CHAPTER 4

SCHEDULING
MANAGEMENT
LEARNING OUTCOMES
Upon completion of this chapter, students should be
able to:

 Identify scheduling management

 Determine scheduling in high volume system
 Determine scheduling in low volume system
 Understand loading such as Gantt chart, input/output
control and assignment method
 SCHEDULING
 Scheduling is the process of arranging,
controlling and optimizing work and workloads in
a production process or manufacturing process.

 Scheduling is used to allocate plant and

machinery resources, plan human resources,
plan production processes and purchase
materials.
SCHEDULING MANAGEMENT
Scheduling deals with the timing of operations

The objective of scheduling management is to allocate

and prioritize demand to available facilities.

Two factor that affecting scheduling are:

 The types of scheduling (forward or backward)
 The criteria for priorities
BENEFIT OF SCHEDULING
Minimize completion time
Maximize utilization
Minimize work in process
Minimize customer waiting time
SCHEDULING IN HIGH VOLUME SYSTEM
The goal is to obtain a smooth rate of flow of goods or
customers through the system in order to get high
utilization of labor and equipment.

Example product :
 Autos, personal computers, radios, toys, television, etc.

 In process industries, example include petroleum

refining, sugar refining.
SCHEDULING IN HIGH VOLUME SYSTEM
Success factors in scheduling high volume system are:

Process and product design

Preventive maintenance
Rapid repair when breakdowns occur
Optimal product mixes
Minimization of quality problems
Reliability and timing supplies
SCHEDULING IN LOW VOLUME SYSTEM
Different from high volume system scheduling.

Types of low volume scheduling are such as Gantt chart,

input/output control and assignment method.

Sequencing: Determine the order in which jobs at a work

center will be processed.

Workstation: An area where one person works, usually

with special equipment, on a specialized job.
 SCHEDULING METHOD OF LOW
VOLUME SYSTEM
GANTT CHART
ASSIGNMENT METHOD
PRIORITY RULES
 FCFS
 SPT
 CR
 EDD

 JOHNSON’S RULE
Gantt Chart
Gantt Chart
Assignment Method
1.
4. If number
Perform rowof reductions
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minimum hasvalue
beeninfound. Make
each row fromassignments
all other row
where zeros appear
values
2. Else
5. modify
Perform matrix
column reductions
 subtract minimum value uncrossed value
in each from from
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all other
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column values
addout
3. Cross it toall
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cells where two lines intersect
in matrix
 other
 values innumber
use minimum matrix remain unchanged
of horizontal and vertical lines
6. Repeat steps 3 through 5 until optimum solution is
reached
Assignment Method: Example 1
Machines
A B C D
J 1 8 6 2 4 These numbers
represent the
o 2 6 7 11 10 costs

b 3 3 5 7 6
4 5 10 12 9
Example 2
Route
A B C D E
T
1 4 5 9 8 7
r
2 6 4 8 3 5
u
3 7 3 10 4 6
c
4 5 2 5 5 8
k
5 6 5 3 4 9
Priority Sequencing Rules
Priority Rules provide guidelines for the sequence in
which jobs should be worked.

In using this rules, job processing times and due dates
are important pieces of information.

Priority Rules try to minimize completion time,

number of jobs in the system, and job lateness, while
maximizing facility utilization.
Priority Sequencing Rules
Critical Ratio (CR)
Earliest Due Date (EDD)
First Come First Serve (FCFS)
Shortest Processing Time (SPT)
Slack per Remaining Operations (S/RO)
CRITICAL RATIO (CR)
The critical ratio (CR) is calculated by dividing the time
remaining until a job’s due date by the total shop time
remaining for the job, which is defined as the setup, processing,
move, and expected waiting times of all remaining operations,
including the operation being scheduled. The formula is

CR = Due date - Today’s date

Total shop time remaining
EARLIEST DUE DATE (EDD)

Jobs are sequenced in the order in which

they due for delivery to
the customer.
FIRST COME FIRST SERVE (FCFS)

Jobs are processed in the order in which

they arrive at a machine
or work center.
SHORTEST PROCESSING TIME (SPT)

A priority sequencing rule that specifies

that the job requiring the shortest
processing time is the next job to be
processed.
SLACK PER REMAINING OPERATION
(S/RO)

A priority sequencing rule that

determines priority by dividing the
slack by the number of operations that
remain, including the one being
scheduled.
 SLACK PER REMAINING OPERATION (S/RO)

S/RO =(Due date - Today’s date) - Total shop time remaining

Number of operations remaining

The job with the lowest S/RO is scheduled next. Ties are
broken in a variety of ways if two or more jobs have the
same priority.

