Unit - II

Sequencing Problems
Johnsons Rule

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 Sequencing Problems
Introduction
- LPP problem category where in we have to determine the order or
sequence in which the jobs are to be processed through machines
so as to minimize the total processing time.
- The total effectiveness, which may be the time or cost that is to be
minimized is the function of the order of sequence. Such type of
problem is known as SEQUENCING PROBLEM.
- Solution to sequencing problem could be done by trial and error
method to decide the optimal sequence (i.e. by method of
enumeration) when number of jobs and machines involved are
small.
But if the number of jobs and machines increases, then the
problem becomes complicated. It cannot be done by method of
enumeration and we employ special algorithms to solve the same.
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 Sequencing Problems
Problem Definition
- A general sequencing problem may be defined as follows:
- Let there be n jobs (J1, J2, J3 Jn) which are to be processed
on m machines (A, B, C,), where the order of processing
on machines i.e. for example, ABC means first on machine A,
second on machine B and third on machine C or CBA means first
on machine C, second on machine B and third on machine A etc.
- The processing time of jobs on machines (actual or expected) is
known to us, then our job is to find the optimal sequence of
processing jobs that minimizes the total processing time or cost.
Hence our job is to find that sequence out of n! sequences, which
minimizes the total elapsed time ( i.e.. time taken to process all the
jobs).

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 Sequencing Problems
Problem Definition
- The usual notations used in this problem are:
Ai = Time taken by i th job on machine A where i = I, 2,3n.
Similarly we can interpret for machine B and C i.e. Bi and Ci
etc.
T = Total elapsed time which includes the idle time of
machines if any and set up time and transfer time.

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 Sequencing Problems
Assumptions
The processing times Ai and Bi etc. are exactly known to us and
they are independent of order of processing the job on the
machine. That is whether job is done first on the machine, last on
the machine, the time taken to process the job will not vary it
remains constant.

The time taken by the job from one machine to other after
processing on the previous machine is negligible. (Or we assume
that the processing time given also includes the transfer time and
setup time).

Each job once started on the machine, we should not stop the
processing in the middle. It is to be processed completely before
loading the next job. 5
 Sequencing Problems
Assumptions
The job starts on the machine as soon as the job and the machine
both become idle (vacant). This is written as job is next to the
machine and the machine is next to the job. (This is exactly the
meaning of transfer time is negligible).

No machine may process more than one job simultaneously. (This

means to say that the job once started on a machine, it should be
done until completion of the processing on that machine).

The cost of keeping the semi-finished job in inventory when next

machine on which the job is to be processed is busy is assumed to
be same for all jobs or it is assumed that it is too small and is
negligible. That is in process inventory cost is negligible.
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 Sequencing Problems
Assumptions
While processing, no job is given priority i.e. the order of
completion of jobs has no significance. The processing times are
independent of sequence of jobs.

There is only one machine of each type.

The cost of keeping the semi-finished job in inventory when next

machine on which the job is to be processed is busy is assumed to
be same for all jobs or it is assumed that it is too small and is
negligible. That is in process inventory cost is negligible.

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 Sequencing Problems
Types of Sequencing Problem
- There are various types of sequencing problems arise in real
world. All sequencing problems cannot be solved. Though
mathematicians and Operations Research scholars are working
hard on these problems, satisfactory method of solving problem is
available for few cases only. The problems, which can be solved,
are:
n jobs are to be processed on two machines say machine A and
machine B in the order AB. This means that the job is to be
processed first on machine A and then on machine B.
n jobs are to be processed on three machines A,B and C in the
order ABC i.e. first on machine A, second on machine B and
third on machine C.
n jobs are to be processed on m machines in the given order
Two jobs are to be processed on m machines in the given order.
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 Sequencing Problems
N Jobs in two machines
Problem 1: The time cost to do six jobs in two machines M1 and M2
are given below. Obtain the optimum sequencing by using Johnsons
rule. Job order is M1-M2.

Job timings in number of days

Machines
J1 J2 J3 J4 J5 J6

M1 5 9 4 7 8 6

M2 7 4 8 3 9 5
 Sequencing Problems
Johnsons Rule Algorithm
Rule 1: Look at the processing time through M1: m11, m12 m1n and
similarly for M2: m21, m22 m2n. Select the job with smallest time
component.

Rule 2: If m1r is the smallest, then the associated job Jr will be taken up
first in the machine M1.

Rule 3: If m2s is the smallest, then the associated job Js will be taken up
last in the machine M2.

