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Operations Management Chapter 15 – Short-Term Scheduling PowerPoint presentation to accompany Heizer/Render Operations Management, 8e © 2006 Prentice Hall, Inc. Hall, Inc. © 2006 Prentice 15 – 1 Strategic Importance of Short-Term Scheduling Effective and efficient scheduling can be a competitive advantage Faster movement of goods through a facility means better use of assets and lower costs Additional capacity resulting from faster throughput improves customer service through faster delivery Good schedules result in more reliable deliveries © 2006 Prentice Hall, Inc. 15 – 2 Scheduling Decisions Organization Arnold Palmer Hospital University of Missouri Lockheed-Martin factory Hard Rock Cafe Delta Airlines Table 15.1 © 2006 Prentice Hall, Inc. Managers Must Schedule the Following Operating room use Patient admissions Nursing, security, maintenance staffs Outpatient treatments Classrooms and audiovisual equipment Student and instructor schedules Graduate and undergraduate courses Production of goods Purchases of materials Workers Chef, waiters, bartenders Delivery of fresh foods Entertainers Opening of dining areas Maintenance of aircraft Departure timetables Flight crews, catering, gate, ticketing personnel 15 – 3 Activity in Sequencing Sequence the following cars into as many work days as needed. Garage can work on two cars simultaneously Assume first come first serve sequencing; 8 hour workday. Customers arrive in the following order DAY 1 Car 3: Maintenance ; time needed 6 hours Car 4: Maintenance ; time needed 10 hours Car 1: Repair ; time needed 2 hours Car 2: Repair ; time needed 2.5 hours DAY 2 Car 5: Maintenance ; time needed 3.5 hours Car 6: Repair ; time needed 3.5 hrs Car 7: Maintenance ; time needed 4 hours © 2006 Prentice Hall, Inc. 15 – 4 Solution: Sequencing Repair Track 1 Car 3: Repair - 6 hours Day 1 Car 1: Maintenance 2 hours Repair Track 1 Car 2: Maintenance 2.5 hours Day 2 Car 6:Maintenance 3.5 hours Repair Track 2 Car 4: Repair – 8 hours Repair Track 2 Car 4: Repair – 2 hours Car 5: Repair – 3.5 hours Car 7:Maintenance 2.5 hours Repair Track 1 Day 3 © 2006 Prentice Hall, Inc. Repair Track 2 Car 7:Maintenance 1.5 hours 15 – 5 Activity in Sequencing_2 Schedule the following cars into 2 work days. Garage can work on two cars simultaneously Method: Garage controlled scheduling (First assigned first serve; or capacity-based scheduling). 8 hours per day work time. Car 3: Maintenance ; time needed 6 hours Car 4: Maintenance ; time needed 10 hours Car 1: Repair ; time needed 2 hours Car 2: Repair ; time needed 2.5 hours Car 5: Maintenance ; time needed 3.5 hours Car 6: Repair ; time needed 3.5 hrs Car 7: Maintenance ; time needed 4 hours © 2006 Prentice Hall, Inc. 15 – 6 Solution: Sequencing _2 Schedule for days 1 and 2. Notice one track for long duration work and the other for fast jobs! Fast turnaround jobs Repair Track 1 Day 1 Car 1: Repair - 2 hours Long turnaround jobs Repair Track 2 Car 4: Repair – 8 hours Car 5: Maintenance 3.5 hours Car 2: Maintenance 2.5 hours Repair Track 1 Day 2 Car 6: Maintenance 3.5 hours Repair Track 2 Car 4: Repair – 2 hours Car 3: Repair – 6 hours Car 7:Maintenance 4.0 hours © 2006 Prentice Hall, Inc. 15 – 7 Definitions Scheduling is the assignment of due dates to specific work or jobs. Loading is the assignment of jobs to work centers. Sequencing: Determining the order in which jobs should be done at each work center so that due dates are met. Input-Output control: Any technique that enables managers to manage workflows