One way is to arbitrarily choose one of the tied jobs for

processing next.
Performance measuring formula:

#Average completion time = Total flow time ÷ No. of jobs

#Average number of jobs = Total flow time ÷ Total job work time
in the system

#Average job lateness = Total late days ÷ No. of jobs

#Utilization = Total job work time÷ Total flow time = in %

4.3.1 Sequencing Rules:
First Come, First Served (FCFS) Example 1
Five jobs are to be done at custom furniture Do all the jobs get done on time?
shop:
Job Days to Date No, Jobs B, C, D
Finish Promised
SOLUTION and E are going
A 2 5 to be late
:Measure of effectiveness:
B 8 8
Sequence Work Due Lateness
Flow Time Date
C 6 12 Time
A 2 2 5 0
D 4 10
B 8 10 8 2
E 1 4
Note! C 6 16 12 4
Flow time: is the amount of time a D 4 20 10 10
job spent in shop/factory
E 1 21 4 17
Total work time/makespan: is the
time needed to process given set of TOTALS 21 69   33
jobs
Lateness: different between
completion time and due date (if (–
ve) put it zero)
Sequencing Rules:
First Come, First Served (FCFS) Example 1

Performance measuring formula:

#Average completion time = Total flow time ÷ No. of jobs

#Average number of jobs = Total flow time ÷ Total job work time
In the system

#Average job lateness = Total late days ÷ No. of jobs

#Utilization = Total job work time÷ Total flow time = in %

4.3.1 Sequencing Rules:
First Come, First Served (FCFS) Example 2

Five jobs are to be assemble in AHP Plastic Sdn. Bhd.:

Sequencing Rules:
First Come, First Served (FCFS) Example 2

SOLUTION:
Sequencing Rules:
Shortest Processing Time (SPT)

 Shortest Processing Time. Jobs with the shortest

processing time are scheduled first.

 Jobs are sequenced in increasing order of their

processing time.

 Shortest processing time is optimal for

minimizing:
 Average and total flow time
 Average waiting time
 Average and total lateness
Sequencing Rules:
Shortest Processing Time (SPT)
The steps for using this rule are :

1. Firstly, the user will input the number of jobs, the job
names, the processing time and the due date of each
job or use the data values given at the starting point.

2. The second step is sorting out the shortest processing

time among the jobs.

3. Thirdly, calculate the flow time of each job by using

the processing time. The flow time is the
accumulation of processing time each job by each
job.
4.3.2 Sequencing Rules:
Shortest Processing Time (SPT) Example 1

Suppose we have the four jobs to the right arrive for processing
on one machine

Jobs (in order Processing Due Date

of arrival) Time (days) (days hence)
A 4 5
B 7 10
C 3 6
D 1 4
Sequencing Rules:
Shortest Processing Time (SPT) Example 1

Answer: Shortest Operating Time Schedule

Sequence Work Flow Time Due Lateness

Time Date
D 1 1 4 0
C 3 4 6 0 Jobs A and B
are going to
A 4 8 5 3 be late
B 7 15 10 5
TOTAL 15 28   8

Average completion time 28/4 = 7 days

Average number of jobs in the system 28/15 = 1.867 jobs
Average lateness 8/4 = 2days
Utilization 15/28 = 53.57%
Sequencing Rules:
Shortest Processing Time (SPT) Example 2

• A Brake Pad have 5 process that will undergo before it will be

produce at a particular point in time . The jobs are labeled A, B, C,
D, and E in the order that they entered the shop. The respective
processing times and due dates are given in the table below.
Determine the schedule by using the SPT rule.

