11.machines flow shop scheduling, processing time associated with probabilities including transportation time and job block criteria

Control Theory and Informatics www.iiste.org
ISSN 2224-5774 (print) ISSN 2225-0492 (online)
Vol 2, No.2, 2012

Minimizing Rental Cost for n-Jobs, 2-Machines Flow Shop
Scheduling, Processing Time Associated With Probabilities
Including Transportation Time and Job Block criteria
Sameer Sharma
Department of Mathematics, Maharishi Markandeshwar University, Mullana, Ambala, India
* E-mail of the corresponding author: samsharma31@yahoo.com

Abstract
This paper deals with a heuristic algorithm to minimize the rental cost of the machines for two stage flow
shop scheduling problem under specified rental policy in which processing times are associated with their
respective probabilities whereas the transportation time from one machine to another machine and an
equivalent job block criteria is being considered. The purposed algorithm is easy to understand and provide
an important tool for the decision makers. A computer program followed by a numerical illustration is also
given to justify the algorithm.
Keywords: Equivalent job, Flow Shop, Rental Policy, Transportation Time, Elapsed Time.

1. Introduction
Scheduling problems concern with the situation in which value of the objective function depends on the
order in which tasks have to be performed. A lot of research work has been done in the area of scheduling
problems for different situations and different criterions. Johnson [1] gave procedure for finding the optimal
schedule for n-jobs, two machine flow-shop problem with minimization of the makespan (i.e. total elapsed
time) as the objective. Ignall and Scharge [2] applied Branch and Bound technique for obtaining a sequence
which minimizes the total flow time. Chandrasekharan [3] has given a technique based on Branch and
Bound method and satisfaction of criterion conditions to obtain a sequence which minimizes total
flow-time subject to minimum makespan in a two stage flow shop problem. Bagga P.C.[4], Maggu and Das
[5], Szwarch [6], Yoshida & Hitomi [7], Singh T.P.[8], Chandra Sekhran [9], Anup [10], Gupta Deepak
[11] etc. derived the optimal algorithm for two/ three or multistage flow shop problems taking into
account the various constraints and criteria. Maggu and Das [ 5] introduced the concept of job-block
criteria in the theory of scheduling. This concept is useful and significant in the sense to create a balance
between the cost of providing priority in service to the customer and cost of giving services with
non-priority customers. The decision maker may decide how much to charge extra to priority customers.
Singh T.P., Gupta Deepak [13] studied n×2 general flowshop problem to minimize rental cost under a
predefined rental policy in which the probabilities have been associated with processing time on each
machine including job block criteria. In this paper we have extended the study made by Singh T.P., Gupta
Deepak [13] by introducing the concept of transportation time. Here we have developed an algorithm to
minimize the rental cost of the machines. The problem discussed here is wider and has significant use of
theoretical results in process industries.

2. Practical Situations
Various practical situations occur in real life when one has got the assignments but does not have one’s own
machine or does not have enough money or does not want to take risk of investing huge amount of money
to purchase machine. Under such circumstances, the machine has to be taken on rent in order to complete
the assignments. As a medical practitioner, in the starting of his career, does not buy expensive machines
say X-ray machine, the ultra sound machine etc. but instead take them on rent. Moreover in

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hospitals/industries concern, sometimes the priority of one job over the other is preferred. It may be
because of urgency or demand of its relative importance. Hence the job block criteria become significant.
Further, when the machines on which jobs are to be processed are planted at different places, the
transportation time which include the loading time, moving time and unloading time etc. has a significant
role in production concern and hence significant.

3. Notations

S : Sequence of jobs 1,2,3,….,n
Mj : Machine j, j= 1,2,…….
Ai : Processing time of ith job on machine A.
Bi : Processing time of ith job on machine B.
A′i : Expected processing time of ith job on machine A.
B′i : Expected processing time of ith job on machine B.
pi : Probability associated to the processing time Ai of ith job on machine A.
qi : Probability associated to the processing time Bi of ith job on machine B.
Si : Sequence obtained from Johnson’s procedure to minimize rental cost.
tAi→Bi : Transportation time from machine A to machine B.
Cj : Rental cost per unit time of machine j.
Ui :Utilization time of B (2 nd machine) for each sequence Si
t1 (Si) :Completion time of last job of sequence Si on machine A.
t2(Si) : Completion time of last job of sequence Si on machine B.
R(Si) : Total rental cost for sequence Si of all machines.
CT(Si) :Completion time of 1 st job of each sequence Si on machine A.

