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Copyright to IJIRSET
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6631
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Copyright to IJIRSET
www.ijirset.com
6632
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
ORDER RELEASE
TO CUSTOMER
DIVIDING
PROCESS
DEPANNING
PROCESS
BAKING
PROCESS
ROUNDING
PROCESS
INITIAL
PROVING
PROCESS
AUTO
PROVING
PROCESS
MOULDING
PROCESS
BAKERY
PRODUCT
There are two main stations in the plant, which are the kneading station and the baking section as shown in the work flow
diagram in Fig 2 below. The processes at the kneading station are: mixing, dividing, rounding, moulding and pan proofing. The
baking process is the only process, which occurs in the oven. The first step involves the weighing of the ingredients to be mixed.
Water temperature is important in controlling the dough temperature. To achieve dough temperature control during the mixing
the following factors must be known and applied:
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6633
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Order Received
Production Planning
Inventory
Kneading Station
Baking Station
Packaging
Delivery to customer
Fig 2: Baking Process Work flow diagram
Mixing of the dough is done to evenly distribute the yeast cells throughout the dough and develop the gluten. The dough is then
cut into loaf, bun or scone size pieces using a divider before weighing of the pieces to ensure uniformity. The divider consists of
a camshaft carrying various cams controls through linkages, the movements of the knife and the ram. A clutch in the gear box at
the front of the divider, under the conveyor, allows the machine to be engaged or disengaged from the main drive. The handle of
the clutch must be removed before opening the clutch box door. The gear reduction ratio is 53/21. The process time of this
process is a variable which is a function of the order quantity and the type of product being produced (bread, buns or
scones).The last process after the kneading procedures is the baking task. This process occurs in the oven. The order quantity
does not affect the baking time since the units are baked in batches.
B. Manufacturing resource requirements
The principle function of a manufacturing process is to convert inputs (labour, energy, and raw materials) into a final product
that is marketable. Fig 3below is a representation of the resources used and the tasks conducted during a baking process.
Copyright to IJIRSET
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6634
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Dough
P-1
P-8
P-7
P-6
P-5
P-16
P-15
P-14
P
Flour
Kneading Task
P
P-10
Baking Task
Bread
P-2
Cooking Oil
Water
Baker
P-11
P-3
Baker
Baker
Oven
P-13
Oven
P-18
P-17
Cleaning Task
Fig 3: Baking operations and resource requirements
The utilized resources are divided into two classes: Renewable resources and unrenewable resources. The renewable resources
in this model are the baker and oven. Renewable resources are restored after the manufacturing process hence there have two
states which are available or not available during the process. One task consumes these resources and restores them at the end of
the task. The unrenewable resources are consumed during tasks and in the process shown above, they include: Flour, water,
cooking oil and dough. Dough that is a mixture of flour and water is regarded as work in progress. The baking process has only
three operations, which are: kneading, baking and cleaning. The cleaning operation is a changeover task or set up for a new
process.
C. Finite Capacity Scheduling System Objectives
Satisfying customer demand on time is our main focus area in this paper. The objectives to achieve this goal are:
Conforming to due dates
Maximizing throughput
Minimizing work in progress and order flow time
Maximizing resource utilization
The scheduling problem at Lobels involved the selection an optimal schedule that will fulfil the above given objectives given
the constraints for available resource capacity, resource availability, labour calendar and machine maintenance calendar. An
objective function for computing the lateness penalty for each order was developed.
D. Mathematical Model Formulation
Minimizing the penalties caused by both the early completion and late delivery of orders, whilst simultaneously considering
available capacity is the objective. The formulated function aggregated a penalty cost for both earliness and tardiness. The
optimum solution was deemed to achieve a minimum total cost:
Copyright to IJIRSET
www.ijirset.com
6635
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
( )
p =ma ( , p
p)
Where
= otal costs
e = enalty rate of earliness
p=
p=
day
day
V. EXPERIMENTAL DESIGN
A simulation model which is a valid representation of the manufacturing process was designed. Data for the model on the
expected orders, resource constraints and labour breaks was extracted from an external database and excel spreadsheet.
