Jonson"s Rule Production scheduling
- 1. (Dr. M K Manik) HOD.mechccetb@gmail.com
- 2. What is Production structure tree Or Bill of materials (BOM) It is a hierarchical Classification of a product A bill of materials (BOM) is a critical product information record That lists the Raw materials Assemblies Components Parts and The quantities of each needed to manufacture a product.
- 5. What are the Types of Scheduling? Forward scheduling is planning the tasks from the date resources become available to determine the shipping date or the due date. Backward scheduling is planning the tasks from the due date or delivery date to determine the start date and/or any changes in capacity What is the function of PPC? This function of PPC is: Efficient utilization of material resources, people and facilities in any undertaking through planning Coordinating and controlling the production activities that transform the raw material into finished products or components as a most optimal manner
- 8. What is the principle of Material-handling? Gravity principle: Utilize gravity to move a material wherever practicable it will generate low cost. Material flow principle: Plan an operation sequence and equipment arrangement to optimize material flow. Simplification principle: Reduce combine or eliminate unnecessary movement of materials/ equipment.
- 9. What do you mean by aggregate planning Aggregate planning: is the process of developing, analyzing, and maintaining a preliminary, approximate schedule of the overall operations of an organization. The aggregate plan generally contains: Targeted sales forecasts, Production levels, Inventory levels, And customer backlogs. Generally speaking, aggregate planning is connected to the budgeting process. Finally, aggregate planning is important because it can help synchronize flow throughout the supply chain; It affects costs, equipment utilization, employment levels, and customer satisfaction
- 10. Difference between aggregate planning and Master scheduling
- 12. Material-handling equipment. • Material handling equipment is mechanical equipment used for: The movement, Storage, Control and protection of materials, Goods and products to be shifted for the process of manufacturing, Distribution, Consumption and disposal.
- 13. Vertical screw conveyor Automatic Robotic Palletizing System Static/ Co robotic operation
- 14. 4 Types of Materials Handling Equipment Examples of storage and handling equipment include: • Racks: such as pallet racks, drive-through or drive-in racks, push-back racks, and sliding racks • Stacking frames: these are interlocking units that enable stacking of a load so crushing doesn’t occur • Shelves • Bins and drawers • Mezzanines: elevated floor systems that are installed between the production floor and ceiling in order to provide additional storage space Engineered Systems •AS/RS: Automated Storage and Retrieval that involves racks, aisles and shelves that are accessible by a type of mechanized shuttle system for the quick retrieval of items. • Conveyor systems: Automated conveyor systems carry heavy materials to specified destinations using belts, flexible chain. It is a highly efficient equipment to move large volumes of material quickly. • Robotic delivery systems– These automated systems are ideal for moving products on an assembly line or transporting goods throughout a plant or warehouse. • Automatic guided vehicles– These vehicles are mobile robots that follow specific markers or wires in the floor to move large materials for AGV navigation.
- 15. Conveyer system motion control automatic storage and retrieval systems Automated guided vehicle
- 16. Industrial Trucks Powered industrial trucks, such as forklifts, are used to move large materials or large quantities of materials around the manufacturing floor. • Hand trucks– Also known as a dolly, or box cart. Hand trucks are l-shaped box- moving handcarts with handles at one end, wheels at the base, and a ledge to set objects on. • Pallet jacks– These are tools are the most basic form of a forklift and used to lift and move pallets within a warehouse. • Pallet trucks– Manual operated or powered industrial forklifts. • Walkie stackers– A pedestrian walk-behind stacker with a mast for lifting pallets to heights. • Platform trucks– These are similar to a two wheeled dolly, but with an extended deck. • Order picker– An electric lift truck specifically designed for filling individual customer orders. This requires piece-part picking rather than selecting full pallets or unit loads. • Side loader– Automated tool similar to a fork lift that loads and unloads from the side of the machine rather than the front. • Automatic guided vehicles
- 17. Bulk Material Handling Equipment Equipment that deals with bulk handling aids in the control and transportation of large volumes of material either in bulk or loose form. In general the equipment is used to move loose parts from one area of the production floor to another. Examples of bulk material handling equipment are: • Conveyor belts • Stackers– Similar to forklifts, stackers help to lift and stack heavy loads on the dock or in the warehouse. • Reclaimers– These are large machines used to recover bulk materials from a stockpile. • Bucket elevators– Also known as a grain leg. These elevators haul flow able bulk materials vertically. • Grain elevators– This type of equipment is used to store and move grain and other similar materials throughout a production pathway. • Hoppers– Hoppers are a container for bulk material such as grain, that tapers and discharges it’s materials at the bottom. • Silos– A tower used to store grain and other materials such as coal, sawdust, woodchips, and food products.
- 19. What are the factors are to be taken into account while selecting the material handling equipment? Properties of the Material. Layout and Characteristic of the building. Production Flow. Cost Considerations. Nature of Operations. Engineering Factors. Equipment reliability.