4. Problem Formulation

Let n jobs say i=1,2,3…n be processed on two machines A & B in the order AB. A job i (i=1,2,3…n) has
processing time A i & B i on each machine respectively, assuming their respective probabilities pi & qi
such that 0≤ pi ≤ 1 & Σpi = 1, 0 ≤ qi ≤ 1 & Σqi=1 and let tAi→Bi be the transportation time from machine A
to machine B of each job i. Let an equivalent job β is defined as (k, m) where k, m are any jobs among the
given n jobs such that k occurs before job m in the order of job block (k , m). The mathematical model of
the problem in matrix form can be stated as :

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jobs Machine A tAi→Bi Machine B

i A p B q
i i i i

1 A p tA1→B1 B q
1 1 1 1

2 A p tA2→B2 B q
2 2 2 2

3 A p tA3→B3 B q
3 3 3 3

4 A p4 tA4→B4 B q
4 4 4
--- --- --- --- --- ---
--- --- --- --- --- ---

n A p tAn→Bn B q
n n n n

Tableau – 1
Our objective is to find the optimal schedule of all jobs which minimize the total rental cost, when costs per
unit time for machines A & B are given while minimizing the makespan.

5. Assumptions
1. We assume rental policy that all the machines are taken on rent as and when they are required and
are returned as when they are no longer required for processing. Under this policy second machine is taken
on rent at time when first job completes its processing on first machine. Therefore idle time of second
machine for first job is zero.
2. Jobs are independent to each other.
3. Machine break down is not considered.
4. Pre- emption is not allowed i.e. once a job started on a machine, the process on that machine can’t be
stopped unless the job is completed.
5. It is given to sequence k jobs i1, i2…ik as a block or group-job in the order (i1, i2…ik ) showing priority
of job i1 over i2
6. Jobs may be held in inventory before going to a machine.

6. Algorithm
To obtain optimal schedule, we proceed as
Step 1. Define expected processing time A′i & B′i on machine A & B respectively as
follows:
A′i = Ai * pi, B′i = Bi * qi
Step 2. Define two fictitious machines G & H with processing time Gi & Hi for job i on machines G & H
respectively, as:
Gi= A′i + tAi→Bi , Hi= tAi→Bi + B′i
Step 3. Take equivalent job β = (k, m ) and define processing time as follows:
Gβ = Gk + Gm - min(Gm , Hk), Hβ = Hk + Hm - min(Gm , Hk)
Step 4. Define a new reduced problem with processing time Gi & Hi where job block (k , m) is
replaced by single equivalent job β with processing time Gβ & Hβ as obtained in step 3.

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Step 5. Apply Johnson’s [1] technique and obtain an optimal schedule of given jobs, using Johnson’s
technique. Let the sequence be S1.
Step 6 : Observe the processing time of 1 st job of S1 on the first machine A . Let it be α.
Step 7 : Obtain all the jobs having processing time on A greater than α. Put these job one by one in the 1 st
position of the sequence S1 in the same order. Let these sequences be S2, S3, S4,…Sr
Step 8 : Prepare in-out table for each sequence Si (i=1,2,…r) and evaluate total completion time of last job
of each sequence t1 (Si) & t2(Si) on machine A & B respectively.
Step 9 : Evaluate completion time CT(Si) of 1 st job for each sequence Si on machine A.
Step 10: Calculate utilization time Ui of 2 nd machine for each sequence Si as:
Ui= t2(Si) – CT(Si) for i=1,2,3,…r.
Step 11: Find Min {Ui}, i=1,2,…r. let it be corresponding to i=m,then Sm is the optimal sequence for
minimum rental cost.
Min rental cost = t1 (Sm)×C1+Um×C2
Where C1 & C2 are the rental cost per unit time of 1 st & 2 nd machine respectively.