Job sequence Processing Time Due Date

A(turning) 6 8
B(drilling) 2 6
C(grinding) 8 18
D(milling) 3 15
E( facing) 9 23
4.3.2 Sequencing Rules:
Shortest Processing Time (SPT) Example 2

Solution:
 Sequencing Rules:
Shortest Processing Time (SPT) Example 2

#Average completion time = Total flow time ÷ No. of jobs

#Average number of jobs = Total flow time ÷ Total job work time
In the system

#Average job lateness = Total late days ÷ No. of jobs

#Utilization = Total job work time÷ Total flow time = in %

Average completion time 65/5 = 13 days

Average number of jobs in the system 65/28 = 2.3214 jobs
Average lateness 9/5 = 1.8 days
Utilization 28/65 = 43.08%
Sequencing Rules:
Earliest Due Date (EDD)

 Jobs are sequenced in increasing order of their due

dates;

 The job with earliest due date is first, the one with the
next earliest due date is second, and so on;

 A priority sequencing rule that specifies that the job

with the earliest due date is the next job to be processed
4.3.3 Sequencing Rules:
Earliest Due Date (EDD)
The steps for using this rule are :

1. Firstly, the user will input the number of jobs, the

job names, the processing time and the due date of
each job or use the data values given at the starting
point.

2. The second step is sorting out the earliest due date

among the jobs.

3. Thirdly, calculate the flow time of each job by using

the processing time. The flow time is the
accumulation of processing time each job by each
job.
 4.3.3 Sequencing Rules:
Earliest Due Date (EDD)

•The formulas for calculation are below:

#Average completion time = Total flow time ÷ No. of jobs

#Average number of jobs = Total flow time ÷ Total job work time
In the system

#Average job lateness = Total late days ÷ No. of jobs

#Utilization = Total job work time÷ Total flow time = in %

4.3.3 Sequencing Rules:
Earliest Due Date (EDD) Example 1

• Five engine blocks are waiting for processing. The

processing times have been estimated. Expected
completion times have been agreed. The table shows the
processing time and due date of those 5 engines.
• Determine the schedule by using the EDD rule.

Engine Block Processing Time Due Date

(Days) (Days)
Ranger 8 10
Explorer 6 12
Bronco 15 20
Econoline 150 3 18
Thunderbird 12 22
4.3.3 Sequencing Rules:
Earliest Due Date (EDD) Example 1
Engine (1) (2) (3) (2)-(3)
Block Processing Completion Due Days Tardy
Sequence Time Time Date (0 if negative)

Ranger 8 8 10 0
Explorer 6 14 12 2
Econoline 150 3 17 18 0
Bronco 15 32 20 12
Thunderbird 12 44 22 22

Total 44 85 36

Average completion time 85/5 = 17 days

Average number of jobs in the system 85/44 = 1.9318 jobs
Average tardiness 36/5 = 7.2 days
Utilization 44/85 = 51.76%
Sequencing Rules:
Critical Ratio (CR)

Is an index number computed by dividing the time

remaining until due date by the work time remaining.

The critical ratio gives priority to jobs that must be

done to keep shipping on schedule.

The critical ratio is measure of urgency of any order

compared to the other orders for the same facility.

The ratio is based on when the completed order is

required and how much time is required to complete.
4.3.4 Sequencing Rules:
Critical Ratio (CR)
•The step for using this rule are:

1. At the starting program, user input the numbers of job, the jobs
name, the works day remaining and the due date of each job and as
well the today's date.
2. The today's date and the number of job are just inputted once time.
Then, the others are followed the value of the number of jobs
inputted. After that, compute the critical ratio by using the formula.
3. The formula for Critical Ratio is:
CR = time remaining / works day remaining
4. After calculating the CR for each job, give the priority order by using
the value of the calculated critical ratio. The priority order is
performed from smaller to larger.
4.3.4 Sequencing Rules:
Critical Ratio (CR)

• There are 3 characteristics can be seen from

the critical ratio:
 A job with low critical ratio(less than 1.0)
---- falling behind schedule.
 If  CR is exactly 1.0 ---- the job is on
schedule.
 If CR is greater than 1.0 ---- the job is
ahead of schedule and has some slack.
4.3.4 Sequencing Rules:
Critical Ratio (CR)

•The critical ratio help in most production scheduling

system as below:

Determine the status of specific job.

Establish relative priority among jobs on a common basis.
Relate both stock and make-to-order jobs on a common
basis.
Adjust priorities (and revise schedules) automatically for
changes in both demand and job progress.
Dynamically track job progress and location.
Sequencing Rules:
Critical Ratio (CR) Example 1

•A machine center in a job shop for a local fabrication company has

five unprocessed jobs remaining at a particular point in time. The
jobs are labeled 1, 2, 3, 4, and 5 in the order that they entered the
shop. The respective processing times and due dates are given in
the table below.
•Sequence the 5 jobs by CR rules.