at each work center by comparing work added to work completed. © 2006 Prentice Hall, Inc. 15 – 8 Positioning Scheduling Figure 15.1 © 2006 Prentice Hall, Inc. 15 – 9 Defining Scheduling Scheduling deals with the assignment of activities (demand) to resources (supply) (or vice-versa) and timing of activities. E.g. supply could be production capacity of a firm) Types of scheduling situations Type I: Supply options (M) are fewer than demand options (N) Type II: Supply options (M) are equal to demand options (N) Type III: Supply options (M) exceed the number of demand options (N) © 2006 Prentice Hall, Inc. 15 – 10 Objectives of Scheduling Goals of scheduling Type I: Supply options (M) are fewer than demand options (N) Assign scarce supply to demand to minimize cost or maximize benefits Type II: Supply options (M) are equal to demand options (N) Assign supply to demand to minimize cost or maximize benefits for total process Type III: Supply options (M) exceed the number of demand options (N) Scheduling is done for limited capacity and excess capacity is outsourced. © 2006 Prentice Hall, Inc. 15 – 11 Methods of Scheduling Forward scheduling concept Scheduling begins as soon as customer requests and requirements are known Scheduling begins from the estimated start date of the project and works forward to determine the start and finish dates for each of the activities that make up the order. Backward scheduling concept Scheduling begins from the expected delivery date and works backwards to determine the finish and start dates for the activities that make up the order. [Usually this method is available for projects that have long completion times, large number of units or parts, and have the completion of project on or before the delivery deadline as a key objective] . © 2006 Prentice Hall, Inc. 15 – 12 Loading_Activity_A We own a hotel which has a large ballroom. We have to schedule activities for two Saturdays in May. The closing time of the ballroom each Saturday is 10 pm. Which activities would you schedule? We charge per hour for the time a client spend using room. No charges for cleaning and preparation times. Event A: 9 am - 1 pm, Cleanup needed after event 2 hrs. Event B: 4 pm – 7 pm, preparation needed before event 0.5 hours. Cleanup needed after event 1 hrs. Event C: 5 pm - 10 pm, preparation needed before event 1 hours. Cleanup after event 2 hrs. Event D: 9 am -12 pm, preparation needed before event 1 hours. Cleanup after event 1 hrs. Event E: 11 am – 8 pm, preparation needed before event 2 hours. Cleanup after event 2 hrs. © 2006 Prentice Hall, Inc. 15 – 13 Activity_A Scheduling Criteria and Options Option1 Event A: 9 am - 1 pm AND Event B: 4 – 7 pm Event D: 9 am -12 pm AND Event C: 5 - 10 pm. Option 2 Event A: 9 am - 1 pm AND Event C 5 - 10 pm. Event D: 9 am -12 pm AND Event B: 4 – 7 pm Option 3 Event A: 9 am - 1 pm AND Event B OR Event C Event E: 11 am – 8 pm Scheduling Criteria: Why did we schedule the way we did? We are tried to maximize the utilization of the ballroom (maximize utilization)! Other criteria; Min. Cost, Min. waiting time or Work in progress (WIP) © 2006 Prentice Hall, Inc. 15 – 14 Comparing Options_Activity_A Option1 Event A: 9 am - 1 pm AND Event B: 4 – 7 pm Event D: 9 am -12 pm AND Event C: 5 - 10 pm. Option 2 Event A: 9 am - 1 pm AND Event C 5 - 10 pm. Event D: 9 am -12 pm AND Event B: 4 – 7 pm Option 3 Event A: 9 am - 1 pm AND Event B OR Event C Event E: 11 am – 8 pm OPTION 3: Less switching costs, maximize utilization, minimize waiting times, maximize profits © 2006 Prentice Hall, Inc. 