7. Computer Program
#include<iostream.h>
#include<stdio.h>
#include<conio.h>
#include<process.h>
void display();
void schedule(int,int);
void inout_times(int []);
void update();
void time_for_job_blocks();

float min;
int job_schedule[16],tt[16];int job_schedule_final[16];int n;
float a1[16],b1[16],a11[16],b11[16];float a1_jb,b1_jb;float a1_temp[15],b1_temp[15];
int job_temp[15];int group[2];//variables to store two job blocks
float a1_t[16], b1_t[16];float a1_in[16],a1_out[16];float b1_in[16],b1_out[16];
float ta[16]={32767,32767,32767,32767,32767},tb[16]={32767,32767,32767,32767,32767};
void main()
{
clrscr();
int a[16],b[16];float p[16],q[16];int optimal_schedule_temp[16];int optimal_schedule[16];
float cost_a,cost_b,cost;float min; //Variables to hold the processing times of the job blocks
cout<<"How many Jobs (<=15) : ";cin>>n;
if(n<1 || n>15)
{cout<<"Wrong input, No. of jobs should be less than 15..n Exitting";getch();

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Vol 2, No.2, 2012

exit(0);
}
cout<<"Enter the processing time and their respective probabilities ";
for(int i=1;i<=n;i++)
{cout<<"nEnter the processing time and its probability of "<<i<<" job for machine A : ";cin>>a[i]>>p[i];
cout<<"nEnter the transportation time of "<<i<<"job from machine A to B : ";cin>>tt[i];
cout<<"nEnter the processing time and its probability of "<<i<<" job for machine B : ";cin>>b[i]>>q[i];
//Calculate the expected processing times of the jobs for the machines:
a11[i] = a[i]*p[i];b11[i] = b[i]*q[i];a1[i]=a11[i]+tt[i];b1[i]=b11[i]+tt[i];
}
for(int k =1;k<=n;k++)
{cout<<"n"<<k<<"tt"<< a1[k]<<"tt"<< b1[k];}
cout<<"nEnter the two job blocks (two numbers from 1 to "<<n<<") : ";cin>>group[0]>>group[1];
cout<<"nEnter the Rental cost of machine A : ";cin>>cost_a;
cout<<"nEnter the Rental cost of machine B : ";cin>>cost_b;
//Function for expected processing times for two job blocks
time_for_job_blocks();int t = n-1;
schedule(t,1);
//Calculating In-Out times
inout_times(job_schedule_final);
//REpeat the process for all possible sequences
for( k=1;k<=n;k++) //Loop of all possible sequences
{
{optimal_schedule_temp[i]=job_schedule_final[i];}
int temp = job_schedule_final[k];optimal_schedule_temp[1]=temp;
for(i=k;i>1;i--)
{optimal_schedule_temp[i]=job_schedule_final[i-1];}
//Calling inout_times()
int flag=0;
for(i=1;i<n;i++)
{
if(optimal_schedule_temp[i]==group[0] && optimal_schedule_temp[i+1]==group[1])
{flag=1;break;}
}
if(flag==1)
{
inout_times(optimal_schedule_temp);
ta[k]=a1_out[n]-a1_in[1];tb[k]=b1_out[n]-b1_in[1];

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if(tb[k]<tb[k+1])
{
//copy optimal_schedule_temp to optimal_schedule
for(int j=1;j<=n;j++)
{
optimal_schedule[j]=optimal_schedule_temp[j];
}}}}

float smalla = ta[1];float smallb = tb[1];float maxv[16];
for(int ii=2;ii<=n;ii++)
{
if(smalla>ta[ii])
smalla = ta[ii];
if(smallb>tb[ii])
smallb = tb[ii];
}
clrscr();
cout<<"nnnnnnnnttt #####THE SOLUTION##### ";
cout<<"nnt***************************************************************";
cout<<"nnnt Optimal Sequence is : ";
for (ii=1;ii<=n;ii++)
{cout<<optimal_schedule[ii]<<" ";}
cout<<"nnt The smallest possible time span for machine A is : "<<smalla;
cout<<"nnt The smallest possible time span for machine B is : "<<smallb;
cost = cost_a*smalla+cost_b*smallb;
cout<<"nnt Total Minimum Rental cost for both the machines is : "<<cost;
cout<<"nnnt***************************************************************";
getch();
}

void time_for_job_blocks()
{
//The expected processing times for two job blocks are
if(b1[group[0]]<a1[group[1]])
{min = b1[group[0]];}
else
{min = a1[group[1]];}
a1_jb = a1[group[0]]+a1[group[1]] - min; //(b1[k]<a1[m])?b1[k]:a1[m];
b1_jb = b1[group[0]]+b1[group[1]] - min; //(b1[k]<a1[m])?b1[k]:a1[m];

