Zagazig University, Faculty of Engineering,

Mechatronics Program

“Manufacturing Management”
Case study

By: Hazem tawfeek yassen tawfeek

Ahmed tarek hamed ahmed
Youssef tarek abdellatif
EZZ Eldin mohammed

Level: 300
Under supervision of : Dr. Mansour Abogamila
 Operations Scheduling Real Case Study

Abstract

In this paper, we analyzed the sequencing situations on two machines where the
machine setup time is not independent of processing order.
A real case study of Badr City Industrial Complex is taken as a model. Data is
collected and analyzed using MS-Excel by different methods. The problem
formulation has been presented. Multiple solutions were obtained by applying
sequencing methods. The comparison of different solutions is done to choose the
optimal solution.

1. Introduction

Operations scheduling is one of the most important problems in the area of

Manufacture management. It can be briefly described as follows: There are a set
of m machines and a set of n jobs. Each job comprises a set of x operations which
must be done on different machines. All jobs have the same processing operation
order when passing through the machines. There are no precedence constraints
among operations of different jobs. Operations cannot be interrupted and each
machine can process only one operation at a time. The problem is to find the job
sequences on the machines which minimize the make span, i.e. the maximum of
the completion times of all operations. As the objective function, mean flow time,
completion time variance and total tardiness.
Scheduling has been defined as the art of assigning resources to tasks in order to
insure the termination of these tasks in a reasonable amount of time ., the general
problem is to find a sequence, in which the jobs pass between the resources,
which is a feasible schedule, and optimal with respect to some performance
criterion.
2. A Model
a number of priority rules are simple heuristics used to select the order in which jobs will be processed.
Such rules are given in Table 1.
Table (1) Priority Sequencing Rules
Rules Description
FCFS First Come First Served
SPT Shortest Processing Time
DDATE Earliest Due Date
CR Critical Ratio
S/O Slack per Operation
SWPT Shortest Weighted Processing Time

sequencing can be difficult for a number of reasons. One is that in reality, an operation
must deal with variability in setup time, processing times, changes in the set of jobs.
For a description of a heuristic that can be used for the case where a set of jobs is to be
processed through one machine given the setup time. Consider the following table which
shows work station machine setup times based on job processing order:
Resulting
following
Job setup
time (min)
is
Setup
time J1 J2 J3
(minutes
)
J1 6 - 12 4
J2 4 2 - 8
J3 4 10 6 -
Note if job J1 is followed by J2, the setup time for J2 will be
12 minutes. Furthermore, if job J1 is completed first, followed by job J2, job J3 will then follow
job J2 and have a setup time of 8 minutes. Then if job J1 is done first, its setup time will be 6
minutes.

The simplest way to determine which sequence will result in the lowest total setup time is to list
each possible sequence and determine its total setup time. In general, the number of different
alternatives is equal to n!. Here, n is equal to 3, so there are six alternatives and their total setup
time is as follows:
Sequencing Total
Setup time
(minutes)
J1-J2-J3 26
J1-J3-J2 16
J2-J1-J3 10
J2-J3-J1 22
J3-J1-J2 26
J3-J2-J1 12

This procedure is relatively simple to do manually when the number of jobs is two or three.
However, as the number of jobs increases, the list of alternatives. quickly becomes larger, since
if the number of machines is more than one. Thus, sequencing will be difficult for this reason.
In this study, we will analyze sequencing situations under two machines where the setup time
would be considered as a factor.

3. Problem Formulation
 To form the general model subject to the setup time, the procedure for two machines is
considered for setup time as a main factor influencing the sequence of a set of jobs. The
following notations are used to design the model:

PTxy : Processing Time of Job x on Machine y

N : Number of jobs to be completed

M : Number of Machines in the workshop
TI xy : Starting Time for Job x on Machine y (Time in)
STxy : Setup time for Machine y where Job x is performed on it
TSTxy : Total Setup time for Machine y where all jobs are performed on it (x=1,2,...,n)
TTSTxy : Total Setup time for all machines where all jobs are performed on them
(x=1,2,...,n)and (y=1,2,...,m)
n

TSTxy  STxy j=1,2,...,m -----< )1)

x 1

m n

TTSTxy  STxy -----< )2)

y 1 x 1
Z: Summation of total setting up times for all the machines for performing n jobs.
The objective function Z will give the total setting up time for all machines to complete
all the jobs.
Now we can form the problem of sequencing if we consider two machines which will be fit
with our case study taken from an industry, the cells in the setup time matrix will differ
accordingly based on job processing order, which job follows and which job immediately
predecessor, Our objective is to find the minimum total setup time on all machines for all the
jobs.

