Professional Documents
Culture Documents
AND
SCHEDULING
Part 1
Planning Hierarchy
Forecasting
MPS
MRP
Balancing
Scheduling
Forecasting
Master Production Planning
(Scheduling)
Material Requirements
Planning (MRP)
Capacity Balancing
Production Scheduling
1970s
Forecasting
MPS
MRP
Balancing
Scheduling
MRP II
MPS
specifies
Sequence and Quantity of Products (C)
MRP
Balancing
EXAMPLE
Jan
200 C1
150 C7
180 C14
Scheduling
Feb
March
195 C4
150 C7
180 C12
128 C17
385 C1
160 C6
670 C7
230 C9
Month
to
Pharmaceutical industry
MPS
Planning horizon:
MRP
1 month to
3 day period
Product C
Balancing
Scheduling
S1
P1
S2
P2
MRP
Record
MRP
Record
MRP Record
Period
Gross requirements
10
Scheduled receipts
On hand
Planned order releases
40
10
-6
50
4
54
44
44
50
Gross requirements
Scheduled receipts
On hand
10
+
4
50
54
-=
44
40
10
-= -=
44
-6
Question?
Period
Gross requirements
Scheduled receipts
On hand
10
+
4
50
54
-=
44
40
10
-= -=
44
-6
50?
What 50?
What will a 50 do to
the MRP record?
The Answer
Period
Gross requirements
Scheduled receipts
10
50
50
54
-=
44
40
10
- = - = 50
44
-6
44
50
Previously omitted
New order release
1
Gross requirements
10
Scheduled receipts
On hand
40
10
50
50
4
54
44
44
-6
44
50
Gross requirements
50
Scheduled receipts
On hand
Planned order releases
Lead time = 1 period
Lot size = 100
8
100
100
-42 58
CAPACITY BALANCING
MPS
MRP
Balancing
Scheduling
8 hour period
5 operations to be assigned to 2 machines
3
2
Part 1
2 operations
Part 2
1 operation
5
Part 3
2 operations
420 [minutes]
Is this correct?
Machine 2
Capacity
480
Question:
Is this Gantt chart a feasible schedule?
Machine 1
NO!
Machine 2
Capacity
420 [minutes]
Time
480
3
1
2
4
5
Why Not?
Conflict 1
Machine 2
Capacity
Machine 1
420 [minutes]
Conflict 2
480
1
2
4
5
M1
M2
Conflict 1
Conflict 2
Capacity
420 [minutes]
3
480
Assignment
M1
Time
[minutes]
M2
Feasible Schedule
Time
3
670
Decision variable
1 if batch i of operations is processed on machine j, j J
x ij =
0 otherwise
C ijxij
i I jJ
machine
batch
x ij = 1
i I
T ijx ij b j
j J
Capacity constraint
x ij = 0 , 1
i I, j J
Integrality constraint
j J
i I
Processing cost
Processing time
Machining capacity
[Cij ] =
1
2
3
4
5
4 7
1.5 1.2
3 6
4 5
2 3
7
6
5
4
2
1
2
3
1
8
1
7
6
[Tij ] = 3
4
3
T
batch x machine
Min
For batch
(row)
i=1
i=2
i=3
i=4
i=5
For machine j = 1
(column)
j=2
j=3
T x b
i I
ij ij
x ij =1
j J
Solution
x11 = 1, x22 = 1, x31 = 1, x43 = 1, x53 = 1
Machine 1: batches 1, 3
Machine 2: batch 2
Machine 3: batches 4, 5
Model 2
min Cijxij + qj z j
x ij = 1
i I
Tijx ij bj
j J
i I jJ
jJ
i I
k ijx ij f jz j
for each j J
xij = 0, 1
for each i I, j J
i I
zj Zj
Integrality constraint
integer for each j J Integrality + bounding
constraint
min
c ijy ij
i I j J
y ij = a i
iI
t ijy ij b j
j J
j J
i I
y ij 0 integ er i I, j J
Integrality constraint
[t ij] =
1
2
3
4
5
6
7
8
9
10
1
29.1
18.4
31.2
24.5
16.5
8.5
35.4
19.4
24.1
2
24.5
14.5
22.0
14.5
6.4
18.1
26.8
20.0
28.0
16.5
17.4
39.1
Batch - machine
matrix
Solution
y12 = 18, y21 = 17, y33 = 15, y42 = 4, y43 = 10,
y51 = 9, y52 = 6, y62 = 20, y72 = 12, y81 = 18,
y91 = 12, y10,1 = 16
Machine 1: 17 operations (of type 2), 9(5), 18(8), 12(9), 16(10)
Machine 2: 18(1), 4(4), 6(5), 20(6), 12(7)
Machine 3: 15(3), 10(4)
Line Balancing
Assignment of tasks to stations
?
What leads to more uniform utilization of
machine capacity:
Capacity balancing with batch splitting, or
Capacity balancing without batch splitting?
?
When the capacity loading Gantt chart
would be equivalent to the schedule Gantt chart?
M1
M2
Conflict 1
Conflict 2
Capacity
420 [minutes]
If there were NO
precedence constraints!
3
1
5
480
Assignment
M1
Time
[minutes]
M2
Schedule
3
670
Manufacturing Scheduling
MPS
MRP
Balancing
Scheduling
Manufacturing Scheduling
8 hour period
Definition
Scheduling is the assignment of operations,
jobs, tasks, etc. to resources in time.
M2
3
0
6
3
2
6
Time
8
8
Makespan = 12
10 12
Manufacturing Scheduling
Basic Models
Flow Shop
Machine 3
P1
P2
M1
M2
M3
M4
P3
Parts
Parts
M1
M2
M3
M4