Rockwell Arena 14.0 was used to design the simulation model while Microsoft Access and Excel software were employed to
create the databases which contain the order status, system definition and the product definition.
A. Dispatch Rule Scenarios
The order sequence with the lowest penalty was deemed the best. Five dispatch rules were evaluated in the study. These were:
Earliest Due Date (EDD)
First Come First Serve (FCFS)
First In System Last Serve (FISLS)
Shortest Processing Time (SPT)
Random (RAN)
VI. SYSTEM ARCHITECTURE
The structure of a simulation scheduling system is shown below in Fig4. Input information, which includes a system definition
(current resource status), a product definition (product range and processes) and a list of actual customer orders, is defined in
external files.
Orders
Product
Definition
System Definition
Definition
SIMULATION
MODEL WITH
SCHEDULING
ALGORITHMS
AND PROCESSING
System
Performance
Dispatch Lists
Predicted Order
Completion
times
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6636
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Resource
Capacity
Batch Processing
Type
Time (min)
Balance
22.36
Mixer
12.61
Divider
13.08
Mould
13.44
Pan Proofer
16.80
3) Order Definition
The purpose of this file was for the capturing of current production orders received from customers. The designed system was
tested using data of five orders collected on within a specific period. The set of orders shown in Table 2 below were used to
demonstrate the functionality of the system.
TABLE 2: ORDER DETAILS
Arrival
Product
Order
Time
type
Quantity
Due Date
5/20/2010
Bread
5/22/2010
Bread
200
5/21/2010
100
5/23/2010
5/22/2010
5/21/2010
Scones
200
5/24/2010
Doughnuts
200
5/24/2010
5/24/2010
Bread
200
5/25/2010
The table above shows data for five Orders which arrived at different times on the same day. Database queries were utilized to
adjust the order sequences based on the heuristic rules stated in the experimental design phase.
Copyright to IJIRSET
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6637
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Cre a te En ti ty to
Re a d s y s te m d a ta
R ead D i v i din g
Ti m e
R ead M ou ldi ng
Ti m e
Di s p o s e Sy s te m
En ti ty
Cre a te Co n tro l En ti ty
to re a d Ord e r d a ta
R ead O rder
D etai ls
As s i g n Pro d u c t 1
Attri b u te s
D el ay ti l l nex t
order
Se p a ra te 2
O r iginal
Duplicat e
P ro duc t Ty pe ?
R oute to
K nea din g
S ta ti on
W o rk Ti c k e t
Pre p a ra ti o n
Else
As s i g n Pro d u c t 2
Attri b u te s
Pr oduct Type==1
Pr oduct Type==2
As s i g n Pro d u c t 3
Attri b u te s
K nea din g
S ta ti on
B ak i ng S tati on
Ba k i n g Pro c e s s
M i x i n g Pro c e s s
Di v i d i n g Pro c e s s
M o u l d i n g Pro c e s s
Pro o fi n g Pro c e s s
W ri te O utput
R oute to
B ak i ng S tati on
Sh i p to c u s to m e r
0
0
VII.
RESULTS
For the set of orders, the simulation model computed the throughput time for each order and penalty for lateness calculations
were used to determine the optimal schedule. The outputs sent to a database included order completion times, dispatch lists and
system performance statics. The objective was to determine the throughput for each order so as to observe the lateness of each
order. Table 3 below displays the rests collected for a specific scenario of five orders.
TABLE 3: SUMMARY OF RESULTS
Rule
Sequence
Penalty/US
Ranking
$/day
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EDD
41235
22.36
SPT
25314
12.61
FCFS
13542
13.08
FISLS
24531
13.44
RAN
12345
16.80
www.ijirset.com
6638
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
The EDD sequence is the optimal schedule of the five. Each scenario may yield a different optimal schedule rule. Furthermore,
the system reckoned information on the resource utilization.
VIII.
CONCLUSIONS AND RECOMMENDATIONS
The paper concentrated on delivery responsiveness as it relates to the customers order. In this sense, better customer service is
characterized by offering competitive lead-times, dealing with Just-in-Time quantities and responding when customers change
items, quantities or dates. The designed finite capacity scheduling system designed was used as decision support tool to help
production planners on how to sequence orders. The usefulness of the developed system is in its ability to plan ahead and
prevent any potential problems from occurring before the detailed production schedule is implemented by the plant. Future
research can be done in using the same tool for applications which facilitate short-term sequencing, exception scheduling and
long range planning.