4. Implementation

To implement the formula and to achieve the above objective, a real case study has been taken
from industry. A group of ten jobs are to be processed through two machines flow shop. The first
operation involves Vertical Cutting and the second operation involves Circular Cutting. In the
existing system, the set of jobs are processed in the same order in which they reached the
department. To implement the model, the jobs are labeled in serial number as they arrived to the
flow shop. The respective processing time for each job is given in the Table 2. Jobs are listed in
order of arrival and the processing time is in hours.

Table (2) Data for Jobs and Processing Time

Job Processing Time Processing Time
Number (hours)for (hours) for
Vertical Cutting Circular Cutting
Machine Machine
1 20 4
2 10 12
3 3 5
4 10 8
5 5 6
6 2 12
7 8 4
8 7 10
9 3 6
10 4 1
 5- Data Analysis
5.1. Existing System

In the existing system, the production manager orders the jobs arbitrary
Notation Meaning
and mainly using First Come First Served (FCFS) rule, i.e. the jobs are
M1 and Vertical Cutting
going to machine for processing in the order in which they are arriving.
M2 Machine and Circular
Cutting Machine
By scheduling the jobs in the order of Machine 1 (Vertical
T(M1) Time of processing for
Cutting) and Machine 2 (Circular Cutting), we calculated the total
and a job for Machine 1 and
setup cost for all jobs. The complete summary of the calculation Machine 2 respectively
T(M2)
for the existing system is shown in the Table 3. In the Table 3
Ti Time in of a job on a
, the following notations are used: machine
To Time out of a job on a
Table ( 3) Calculation of Setup time by Existing Sequence
machine
Job M1 M2 Setup Time ST1 Setup time required for
T(M1) T(M2)
No. Ti To Ti To ST1 ST2 TST Machine 1 to process a
1 20 4 0 20 20 24 5 5 10 job
2 10 12 20 30 30 42 18 25 43 ST2 Setup time required for
3 3 5 30 33 42 47 10 20 30 Machine 2 to process a
4 10 8 33 43 47 55 15 25 40 job
5 5 6 43 48 55 61 12 28 40 TST Total Setup time
6 2 12 48 50 61 73 5 15 20 required for two
7 8 4 50 58 73 77 20 10 30 machines to process a
8 7 10 58 65 77 87 3 12 15 job
9 3 6 65 68 87 93 23 7 30
10 4 1 68 72 93 94 7 20 27
72 68 653 118 167 285

Mean Flow Time = 65.3

It is clear from Table 3 that all the ten jobs must be processed by Machine 1 and Machine
2 in 72 and 68 hours respectively but due to idle of the machines, all the jobs will be
finished in 72 and 94 hours.
Total setup time for Machine 1 and Machine 2 for all jobs will be 118 minutes and 167
minutes respectively. So the total setup time for both machines required to process all
the jobs in the existing sequence will be 285 minutes. In this sequence, the mean flow
time is 65.3 (653/10) hours.

5.2. Searching The Optimum Sequence

By applying the efficient algorithm suggested by Johnson for solving two machine problems,
multiple optimum sequences are generated. Each sequence is like an array of size 10 cells
starting from left to right. These four sequences obtained are labeled as S1, S2, S3, and S4. The
order of the jobs in each sequence is shown inside the chart.

S1: 6 3 9 5 8 2 4 1 7 10
S2: 6 9 3 5 8 2 4 1 7 10

S3: 6 3 9 5 8 2 4 7 1 10
S4: 6 9 3 5 8 2 4 7 1 10

The results are presented in the following tables Table 5, Table 6, Table 7 and Table 8 for the
sequences S1, S2, S3 and S4 respectively.