15 – 15 Activity_Scheduling If you could change one thing in the operations scheduling of this case, what would you change? We own a hotel which has a large ballroom. We have to schedule activities for two Saturdays in May. The closing time of the ballroom each Saturday is 10 pm. Which activities would you schedule? We charge per hour for time spent in room. No charges for cleaning and preparation times. Event A: 9 am - 1 pm, Cleanup needed after event 2 hrs. Event B: 4 pm – 7 pm, preparation needed before event 0.5 hours. Cleanup needed after event 1 hrs. Event C: 5 pm - 10 pm, preparation needed before event 1 hours. Cleanup after event 2 hrs. Event D: 9 am -12 pm, preparation needed before event 1 hours. Cleanup after event 1 hrs. Event E: 11 am – 8 pm, preparation needed before event 2 hours. Cleanup after event 2 hrs. © 2006 Prentice Hall, Inc. 15 – 16 Activity_Scheduling If you could change one thing in the operations scheduling of this case, what would you change? Demand Options: Charge for cleaning time Set minimum reservation time Capacity Options: Build new ballroom Extend working hours per day © 2006 Prentice Hall, Inc. 15 – 17 Scheduling Criteria Types of scheduling/sequencing criteria Goal-based approaches Minimize cost, waiting times Minimize work-in-process Maximize profits Priorities-based approaches First-come first serve or Last-in-first-out Longest processing time Earliest due date Shortest processing time © 2006 Prentice Hall, Inc. 15 – 18 Job Loading Methods Types of scheduling methods Arbitrary approaches Useful when there are no constraints of resources (Supply exceeds demand) Rule-based approaches Useful when there are constraints of resources Priorities-based approaches Useful when there are constraints of resources and there are priorities among suppliers or customers © 2006 Prentice Hall, Inc. 15 – 19 Assignment Method (Type II Scheduling) A special class of linear programming models that assign tasks or jobs to resources Objective is to minimize cost or time Only one job (or worker) is assigned to one machine (or project) © 2006 Prentice Hall, Inc. 15 – 20 Assignment Method 1. Create zero opportunity costs by repeatedly subtracting the lowest costs from each row and column 2. Draw the minimum number of vertical and horizontal lines necessary to cover all the zeros in the table. If the number of lines equals either the number of rows or the number of columns, proceed to step 4. Otherwise proceed to step 3. 3. Subtract the smallest number not covered by a line from all other uncovered numbers. Add the same number to any number at the intersection of two lines. Return to step 2. 4. Optimal assignments are at zero locations in the table. Select one, draw lines through the row and column involved, and continue to the next assignment. © 2006 Prentice Hall, Inc. 15 – 21 Assignment Example Typesetter Job R-34 S-66 T-50 Step 1a - Rows C $11 $ 8 $ 9 $14 $10 $12 $ 6 $11 $ 7 Least numbers per row Typesetter A © 2006 Prentice Hall, Inc. B Step 1b - Columns Typesetter Job R-34 S-66 T-50 A $ 5 $ 0 $ 2 B $ 8 $ 2 $ 5 C $ 0 $ 3 $ 0 Job R-34 S-66 T-50 Least numbers per column A B C $ 5 $ 0 $ 2 $ 6 $ 0 $ 3 $ 0 $ 3 $ 0 15 – 22 Assignment Example Step 2 - Lines Typesetter Job R-34 S-66 T-50 A B C $ 5 $ 0 $ 2 $ 6 $ 0 $ 3 $ 0 $ 3 $ 0 The smallest uncovered number is 2 so this is subtracted from all other uncovered numbers and added to numbers at the intersection of lines Step 3 - Subtraction Typesetter Because only two lines are needed to cover all the zeros, the solution is not optimal (it is fewer than the