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cout<<"/n abeta = "<<a1_jb<<"n bbeta ="<<b1_jb;
getch();
}

void inout_times(int schedule[])
{
{
//Reorder the values of a1[] and b1[] according to sequence
a1_t[i] = a11[schedule[i]];b1_t[i] = b11[schedule[i]];
cout<<"n"<<schedule[i]<<"tt"<<a1_t[i]<<"tt"<<b1_t[i];
}
for(i=1;i<=n;i++)
{
if(i==1)
{a1_in[i]=0.0; a1_out[i] = a1_in[i]+a1_t[i];b1_in[i] = a1_out[i]+tt[schedule[i]];
b1_out[i] = b1_in[i]+b1_t[i];}
else
{
a1_in[i]=a1_out[i-1];a1_out[i] = a1_in[i]+a1_t[i];
if(b1_out[i-1]>=(a1_out[i]+tt[schedule[i]]))
{b1_in[i] = b1_out[i-1];b1_out[i] = b1_in[i]+b1_t[i];}
else
{b1_in[i] = a1_out[i]+tt[schedule[i]];b1_out[i] = b1_in[i]+b1_t[i];
}}}}
int js1=1,js2=n-1;
void schedule(int t, int tt)
{
if(t==n-1)
{js1=1; js2=n-1;}
if(t>0 && tt==1)
{
for(int i=1,j=1;i<=n;i++,j++) //loop from 1 to n-1 as there is one group
{if(i!=group[0]&&i!=group[1])
{a1_temp[j] = a1[i];b1_temp[j] = b1[i];job_temp[j] = i;}
else if(group[0]<group[1] && i==group[0])
{a1_temp[j] = a1_jb;b1_temp[j] = b1_jb;job_temp[j] = -1;}
else
{ j--;}}

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//Finding smallest in a1
float min1= 32767;
int pos_a1;
for(j=1;j<n;j++)
{
if(min1>a1_temp[j])
{pos_a1 = j;min1 = a1_temp[j];}
}
//Finding smallest in b1
float min2= 32767;int pos_b1;
for(int k=1;k<n;k++)
{if(min2>b1_temp[k])
{pos_b1 = k;min2 = b1_temp[k] }}
if(min1<min2)
{job_schedule[js1] = job_temp[pos_a1];js1++;a1_temp[pos_a1]=32767;b1_temp[pos_a1]=32767;}
else
{job_schedule[js2] = job_temp[pos_b1];js2--;a1_temp[pos_b1]=32767;b1_temp[pos_b1]=32767;
}}
else if(t>0 && tt!=1)
{//Finding smallest in a1
float min1= 32767;int pos_a1;
for(int i=1;i<n;i++)
{if(min1>a1_temp[i])
{pos_a1 = i;min1 = a1_temp[i];
}}
//Finding smallest in b1
float min2= 32767;int pos_b1;
for(i=1;i<n;i++)
{if(min2>b1_temp[i])
{pos_b1 = i;min2 = b1_temp[i];
}}
if(min1<min2)
{job_schedule[js1] = job_temp[pos_a1];js1++;a1_temp[pos_a1]=32767;b1_temp[pos_a1]=32767;}
else
{job_schedule[js2] = job_temp[pos_b1];js2--;a1_temp[pos_b1]=32767;b1_temp[pos_b1]=32767;}}
t--;
if(t!=0)
{schedule(t, 2);}
//final job schedule

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int i=1;
while(job_schedule[i]!=-1)
{job_schedule_final[i]=job_schedule[i];i++;}
job_schedule_final[i]=group[0];i++;
job_schedule_final[i]=group[1];i++;
while(i<=n)
{job_schedule_final[i]=job_schedule[i-1];i++;}}