Table (4) Calculation of Setup Time for sequence S1

Machine1 Machine2 Setup Time
 Ti To Ti To ST1 ST2 TST
Job T(M1) T(M2)
6 2 12 0 2 2 14 15 7 22
3 3 5 2 5 14 19 10 5 15
9 3 6 5 8 19 25 10 18 28
5 5 6 8 13 25 31 9 12 21
8 7 10 13 20 31 41 6 17 23
2 10 12 20 30 41 53 6 20 26
4 10 8 30 40 53 61 4 30 34
1 20 4 40 60 61 65 10 12 22
7 8 4 60 68 68 72 15 13 28
10 4 1 68 72 72 73 8 4 12
454 93 138 231
Mean Flow Time = 45.4
Table (5) Calculation of Setup Time for sequence S2
Machine1 Machine2 Setup Time
Job T(M1) T(M2)
Ti To Ti To ST1 ST2 TST
6 2 12 0 2 2 14 15 7 22
9 3 6 2 5 14 20 5 13 18
3 3 5 5 8 20 25 17 17 34
5 5 6 8 13 25 31 18 11 29
8 7 10 13 20 31 41 6 17 23
2 10 12 20 30 41 53 6 20 26
4 10 8 30 40 53 61 4 30 34
1 20 4 40 60 61 65 10 12 22
7 8 4 60 68 68 72 15 13 28
10 4 1 68 72 72 73 8 4 12
455 104 144 248
Mean Flow Time = 45.5
Table (6) Calculation of Setup Time for sequence S3
Machine1 Machine2 Setup Time
Job T(M1) T(M2)
Ti To Ti To ST1 ST2 TST
6 2 12 0 2 2 14 15 7 22
3 3 5 2 5 14 19 10 5 15
9 3 6 5 8 19 25 10 18 28
5 5 6 8 13 25 31 9 12 21
8 7 10 13 20 31 41 6 17 23
2 10 12 20 30 41 53 6 20 26
4 10 8 30 40 53 61 4 30 34
7 8 4 40 48 61 65 3 2 5
1 20 4 48 68 68 72 2 6 8
10 4 1 68 72 72 73 1 15 16
454 66 132 198
Mean Flow Time = 45.4
Table (7) Calculation of Setup Time for sequence S4
Machine1 Machine2 Setup Time
Job T(M1) T(M2)
Ti To Ti To ST1 ST2 TST
6 2 12 0 2 2 14 25 7 32
9 3 6 2 5 14 20 5 13 18
3 3 5 5 8 20 25 17 17 34
5 5 6 8 13 25 31 18 11 29
8 7 10 13 20 31 41 6 17 23
2 10 12 20 30 41 53 6 20 26
4 10 8 30 40 53 61 4 30 34
7 8 4 40 48 61 65 3 2 5
1 20 4 48 68 68 72 2 6 8
10 4 1 68 72 72 73 1 15 16
455 87 138 225
Mean Flow Time = 45.5
It is obvious from each solution that the total time to complete all the jobs is 73 hours for all the
solutions. Hence each solution is an optimum solution in case of minimum completion time.
But if production manager considers the setup time, it varies as well as the mean flow time as
shown in the tables.
Each sequence has different order of jobs which can be represented in a Gantt chart. The Gantt
chart is for sequence S3. The time scale on each machine is shown as starting and ending time.
Inside the chart, jobs are written in order for sequence S3. Each job has to wait for Machine 2
until it is free. For example, Job 8 (J8) is finished from Machine 1 after 20 hours and it will not
go directly to Machine 2 until it is free. So, Machine 2 will be free after 31 hours and J8 has to
wait until 31 hours for Machine 2. Opposite to this situation, sometimes the machine has to wait
for jobs. As happened for Machine 2, it will finish from Job 7 (J7) at 65 hours while it will not
start to perform Job 1 (J1) until J1 is finished from Machine 1. That means, Machine 2 has to
wait 3 hours. This time is known as idle time and it is marked as shadow.

6. Comparison Of The Study

The result for existing and proposed system is summarized in the Table 12.
It can be seen from the Table 8 that
Table (8) Summary of Calculation of Setup Time
Time Time Setup Setup Total Mean
to to time time Setup Flow
Sequence finish finish for all for all Time Time
all jobs all jobs jobs jobs Z=ST1+S
by M1 by M2 for M1 for M2 T2
S1 72 73 93 138 231 45.4
S2 72 73 104 144 248 45.5
S3 72 73 66 132 198 45.4
S4 72 73 87 138 225 45.5
Existing 72 94 118 167 285 65.3
Sequence
Reduction(%) 0 21 52 35 87 30.4

 the time taken by Machine 1 (Vertical Cutting) is 72 for all the sequences as
well as by existing sequence, while time taken by Machine 2 (Circular Cutting)
is 94 for existing which is reduced to 23% for each proposed sequence,

 the setup time is drastically reduced by approximately 44% on Machine 1 and

21% on Machine 2 for the proposed solution (S3) as compared to the existing
one.
Moreover, it is obvious that the third sequence generates the optimal solution according to the different
factors. It gives the minimum time to finish all the jobs and contains lowest setup time for all the jobs on
both machines .The significant reduction occurs in mean flow time by almost 46.5%. the third sequence
(S3) gives the best optimal solution in terms of setup time and completion time.