Rule 4: If m1r = m2s and are the smallest, then the job Jr first in the
machine M1 and do the job Js last in the machine M2 .
 Sequencing Problems
Johnsons Rule Algorithm
Rule 5: If m1r = m1p and are the smallest, then do either Jr-Jp order or
Jp-Jr order, first in the machine M1.

Rule 6: If m2s = m2t and are the smallest, then do either Js-Jt order or
Jt-Js order, last in the machine M2.

Rule 7: Eliminate the decided job(s) from the analysis and repeat steps
1 to 6 for sequencing the remaining jobs. Continue this process by
placing these jobs next to the first or preceding to the last, as the case
may be.
 Sequencing Problems
Johnsons Rule Algorithm
Rule 8: After placing all the jobs we simply calculate the overall time
elapsed, as the time between the start time of job 1 in machine M1 and
the finish time o the last job in machine M2.
Calculation of Idle time:
Sequencing does not keep both machines fully engaged. Sometimes
M2 is kept idle till the needed job gets completed in M1 because of
M1M2 order. Similarly if all jobs go for second round, M1 will have to
wait for the completion of last job in M2.
Idle time of machine M1 = completion time of last job in M2
completion time of last job in M1.
Idle time of machine M2 = sum of all idle times from the very
beginning till the end.
 Sequencing Problems
N Jobs in two machines

Job timings in number of days

Machines
J1 J2 J3 J4 J5 J6

M1 5 9 4 7 8 6

M2 7 4 8 3 9 5

Step 1: Look at the processing time through M1 as well as M2.

Select the job with smallest time component.
M2 component of J4 is smallest. Place J4 as the last job in M2 and
eliminate J4 from further analysis.
 Sequencing Problems
N Jobs in two machines

Job timings in number of days

Machines
J1 J2 J3 J4 J5 J6

M1 5 9 4 7 8 6

M2 7 4 8 3 9 5

Step 2: Look at the processing time through M1 as well as M2.

Select the job with smallest time component.
M1 component of J3 and M2 component of J2 are smallest. Place J3
as the first job in M1 and J2 as the last one before (fifth) M2.
Eliminate J2 and J3 from analysis.
 Sequencing Problems
N Jobs in two machines

Job timings in number of days

Machines
J1 J2 J3 J4 J5 J6

M1 5 9 4 7 8 6

M2 7 4 8 3 9 5

Step 3: Look at the processing time through M1 as well as M2.

Select the job with smallest time component.
M1 component of J1 and M2 component of J6 are smallest. Place J1
as the second job in M1 and J6 as fourth in M2. Eliminate J1 and J6
from analysis.
 Sequencing Problems
N Jobs in two machines

Job timings in number of days

Machines
J1 J2 J3 J4 J5 J6

M1 5 9 4 7 8 6

M2 7 4 8 3 9 5

Step 3: Look at the processing time through M1 as well as M2.

Select the job with smallest time component.
J5 is placed as third job is M1.
 Sequencing Problems
Final result with idle time
M1 M2
Job
Sequence Job Time Idle Job Time Idle
Time In Time In
Time Out Time Time Out Time
J3 0 4 4 0 4 8 12 4

J1 4 5 9 0 12 7 19 0

J5 9 8 17 0 19 9 28 0

J6 17 6 23 0 28 5 33 0

J2 23 9 32 0 33 4 37 0

J4 32 7 39 3 39 3 42 2

Total 3 6

Total Time required = 42 days

 Sequencing Problems
N Jobs in two machines
Problem 2: The time cost to do six jobs in two machines M1 and M2
are given below. Obtain the optimum sequencing by using Johnsons
rule. Job order is M1-M2.

Job timings in number of days

Machines
J1 J2 J3 J4 J5 J6

M1 4 7 3 12 11 9

M2 11 7 10 8 10 13
 Sequencing Problems
Final result with idle time
M1 M2
Job
Sequence Job Time Idle Job Time Idle
Time In Time In
Time Out Time Time Out Time
J3 0 3 3 0 3 10 13 3

J1 3 4 7 0 13 11 24 0

J6 7 9 16 0 24 13 37 0

J5 16 11 27 0 37 10 47 0

J4 27 12 39 0 47 8 55 0

J2 39 7 46 16 55 7 62 0

Total 16 3

Total Time required = 62 days

 Sequencing Problems
N Jobs in three machines
Problem 3: The time cost to do six jobs in three machines M1, M2 and
M3 are given below. Obtain the optimum sequencing by using
Johnsons rule. Job order is M1-M2-M3.