8. Numerical Illustration
Consider 5 jobs and 2 machines problem to minimize the rental cost. The processing times with their
respective probabilities and transportation time from one machine to another machine are given as follows:

job Machine A tAi →Bi Machine B
i Ai pi Bi qi
1 12 0.2 6 8 0.1
2 16 0.3 5 12 0.2
3 13 0.3 4 14 0.3
4 18 0.1 3 17 0.2
5 15 0.1 4 18 0.2

Tableau-1

Rental costs per unit time for machines M1 & M2 are 15 & 13 units
respectively, and jobs 2, 5 are to be
processed as an equivalent group job β. Also ∑ pi=1, ∑qi=1.
Solution:
As per step 1 expected processing times are as under:
Jobs Ai′ tAi →Bi Bi′
1 2.4 6 0.8
2 4.8 5 2.4
3 3.9 4 4.2
4 1.8 3 3.4
5 1.5 4 3.6
Tableau-2
As per step 2 :
Calculate Gi= A′i + tAi→Bi & Hi= tAi→Bi + B′i

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Jobs Gi Hi
1 8.4 6.8
2 9.8 7.4
3 7.9 8.2
4 4.8 6.4
5 5.5 7.6
Tableau-3
As per step 3 :
the processing times of equivalent job block β = (2,5) are given by
Gβ = 9.8+5.5-5.5= 9.8 and Hβ = 7.4+7.6 -5.5=9.5
Jobs Gi Hi
1 8.4 6.8
β 9.8 9.5
3 7.9 8.2
4 4.8 6.4
Tableau-4

As per step 4 :
Using Johnson’s method optimal sequence is
S1 = 4,3, β,1
i.e. 4-3-2-5-1
Other optimal sequences for minimize rental cost, are
S2 =1-4-3-2-5
S3 = 3-4-2-5-1
S4 = 2-5-4-3-1
In-out table for these sequences are given from tableau-5 to tableau-8:
S1 = 4-3-2-5-1
Jobs A tAi →Bi B
In-Out In-Out
4 0-1.8 3 4.8-8.2
3 1.8-5.7 4 9.7-13.9
2 5.7-10.5 5 15.5-17.9
5 10.5-12 4 17.9-21.5
1 12-14.4 6 21.5-22.3
Tableau-5
Thus the total elapsed time = 22.3 units and
utilization time for M2 = 22.3-4.8

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=17.5 units.

S2=1-4-3-2-5
Jobs A tAi →Bi B
In-Out In-Out
1 0-2.4 6 3.0-3.8
4 2.4-4.2 3 7.2-10.6
3 4.2-8.1 4 12.1-16.3
2 8.1-12.9 5 17.9-20.3
5 12.9-14.4 4 20.3-23.9
Tableau-6

Total elapsed time = 23.9 units
Utilization time of B = 23.9- 3.0 =20.9 units

REMARKS:
i. The following algebraic properties can be easily proved with the numerical examples:
a) Equivalent job formation is associative in nature
i.e. the block ((1,3)5) =(1(3.5)).

b) The equivalent job formation rule is non commutative
i.e. the block (1,5) ≠ (5,1).
ii. The study may be extended further for three machines flow shop, also by considering various
parameters such as break down interval etc.
References
Johnson S. M. [1954], optimal two and three stage production schedule with set up times included. Nay
Res Log Quart Vol 1 pp 61-68.
Ignall, E., and Schrage, L.[1965], “Application of the branch and bound technique to some flow shop
scheduling problems.”Operation Research, 13, 400-412
Chandrasekharan Rajendaran [1992], “Two-Stage Flowshop Scheduling Problem with Bicriteria ” O.R.
Soc. Vol. 43, No. 9, 871-84.
P.C.Bagga[1969], Sequencing in a rental situations, Journal of Canadian Operation Research Society
7 ,152-153
Maggu P. L and Das G.[1977], equivalent jobs for job block in job sequencing, Opsearch, Vol 14, No. 4,
277-281.
Szware, W [1977], Special cases of the flow shop problems, Naval Research Log,Quartly 24,403-492.
Yoshida and Hitomi[1979], optimal two stage production scheduling with set up times separated.
AIIETransactions. Vol. II.pp 261-263.
Singh T.P [1985], on n×2 shop problem involving job block. Transportation times and Break-down
Machine times, PAMS Vol. XXI No. 1-2

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