Explorer Explorer Econoline Ranger 150 Bronco Thunderbird Bronco Thunderbird
0 0 8 3 14 9 17 17 29 29
+ + + + +
3 8 6 6 8 3 12 15 15 12
= = = = =
44
10 18 12 12 18 10 22 20 20 22
44
24
Average WIP = 2.32 blocks +9 17+ + 44 29 + 44 18 + 12 +317 ++20 Average total inventory = 2.73 engine blocks 44 44 2007 Pearson Education
Average job flow time Average hours early Average hours past due Average WIP Average total inventory
The SPT schedule has a lower average job flow time and lower WIP inventory. The EDD schedule has better customer service, (average hours past due) and lower maximum hours past due. EDD also has a lower total inventory because fewer hours were spent waiting for customers to pick up their engine blocks after they had been completed.
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Example 16.3
Multiple-Dimension Rule CR
Operation Time Time at Remaining Engine to Due Date Lathe (hr) (Days)
Job
CR
S/RO
1 2 3 4
15 10 20 8
10 2 12 5
Example 16.3
Multiple-Dimension Rule S/RO
Operation Time Time at Remaining Engine to Due Date Lathe (hr) (Days)
Job
CR
S/RO
1 2 3 4
15 10 20 8
10 2 12 5
Time remaining to due date Shop time remaining S/RO = Number of operations remaining
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Job
CR
S/RO
1 2 3 4
15 10 20 8
10 2 12 5
= = = = =
FCFS
Critical Ratio
Avg Flow Time Avg Early Time Avg Past Due Avg WIP Avg Total Inv
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Johnsons Rule
Johnsons rule: A procedure that minimizes makespan
when scheduling a group of jobs on two workstations. Step 1. Find the shortest processing time among the jobs not yet scheduled. If two or more jobs are tied, choose one job arbitrarily. Step 2. If the shortest processing time is on workstation 1, schedule the corresponding job as early as possible. If the shortest processing time is on workstation 2, schedule the corresponding job as late as possible. Step 3. Eliminate the last job scheduled from further consideration. Repeat steps 1 and 2 until all jobs have been scheduled.
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Example 16.5
Johnsons Rule
Motor Workstation 1 at the Morris Machine Co. Time (hr) Workstation 2
M1 M2 M3 M4 M5
12 4 5 15 10
22 5 3 16 8
Eliminate M3 from consideration. The next shortest time Eliminate M1 and the only job remaining to be Eliminate M5 from consideration. The next shortest time is Eliminate M2 from consideration. The next shortest time is Shortest time is 3 hours at workstation 2, so isat M2 at Workstation 1,schedule so schedule M2 first. scheduled is M4. M1 at workstation #1, so schedule M1 next. M5 workstation #2, so M5 next to last. schedule job M3 last.
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Sequence = M2
M1
M4
M5
M3
Example 16.5
Johnsons Rule
at the Morris Machine Co.
The schedule minimizes the idle time of workstation 2 and gives the fastest repair time for all five motors. No other sequence will produce a lower makespan.
Gantt Chart for the Morris Machine Company Repair Schedule
Workstation M2 (4) Idle M2 (5) M1 (12) M4 (15) M1 (22) M5 (10) M3 (5) M4 (16) Idleavailable for further work M5 (8) M3 (3)
Idle
10
15
20
25
30
35 Day
40
45
50
55
60
65
Labor-limited Environments
The limiting resource thus far has been the number of machines or workstations available. A more typical constraint is the amount of labor available.
4.
the supply chain and align daily operations with strategic goals. Four characteristics of these systems are: Demand Planning. This capability enables companies in a supply chain to share demand forecasts. Supply Network Planning. Optimization models based on linear programming can be used to make long-term decisions. Available-to-Promise. Firms can use this capability to promise delivery to customers by checking the availability of components and materials at its suppliers. Manufacturing Scheduling. This module attempts to determine an optimal grouping and sequencing of manufacturing orders based on detailed product attributes, production line capacities, and material flows.
Solved Problem 1
The Food Bin grocery store operates 24 hours per day, 7 days per week. At the end of the month, they calculated the average number of checkout registers that should be open during the first shift each day. Results showed peak needs on Saturdays and Sundays.
1. Develop a schedule that covers all requirements while giving two consecutive days off to each clerk. How many clerks are needed? 2. Plans can be made to use the clerks for other duties if slack or idle time resulting from this schedule can be determined. How much idle time will result from this schedule, and on what days?
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Solved Problem 1
Solved Problem 1
Solved Problem 2
The Neptunes Den Machine Shop specializes in overhauling outboard marine engines. Currently, five engines with varying problems are awaiting service. The best estimates for the labor times involved and the promise dates (in number of days from today) are shown in the following table. Customers usually do not pick up their engines early.
Develop separate schedules using SPT and then EDD rules. Compare them using average job flow time, % of past due jobs, and maximum past due days. Calculate average WIP inventory (in engines) and average total inventory.
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Solved Problem 2
SPT
EDD
Solved Problem 2
SPT Average job flow time 9.80 EDD 15.20
40%
11 2.13
60%
7 3.30
3.52
3.52
Solved Problem 4
Cleanup of chemical waste storage basins involves two operations. Operation 1: Drain and dredge basin. Operation 2: Incinerate materials. Management estimates that each operation will require the following amounts of time (in days):
Find a schedule that minimizes the makespan. Calculate the average job flow time of a storage basin through the two operations. What is the total elapsed time for cleaning all 10 basins?
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Solved Problem 4
Four jobs are tied for the shortest process time: A, D, E, and H. (E and H are tied for first place, while A and D are tied for last place.) We arbitrarily choose to start with basin E Dredge Incinerate A B C D E F G H E H G F B J I C D A I J 3 4 3 6 1 3 2 1 8 4 1 4 2 1 2 6 4 1 2 8
Solved Problem 4
The Gantt machine chart for this schedule
Storage basin
Dredge Incinerate EH G E H F G B F J B I J C I D C D A A