number of jobs to assign) © 2006 Prentice Hall, Inc. Job R-34 S-66 T-50 A B C $ 3 $ 0 $ 0 $ 4 $ 0 $ 1 $ 0 $ 5 $ 0 15 – 23 Assignment Example Step 2 - Lines Typesetter Job R-34 S-66 T-50 A B C $ 3 $ 0 $ 0 $ 4 $ 0 $ 1 $ 0 $ 5 $ 0 Because three lines are needed to cover all the numbers, the solution is optimal and job assignments can now be made © 2006 Prentice Hall, Inc. Start by assigning S-66 for worker B. Job T-50 must go to worker A. This leaves R-34 to worker C as this is the least cost assignment for worker C. Step 4 - Assignments Typesetter Job R-34 S-66 T-50 A B C $ 3 $ 0 $ 0 $ 4 $ 0 $ 1 $ 0 $ 5 $ 0 15 – 24 Assignment Example From the original cost table Minimum cost = $6 + $10 + $9 = $25 Step 4 - Assignments Costs Table Typesetter Typesetter A Job R-34 S-66 T-50 © 2006 Prentice Hall, Inc. $11 $ 8 $ 9 B $14 $10 $12 C $ 6 $11 $ 7 Job R-34 S-66 T-50 A B C $ 3 $ 0 $ 0 $ 4 $ 0 $ 1 $ 0 $ 5 $ 0 15 – 25 Opportunity Loss: Example 2 (Deriving Opportunity Loss Table) Assignment Costs Table Typesetter Job R-34 S-66 T-50 A B C $11 $ 8 $ 9 $14 $10 $12 $ 6 $11 $ 7 Opportunity Loss Table (Sales – Costs) Table Typesetter Typesetter A B C Job R-34 S-66 T-50 © 2006 Prentice Hall, Inc. Assume that the fixed sale price for each job is as follows : R-34 = $ 15 /unit; S-66 = $ 15 /unit; T-50 = $ 14 /unit; $15-$11 $15-$14 $15-$6 $15-$8 $15-$10 $15-$11 $14-$9 $14-$12 $14-$7 Job R-34 S-66 T-50 A B C $ 4 $ 7 $ 5 $ 1 $ 5 $ 2 $ 9 $ 4 $ 7 15 – 26 Assignment: Example 2 (Deriving Opportunity Loss Table) The table has profit margins that are earned for each unit made. To find the optimal assignment, use the method but subtract the highest score of each row not the least one. Typesetter A Job R-34 S-66 T-50 B 1 Typesetter C Opportunity Loss Table $ 4 $ 7 $ 5 $ 1 $ 5 $ 2 $ 9 $ 4 $ 7 Take highest number from each column and subtract from all the numbers in the column. Note -2 is the highest number in column B! © 2006 Prentice Hall, Inc. Job R-34 S-66 T-50 A B -$ 5 $0 -$ 2 -$ 8 -$ 2 -$ 5 Typesetter Job R-34 S-66 T-50 A B -$ 5 $0 -$ 2 -$ 6 $0 -$ 3 2 C $0 -$ 3 $0 3 C $0 -$ 3 $0 15 – 27 Assignment: Example 2 (Deriving Opportunity Loss Table) Draw lines across the zeros. As only two lines cross all the zeros, solution is not yet optimal. Opportunity Loss Table Typesetter Job R-34 S-66 T-50 4 A B -$ 5 $0 -$ 2 -$ 6 $0 -$ 3 C $0 -$ 3 $0 Take highest number from uncrossed cells and subtract it from all other uncrossed numbers in each column. Add the number to number on the intersection Intersection to get table 5. This is not an optimal solution – 2 lines through all zeros © 2006 Prentice Hall, Inc. 15 – 28 Opportunity Loss: Example 2 Largest uncrossed number Table 5 now has three lines going through all the zeros. An optimal assignment can now be Made for our problem! Typesetter Assign C to R-34; assign A to T-50; assign B to S-66; The profit margin of the assignment is taken from first table: = $5 + $ 5 + $ 9 = $ 19 Gross Margin - Opportunity Loss Table Typesetter A Job R-34 S-66 T-50 © 2006 Prentice Hall, Inc. $ 4 $ 7 $ 5 B $ 1 $ 5 $ 2 1 Job R-34 S-66 T-50 A B -$ 5 $0 -$ 2 -$ 6 $0 -$ 3 Typesetter C $ 9 $ 4 $ 7 Job R-34 S-66 T-50 4 A B -$ 3 $0 $0 -$ 4 $0 -$ 1 5 C $0 -$ 3 $0 C $0 -$ 5 $0 15 – 29 Gantt Load Chart Method (Type III Scheduling) Day Work Center Metalworks Monday Tuesday Job 349 Job 349 Job 408 Painting Processing Thursday Friday Job 350 Mechanical Electronics Wednesday Job 408 Job 349 Job 295 Job 408 Unscheduled Job 349 Center not available Figure 15.3 © 2006 Prentice Hall, Inc. 15 – 30 Plan 1: Gantt Staffing Chart (Type III Scheduling) Bill