Job timings in number of days

Machines
J1 J2 J3 J4 J5 J6

M1 8 3 7 2 5 1

M2 3 4 5 2 1 6

M3 8 7 6 9 10 9
 Sequencing Problems
N Jobs in three machines
Characteristics:
Only three machines are involved in processing.
Job is done only in the prescribed order M1-M2-M3.
No surpassing of job is permitted.
The actual processing time on all the three machines are known in
advance.

Solution principle:
Johnson method is applicable if and only either of the following
conditions are fulfilled.
The smallest processing time in M1 is greater or equal to the largest
processing time in M2.
The smallest processing time in M3 is greater or equal to the largest
processing time in M2.
 Sequencing Problems
N Jobs in three machines
Machines
Jobs
M1 M2 M3
J1 8 3 8
J2 3 4 7
J3 7 5 6
J4 2 2 9
J5 5 1 10
J6 1 6 9

Smallest processing time on M3 (6 days) is greater than or equal to

the largest processing time on M2 (6 days).
Hence Johnsons rule could be applied.
 Sequencing Problems
N Jobs in three machines
Create hypothetical machines M4 and M5 such that jobs hours of
M4 is (M1+M2) and jobs hours of M5 is (M2+M3)

Machines Hypothetical Machines

Jobs
M1 M2 M3 M4 M5

J1 8 3 8 11 11

J2 3 4 7 7 11

J3 7 5 6 12 11

J4 2 2 9 4 11

J5 5 1 10 6 11

J6 1 6 9 7 15
 Sequencing Problems
N Jobs in three machines
Perform the regular algorithm of Johnsons rule to these two new
machines M4 and M5

Machines Hypothetical Machines

Jobs
M1 M2 M3 M4 M5

J1 8 3 8 11 11

J2 3 4 7 7 11

J3 7 5 6 12 11

J4 2 2 9 4 11

J5 5 1 10 6 11

J6 1 6 9 7 15
 Sequencing Problems
N Jobs in three machines
Perform the regular algorithm of Johnsons rule to these two new
machines M4 and M5

Hypothetical Machines Job Ranks

Jobs
M4 M5 M4 M5

J1 11 11 5

J2 7 11 3

J3 12 11 6

J4 4 11 1

J5 6 11 2

J6 7 15 4
 Sequencing Problems
Final result with idle time

Job M1 M2 M3
Seque
nce TI JT TO IT TI JT TO IT TI JT TO IT

J4 0 2 2 0 2 2 4 2 4 9 13 4

J5 2 5 7 0 7 1 8 3 13 10 23 0

J2 7 3 10 0 10 4 14 2 23 7 30 0

J6 10 1 11 0 14 6 20 0 30 9 39 0

J1 11 8 19 0 20 3 23 0 39 8 47 0

J3 19 7 26 27 26 5 31 25 47 6 53 0

Total 27 32 4

Total Time required = 53 days

 Sequencing Problems
N Jobs in three machines
Problem 4: The time cost to do five jobs in three machines M1, M2 and
M3 are given below. Obtain the optimum sequencing by using
Johnsons rule. Job order is M1-M2-M3.

Job timings in number of days

Machines
J1 J2 J3 J4 J5

M1 16 20 12 14 22

M2 10 12 4 6 8

M3 8 18 16 12 10
 Sequencing Problems
Final result with idle time

Job M1 M2 M3
Seque
nce TI JT TO IT TI JT TO IT TI JT TO IT

J3 0 12 12 0 12 4 16 12 16 16 32 16

J2 12 20 32 0 32 12 44 16 44 18 62 12

J4 32 14 46 0 46 6 52 2 62 12 74 0

J5 46 22 68 0 68 8 76 16 76 10 86 2

J1 68 16 64 18 84 10 94 16 94 8 102 8

Total 18 62 38

Total Time required = 102 days

 Sequencing Problems
Practice Problems
A book binder has one printing press, one binding machine and 6
books to be printed & binded. The time to perform the printing and
binding of each book is given. Determine the order in which the books
should be processed in order to minimize the total time.

Books 1 2 3 4 5 6

Printing
30 120 50 20 90 100
time (h)

Binding
80 100 90 60 30 10
time (h)
 Sequencing Problems
Practice Problems
A company has six jobs which go through machines X, Y and Z in the
order X-Y-Z. Processing time of each job in each machine is given
below. What should be the sequence of the jobs?

JOBS
MACHIN
ES
1 2 3 4 5 6

X 18 12 29 35 43 37

Y 7 12 11 2 6 12

Z 19 12 23 47 28 36