Job number Processing Time Due Date

1 11 61
2 29 45
3 31 31
4 1 33
5 2 32
4.3.4 Sequencing Rules:
Critical Ratio (CR) Example 1

Current time: t=0

Job number Processing Time Due Date Critical Ratio
1 11 61 61/11(5.545)
2 29 45 45/29(1.552)
3 31 31 31/31(1.000)
4 1 33 33/1 (33.00)
5 2 32 32/2 (16.00)

Current time should be reset after scheduling one job

Current time: t=31
Job number Processing Time Due Date-Current Time Critical Ratio
1 11 30 30/11(2.727)
2 29 14 14/29(0.483)
4 1 2 2/1 (2.000)
5 2 1 1/2 (0.500)
4.3.4 Sequencing Rules:
Critical Ratio (CR) Example 1

Current time=60
Job number Processing Time Due Date- Critical Ratio
Current Time
1 11 1 1/11(0.0909)
4 1 -27 -27/1<0
5 2 -28 -28/2<0

Both Jobs 4 and 5 are later, however Job 4 has shorter processing time
and thus is scheduled first; Finally, job 1 is scheduled last.
4.3.4 Sequencing Rules:
Critical Ratio (CR) Example 1

Job number Processing Completion Due Date Tardiness

Time Time
3 31 31 31 0
2 29 60 45 15
4 1 61 33 28
5 2 63 32 31
1 11 74 61 13
Totals 74 289 87

Average completion time 289/5 = 57.8 days

Average number of jobs in the system 289/74 = 3.905 jobs
Average tardiness 87/5 = 17.4 days
Utilization 74/289 = 25.61%
 4 Rules Application - Example

Processing Time (including setup times) and due dates for six jobs waiting to
be processed at a work center are given in the following table. Determine the
sequence of jobs, the average flow time, average tardiness, and number of
jobs at the work center, for each of these rules:
•FCFS
•SPT
•EDD
•CR
Job number Processing Time Due Date

A 2 7
B 8 16
C 4 4
D 10 17
E 5 15
F 12 18
 4 Rules Application – Example (FCFS)

Job Processing Flow Time Due Date Tardiness

Sequence Time
A 2 2 7 0
B 8 10 16 0
C 4 14 4 10
D 10 24 17 7
E 5 29 15 14
F 12 41 18 23
Totals 41 120 54

Average completion time 120/6 = 20 days

Average number of jobs in the system 120/41 = 2.93 jobs
Average tardiness 54/6 = 9 days
Utilization 41/120 = 34.17%
 4 Rules Application – Example (SPT)
Job Processing Flow Time Due Date Tardiness
Sequence Time
A 2 2 7 0
C 4 6 4 2
E 5 11 15 0
B 8 19 16 3
D 10 29 17 12
F 12 41 18 23
Totals 41 108 40

Average completion time 108/6 = 18 days

Average number of jobs in the system 108/41 = 2.63 jobs
Average tardiness 40/6 = 6.67 days
Utilization 41/108 = 37.96%
 4 Rules Application – Example (EDD)
Job Processing Flow Time Due Date Tardiness
Sequence Time
C 4 4 4 0
A 2 6 7 0
E 5 11 15 0
B 8 19 16 3
D 10 29 17 12
F 12 41 18 23
Totals 41 110 38

Average completion time 110/6 = 18.33 days

Average number of jobs in the system 110/41 = 2.68 jobs
Average tardiness 38/6 = 6.33 days
Utilization 41/110 = 37.27%
 4 Rules Application – Example (CR)
At t=0,
Job Sequence Processing Time Due Date Critical Ratio
Calculation
A 2 7 (7-0) / 2 = 3.5
B 8 16 (16-0) / 8 = 2.0
C 4 4 (4-0) / 4 = 1.0 (Lowest)
D 10 17 (17-0) / 10 = 1.7
E 5 15 (15-0) / 5 = 3.0
F 12 18 (18-0) / 12 = 1.5

•Job C is the first job to complete base on the lowest

critical ratio.
 4 Rules Application – Example (CR)
At t=4, day 4 [C completed],
Job Sequence Processing Time Due Date Critical Ratio
Calculation
A 2 7 (7-4) / 2 = 1.5
B 8 16 (16-4) / 8 = 1.5
C - - -
D 10 17 (17-4) / 10 = 1.3
E 5 15 (15-4) / 5 = 2.2
F 12 18 (18-4) / 12 = 1.17
(Lowest)