Mon Tue Off Off Mary Wed Thu Off Off Sue Schedule Off Will Off Off Bob Off Off Mon Off Fri Sat Sun Off Off Josh Off Off 1. Required Capacity 5 5 6 5 8 9 9 2. Max available staff 7 7 7 7 7 7 7 3. Max off duty limits 2 2 1 2 -1 -2 -2 4. Scheduled off-duty 3 3 2 3 2 1 0 5. Extra staff needed 1 1 1 1 3 3 2 Scheduled off duty minus Max. off duty limit ( row 4. Minus row 3.) What would you advise the manager to do? © 2006 Prentice Hall, Inc. 15 – 31 Plan 2: Gantt Staffing Chart (Type III Scheduling) Sat Sun Bill Off Off Mary Off Off Sue Off Off Mon Schedule Tue Wed Thu Fri Will Off Off Bob Off Off Mon Josh Off Off Off Off 1. Required Capacity 5 5 6 5 8 9 9 2. Max available staff 7 7 7 7 7 7 7 3. Max off duty staff 2 2 1 2 -1 -2 -2 4. Scheduled off-duty 1 2 1 2 2 3 3 5. Extra staff needed -1 0 0 0 3 5 5 4. Minus 3 This solution shifts all temp staff requirement to weekends What could be the benefit/problem with this plan? © 2006 Prentice Hall, Inc. 15 – 32 Gantt Schedule Chart Example Job Day 1 Day Day 2 3 Day Day Day Day Day 4 5 6 7 8 A B Start of an activity End of an activity Scheduled activity time allowed Actual work progress Maintenance Nonproduction time C Figure 15.4 © 2006 Prentice Hall, Inc. Point in time when chart is reviewed Now 15 – 33 Sequencing Specifies the order in which jobs should be performed at work centers Priority rules are used to dispatch or sequence jobs FCFS: First come, first served SPT: Shortest processing time EDD: Earliest due date LPT: Longest processing time © 2006 Prentice Hall, Inc. 15 – 34 Sequencing Example Apply the four popular sequencing rules to these five jobs Job A B C D E © 2006 Prentice Hall, Inc. Job Work (Processing) Time (Days) 6 2 8 3 9 Job Due Date (Days) 8 6 18 15 23 15 – 35 Sequencing: FCFS Example FCFS: Sequence A-B-C-D-E (assume that all jobs arrived on same day in the sequence given). Job Sequence Job Work (Proce ssing) Time Wait Times Flow Time Job Due Date A 6 0 6 8 0 B 2 6 8 6 2 C 8 8 16 18 0 D 3 16 19 15 4 E 9 19 28 23 5 28 28 49 77 © 2006 Prentice Hall, Inc. Job Lateness 11 15 – 36 Sequencing Example FCFS: Sequence A-B-C-D-E Average completion time = Total flow time = 77/5 = 15.4 days Number of jobs Total job work time Utilization = Total flow time = 28/77 = 36.4% Total flow time Average number of jobs in the system = Total job work time = 77/28 = 2.75 jobs/month Total late days Average job lateness = Number of jobs = 11/5 = 2.2 days © 2006 Prentice Hall, Inc. 15 – 37 Sequencing Example SPT (Shortest processing time): Sequence B-D-A-C-E Job Sequence Job Work (Processing) Time Flow Time Job Due Date B 2 2 6 0 D 3 5 15 0 A 6 11 8 3 C 8 19 18 1 E 9 28 23 5 28 65 Job Lateness 9 The sequence changes with the priority rule © 2006 Prentice Hall, Inc. 15 – 38 Sequencing Example SPT: Sequence B-D-A-C-E Total flow time Average completion time = = 65/5 = 13 days Number of jobs Total job work time Utilization = Total flow time = 28/65 = 43.1% Total flow time Average number of = = 65/28 = 2.32 jobs in the system Total job work time jobs/months Total late days Average job lateness = Number of jobs = 9/5 = 1.8 days © 2006 Prentice Hall, Inc. 15 – 39 Sequencing Example EDD (Earliest due date) : Sequence B-A-D-C-E Job Sequence Job Work (Processing) Time Flow Time Job Due Date B 2 2 6 0 A 6 8 8 0 D 3 11 15 0 C 8 19 18 1 E 9 28 23 5 28 68 © 2006 Prentice Hall, Inc. Job Lateness 6 15 – 40 Sequencing Example EDD: Sequence B-A-D-C-E Total flow time Average completion time = Number of jobs = 68/5 = 13.6 days Total job work time Utilization = Total flow time = 28/68 = 41.2% Total flow