ACKNOWLEDGEMENTS
The researchers wish to acknowledge Lobels Company and other contributors who helped towards developing data for the case
study material.
REFERENCES
[1] Wuttipornpun ., Wangrakdiskul U., and Songserm W. An Algorithm of Finite Capacity MaterialRequirement Planning System for Multi-stageAssembly
Flow Shop, World Academy of Science, Engineering and Technology, pp. 499 509, 2010
[2] Lehtonen, J.M, Appelqvist, ., Ruohola, ., and Mattila, I. actory Scheduling: simulation-based finite scheduling at Albany International Winter
Simulation Conference Proceedings, pp. 1449-1455, 2003
[3] Novels, M., and Jonik, S.,Scheduling with Simulation in the ood & rinks Industry Proceeding of the 1996 Winter Simulation Conference, pp. 1252
1256, 1996
[4] Martin, R.L., inite Capacity scheduling with mi ed duration tooling duration trees. International Journal of roduction Research, vol 46, issue 6, pp.
1539-1565, 2007
[5] Novels, M. A new approach to capacity planning and scheduling. International Journal of airy echnology, Vol 49, issue 2, pp. 49 52, 2007.
[6] Chang, L. The study of dispatching rules for spraying and drying processes scheduling in a painting workshop The 2nd International Conference Computer
and Automation Engineering (ICCAE Volume 2), 2010
[7] Ram, B. and G. Patel, Modelling furnace operations using simulation and heuristics, Proceedings of the 1998 Winter Simulation Conference, pp. 957
963, 1998.
[8] Musselman, K., J.O. Reilly and S. uket, The role of simulation in advanced planning and scheduling, Proceedings of the 2002 Winter Simulation
Conference, pp. 1825 1830, 2002
[9] Riane, F., A. Artiba and S. Iassinovski An integrated production planning and scheduling system for hybrid flowshop organizations International Journal
of Production Economics, Vol. 74, pp. 33 48, 2001
[10] Appelqvist, P. and Lehtonen J-M, Increasing productivity in steel making: case Rautaruukki with Delfoi Planner, 33rd International Symposium on
Robotics, Stockholm, Sweden, 2002
Copyright to IJIRSET
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6639
ISSN: 2319-8753
International Journal of Innovative Research in Science,
Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
BIOGRAPHY
Mr. Mncedisi Trinity Dewa holds a BEng in Industrial and Manufacturing Engineering and
MEng in Manufacturing Systems and Operations Management. He is a PhD student in the field of
e-manufacturing in the Department of Industrial Engineering at University of Stellenbosch. He is
a graduate member of the Zimbabwe Institution of Engineers (ZIE). His research interests are in
e-manufacturing, holonic manufacturing and systems modelling and simulation.
Mr. Samson Mhlanga, PhD candidate University of Johannesburg, South Africa, Senior
Lecturer/ Chairman of Industrial and Manufacturing Engineering at NUST who hold an MSc in
Advanced Manufacturing Systems (Brunel UK), BEng in Industrial Engineering (NUST). He is a
member of the Zimbabwe Institution of Engineers (ZIE), Southern African Institute of Industrial
Engineering (SAIIE). Research interests are Modelling and Simulation, Engineering Management
Optimization, Renewable and Non-Renewable Energy Design and Optimization. He has over
16years of experience.
Ms. Lodrina Masiyazi holds a BEng in Industrial and Manufacturing Engineering (NUST) and
an Executive Masters in Business Administration (AU). She is an assistant lecturer in the
Department of Industrial& Manufacturing Engineering at the Harare Institute of Technology. Her
research interests are in engineering management, systems optimization, cost engineering and
business engineering.
Mr. Donald Museka holds a BEng in Industrial and Manufacturing Engineering (NUST). He is
an assistant lecturer in the Department of Industrial & Manufacturing Engineering at the Harare
Institute of Technology. His research interests are concurrent engineering, computer modelling
and system development.
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