- 20. . So, if I make a pen, It has a cap, A barrel, A spring. And a refill. Based on the definition above, the pen is an MPS item. The cap, barrel, spring and refill are MRP items.
- 22. Problem1. using Jonson’s sequencing algorithm, solve n-jobs× 2 machine problem with reference to table below Job J1 J2 J3 J4 J5 Machine-1(hrs) 7 4 3 5 2 Machine-2 (hrs) 6 2 8 9 1 i)Calculate total elapsed time ii)Idle time for machine two iii)Optimal sequence As per the rule lowest processing time in M1 will be scheduled first and the lowest time in M2 will scheduled at the end of the processing. Hence the above jobs will be scheduled as per As J3 job is to be processed 1st , Hence processing of all the job will be as per given below J3 J4 J1 J2 J5 Job M1 (In) M1(out) M2(In) M2(out) Remarks J3 00 0+3=3 3 3+8 =11 M2 idle for initial 3 hrs J4 3 3+5=8 11 11+9=20 J1 11 11+7=18 20 20+6=26 ×× Total elapsed time is 29 hrs J2 18 18+4=22 26 26+2=28 J5 22 22+2=24 28 28+1=29 M1 machine idle for(29-24) 5Hrs
- 23. Problem2. using Jonson’s sequencing algorithm, solve n-jobs× 2 machine problem with reference to table below Job J1 J2 J3 J4 J5 Machine-1(hrs) 3 8 7 5 4 Machine-2 (hrs) 4 5 1 2 3 Machine-3 (hrs) 7 9 5 6 10 Solution: Johnson condition 1)Minimum processing time of extreme row ≥ Max. processing time of middle row 2)Here minimum process time of extremes row are 3 or 5 And Max. processing time of middle row 5 Hence 3 or 5 ≥ 5 then the condition is satisfied 3) Then above three machines scheduled to be converted into two machine scheduled as per process. i)Calculate total elapsed time ii)Idle time for machine Two, Three iii)Optimal sequence
- 24. As per the rule lowest processing time in M1 will be scheduled first and the lowest time in M2 will scheduled at the end of the processing. Hence the above jobs will be scheduled as per As J4 job is to be processed 1st , Hence processing of all the job will be as per given below Job M1 (In) M1(out) M2(In) M2(out) M3(In) M3(out) Remarks J4 00 0+5=5 5 5+2 =7 7 7+6=13 M2 idle for initial 5 hrs & M3 idle for initial 7 hrs J1 5 5+3=8 8 8+4=12 13 13+7=20 M2 idle for initial 8-7=1hrs J5 8 8+4=12 12 12+3=15 20 20+10=30 J2 12 12+8=20 20 20+5=25 30 30+9=39 M2 idle for (20-15= 5 hrs) J3 20 20+7=27 27 27+1=28 39 39+5=44 M1 machine idle for(44-27) 17Hrs & M2 for 27-25=2 Hrs Total elapsed time is 44 hrs, M1 for 17 hrs, M2 for 13 hrs and M3 for 7 hrs were idle in operation
- 26. Solution: Four Jobs 1,2,3&4 are to be processed in each of the four machines such as a, b ,c and d in the order given below Process time is given in Hrs. Find minimum elapsed time for processing all the Jobs and idle time for the machines. JOB Ma Mb Mc Md 1 54 14 14 18 2 30 10 18 32 3 28 12 16 44 4 14 16 12 42 Solution: Johnson condition 1)Minimum processing time of extreme column ≥ Max. processing time of middle column. 2) Here minimum process time of extremes column are 14 or18 And Max. processing time of middle column 18 Hence 14 or18 ≥ 18 then the condition is satisfied 3) Then four machine scheduled to be converted into two machine scheduled as per process.
- 28. Flow process Chart The Flow process Chart is a simple half-text, half-picture used for showing the steps in a process, Using symbols to indicate the type of action being taken and text to give details of the action. The chart can selectively be used to show what happens to selected people, materials or equipment.
- 31. Bar chart or bar graph A bar chart or bar graph is a Chart or graph that presents categorical data with rectangular bars with heights or lengths proportional to the values that they represent. The bars can be plotted vertically or horizontally. A vertical bar chart is sometimes called a line graph.
- 33. What is a Gantt Chart useful? Gantt charts are useful for planning and scheduling projects. They help you assess how long a project should take, It Helps to determine the resources needed, It also indicate the plan /order in which you'll complete tasks. They're also helpful for managing the dependencies between tasks Gantt charts are a visual view of tasks displayed against time. They represent critical information such as who is assigned to what, Duration of tasks, And overlapping activities in a project. Gantt charts are the perfect allies for planning, scheduling, and managing a project.
- 34. Gantt chart A Gantt chart is a type of bar chart that illustrates a project schedule. This chart lists the tasks to be performed on the vertical axis, and time intervals on the horizontal axis. The width of the horizontal bars in the graph shows the duration of each activity
- 36. Thank youTo all