time Average number of = = 68/28 = 2.43 jobs/ jobs in the system Total job work time month Total late days Average job lateness = Number of jobs = 6/5 = 1.2 days © 2006 Prentice Hall, Inc. 15 – 41 Sequencing Example LPT (Longest processing time): Sequence E-C-A-D-B Job Sequence Job Work (Processing) Time Flow Time Job Due Date E 9 9 23 0 C 8 17 18 0 A 6 23 8 15 D 3 26 15 11 B 2 28 6 22 28 103 © 2006 Prentice Hall, Inc. Job Lateness 48 15 – 42 Sequencing Example LPT: Sequence E-C-A-D-B Total flow time Average completion time = = 103/5 = 20.6 days Number of jobs Total job work time Utilization = Total flow time = 28/103 = 27.2% Total flow time Average number of = = 103/28 = 3.68 jobs jobs in the system Total job work time Total late days Average job lateness = Number of jobs = 48/5 = 9.6 days © 2006 Prentice Hall, Inc. 15 – 43 Summary Sequencing Examples Summary of Rules Average Number of Jobs in Average Utilization System per Lateness (%) month (Days) Rule Average Completion Time (Days) FCFS 15.4 36.4 2.75 2.2 SPT 13.0 43.1 2.32 1.8 EDD 13.6 41.2 2.43 1.2 LPT 20.6 27.2 3.68 9.6 © 2006 Prentice Hall, Inc. 15 – 44 Comparison of Sequencing Rules No one sequencing rule excels on all criteria SPT does well on minimizing flow time and number of jobs in the system But SPT moves long jobs to the end which may result in dissatisfied customers FCFS does not do especially well on any criteria (or does poorly on most criteria) but it is perceived as fair by customers EDD minimizes lateness © 2006 Prentice Hall, Inc. 15 – 45 Improving Performance of System Changing setting of due dates Changing process serial to parallel form A B C A B E C © 2006 Prentice Hall, Inc. E D D 15 – 46 Example from Service Industry Patie nt Health Issue (Treatment time) A F G B C I D H E Pain in head (1 hr) Skin disease (1 hr) Sun burns (1 hr) Brain tumor (2 hrs) Depression (1 hr) Pollen issues (2 hrs) Migraine pains (2 hrs) Skin cancer (2 hrs) Skin exam (1 hr) First priority Second priority appointment appointment 8-9 am 9-10 am 10-11 am 8-10 am 2-3 pm 2-4 pm 2-4 pm 8-10 am 11-12 am 10-11 am 10-11 am 11-12 pm 10-12pm 1-2 pm 10-12 pm 8-10 am 2-4 pm 2-3 pm There are two doctors in a specialist clinic, one is a dermatologist the other is a neurologist. The patients call-in the order shown. Create a schedule for the clinic assuming that each specialist works 8-12 pm and 1-4pm daily. Assign slots to patients using First come First serve priority rule. Assume that the appointments slots are one hour each. 15 – 47 © 2006 Prentice Hall, Inc. Resolution from Service Industry Day 1 8-9 Nurlo gist 9-10 A Aller gist F Day 2 10-11 11-12 B B G 1-2 2-3 3-4 C H 8-9 9-10 10-11 D D H 1112 E I I There are two doctors in a specialist clinic, one is a dermatologist the other is a neurologist. The patients call-in the order shown. Create a schedule for the clinic assuming that each specialist works 8-12 pm and 1-4pm daily. Assign slots to patients using First come First serve priority rule. Assume that the appointments slots are one hour each. © 2006 Prentice Hall, Inc. 15 – 48 Resolution from Service Industry Day 1 8-9 9-10 Day 2 10-11 11-12 Nurlo gist B A E Aller gist H F G 1-2 C 2-3 3-4 8-9 9-10 10-11 1112 D I There are two doctors in a specialist clinic, one is a dermatologist the other is a neurologist. The patients call-in the order shown. Create a schedule for the clinic assuming that each specialist works 8-12 pm and 1-4pm daily. Assign slots to patients using First come First serve priority rule combined with SPT and LPT time slots © 2006 Prentice Hall, Inc. 15 – 49