Unit 2

Management of Conversion System

Chapter 9: Project Scheduling
Lesson 28 -Tutorial 8

Case

Scheduling at Bellop
INTRODUCTION
Bellop Ltd. established in the early 1960s as a private firm, is
manufacturing a number of electronic equipment items. The organization,
being a fairly large one, is a pioneer in the range of products manufactured
by it. The technological excellence of its products has gained it a place
among organizations, which undertake complex design _d development
work for the electronic industry as a whole.
During the late eighties, the company established a unit within its present
manufacturing premises, exclusively dedicated to such developmental tasks. The
unit was organized to produce fabricated components on the cellular
manufacturing principle.
Currently, its fabrication shop is divided into five work cells. These cells are,
more or less, divided on the basis of operation layouts for components. Each cell
processes a group of similar products, due to which, flexibility and economy are
achieved in manufacturing.
Material flow is shown in Fig. 14.1. Approximately 50 to 70 per cent of
mechanical parts go

I
1
1 I 1
Work cell Work cell Work cell Work cell Work cell
----. -- --. I--
1 2 3 4 5
l
 Plating
shop shop Assembly

Fig. 14.1 Material flow

through the paint shop to the assembly; hence, the importance of the paint shop.
The present trenc indicates that about 70 per cent of the load in the paint shop is
due to jobs related to PRC and RRA projects
.A job which takes the longest production route is shown in Fig. 14.2 as a process
flow. The
Workcell or slores
 To assembly /
slores

Fig. 14.2 Process flow.

sequence is maintained for all the jobs but some operations may be skipped
depending upon the, routing of a job. More details about various operations in their
sequence for the jobs of the particular month studied, are given in Table 14.1.
The paint shop can be considered as a job shop with inputs coming in batches
of different quantities and of different types at different points in time. The overall
information system existing; in the organization, with a specific reference to paint
shop and its interface with other work cells i shown in Fig. 14.3.
Yearly forecast/order booking is done by the Sales Department. The forecast
gives an idea 0 how many jobs per project are to be processed during the current
year. It includes any backlog 0 the previous orders as well. This forecast is
considered by various project cells so as to make
quarterly schedule for the number of jobs. There are five project cells which
monitor the progress of various jobs produced against their requirements. These
cells expedite the production in the pair shop on the basis of assembly
requirements.
The job plan is divided into the
categories:
1. Monthly production.
2. Quarterly
production.
3. Yearly
production.

The quarterly plan is broken into a monthly plan or monthly list for the parts
to be delivered (which are in short supply) for the assembly requirements.
 Table 14.1 Sequence of Operations for Jobs
Sand Make Applying Putty Primer Final Sten- Screen Letter G
Part number Name Quantity Mask Demask Blast Seal putty rubbing coat coat cilling Printing Painting
2016496501 Housing 245 .103 .22 .045 .053 1
210004960133 Housing 275 .1027 .21 .043 .054 1
.004
475612420122 Knob 539 .0031 .005 .0057 .
2
.003
35001035022 Clamp 244 .0044 .007 .009
6
110000403272 Heatsink 30 .035 .047 .036 .017 .0.17
110000403175 Heatsink 30 .035 .047 .036 .017 .017
110000045245 Frame 12 .084 .081 .47 .039 .042
210002360145 Box assembly 50 .078 .085 .0765 .52 .141 .406 .047 .054 .047 7
20162300234 Clamping frame 33 .031 .046 .021 .024
130384 Window 45 .0083
.002
250010360213 Clamp 500 .0051 .0056 .0061
7
.001
210001600150 Capnut 952 .0023 .0042 .0052 1
9
11000253795 Box 31 .082 .094 .082 .44 .130 .412 .058 .062 .066 4
1.00004700324 Reflector 4 .014 .0267 .0517 .053
assembly
210001610184 Cavity tube 14 .023 .05 .0048 .0052
110000023323 Radiator holder 15 .116 .067 .23 .673 .1152

100004700324 Reflector 21 .014 .267 .0517 .053

assembly
.066
110000020122 Radiator wing 7 .82 .275 .091 .097
7
35001037024 Plate 131 .031 .033 .029 .0834 .375 .0416
.061
110.00'0072114 Device panel 1 .068 .05 .1083 .5 .029 .033 .1416
6
110000023226 Spine 13 .064 .021 .033
110000024487 Frame 9 .094 .085 .324 .112 .03
.004
11000002019 Radiator 139 .029 .0633 .017 .1 J5
2
.003
110000041268 Site cover 31 .012 .021
6
11000032221 Box cover 275 .035 .017 .011
2016201180164C. bar 19 .038 .04
110000024681 Device 4 box 35 .084 .083 .078 .43 .061 .066 .066
110000128374 Device 2 panel 18 .078 .091 .051 .084 .2523 .021 .031 .3
100004512532 Device 1 cab 16 .031 .1033 .108 .3 .074 .093 .011
1000047000309 Angle 300 .062 .003 .004
.002
210001810155 Sub panel 104 .0491 .0035 .0042 .091
7
.001
100004524366 Device 2 cab 19 .05 .129 .37 .052 .059 .091
9
210002950165 Flange 80 .022 .0375 .0183 .023 . .046