•Job F is the second job to complete base on the

lowest critical ratio.
 4 Rules Application – Example (CR)
At t=16, day 16 [C and F completed],
Job Sequence Processing Time Due Date Critical Ratio
Calculation
A 2 7 (7-16) / 2 = -4.5 (Lowest)
B 8 16 (16-16) / 8 = 0
C - - -
D 10 17 (17-16) / 10 = 0.1
E 5 15 (15-16) / 5 = -0.2
F - - -

•Job A is the third job to complete base on the

lowest critical ratio.
 4 Rules Application – Example (CR)
At t=18, day 18 [C, F and A completed],
Job Sequence Processing Time Due Date Critical Ratio Calculation
A - - -
B 8 16 (16-18) / 8 = -0.25
C - - -
D 10 17 (17-18) / 10 = -0.10
E 5 15 (15-18) / 5 = -0.60
F - - (Lowest)
-

•Job E is the fourth job to complete base on the

lowest critical ratio.
 4 Rules Application – Example (CR)
At t=23, day 23 [C, F, A and E completed],
Job Sequence Processing Time Due Date Critical Ratio Calculation
A - - -
B 8 16 (16-23) / 8 = -0.875
C - - (Lowest)
D 10 17 -
E - - (17-23) / 10 = -0.60
F - - -
-

•Job B is the fifth job to complete base on the lowest

critical ratio and follow by Job D in last.
 4 Rules Application – Example (CR)
Job Processing Flow Time Due Date Tardiness
Sequence Time
C 4 4 4 0
F 12 16 18 0
A 2 18 7 11
E 5 23 15 8
B 8 31 16 15
D 10 41 17 24
Totals 41 133 58

Average completion time 133/6 = 22.17 days

Average number of jobs in the system 133/41 = 3.24 jobs
Average tardiness 58/6 = 9.67 days
Utilization 41/133 = 30.83%
 4 Rules Application – Example
(CR)
Rules Average Flow Average Average Utilization
Time (days) Tardiness Number of (%)
(days) Jobs at the
Work Center
FCFS 20.00 9.00 2.93 34.17
SPT 18.00 6.67 2.63 37.96
EDD 18.33 6.33 2.68 37.27
CR 22.17 9.67 3.24 30.83
Example 2
The work is waiting to be processed at a central
machine. Work presented in accordance with the
rules it up to the machining center. below shows the
work to be processed, completion date and duration
of the processing work.

Get the best job with the priority rules (a) FCFS, (b)
EDD (c) SPT . Assuming five working days of the
receipt of 275 calendar production.
 Due Date Processing Time
Work
(days) (days)

A 313 8
B 312 16
C 325 40
D 314 5
E 314 3

Job Sequence in Work Center

Try to solve this question….
Johnson’s Rule
Is the technique for minimizing completion time for a
group of jobs to be processed on two machines or at two
work centers.

Johnson’s rule requires satisfying the following conditions:

1. Job time must be known and constant
2. Job times must be independent of sequence
3. Job must follow same two step sequence
4. Job priorities cannot be used
5. All units must be completed at the first work center before
moving to second
Johnson’s Rule
Objective:

Minimize process time.

Minimize idle time (masa melahu) machine.

Example for Johnson’s rule
 5 special work in Tool & Die Factory at Mentakab have to work in
to work at two work station (gerudi machine and Lathe machine)
to process. Process time for every work are specified at table below:

Process Time (in hours ) For Every Work

WORK STATION 1 WORK STATION 2
WORK
(MESIN GERUDI) (LATHE MACHINE)
A 5 2
B 3 6
C 8 4
D 10 7
E 7 12
Try to solve this question….
EXAMPLE 2
By using Johnson's Rule, look for an optimal sequence for processing
the following works through two (2) business center as in the table
below. Time at each work center is in hour

KERJA PUSAT KERJA 1 PUSAT KERJA 2

A 6 12
B 3 7
C 18 9
D 15 14
E 16 8
F 10 15
Masa Memproses Kerja Melalui Pusat Kerja 1 & 2
Try to solve this question….
 THE END
OF
CHAPTER 4