PRODUCTION PLANNING AND

CONTROL

Dr Vijaya Kumar M
NIT Warangal
Mechanical Engineering Department
PRODUCTION PLANNING AND CONTROL
PRODUCTION PLANNING AND CONTROL
After completion of this session one can able to understand the details of
Industrial Revolutions and significant events occurred over the years of
Industrial revolution

Contents can be covered are as follows:

 Industrial Revolution

 Significant events occurred over the years of Industrial Revolution

 Various Scientists and their contribution during the IR

Industrial Revolution

--- Prof Imre

Significant Events in IE
Significant Events in IE

• Division of labor (Smith, 1776)

• Standardized parts (Whitney, 1800)
• Scientific management (Taylor, 1881)
• Coordinated assembly line (Ford 1913)
• Gantt charts (Gantt, 1916)
• Motion study (the Gilbreths, 1922)
© 1995 Corel Corp.
© 1995 Corel Corp.

• Quality control (Shewhart, 1924)

• CPM/PERT (Dupont, 1957)
• MRP (Orlicky, 1960)
• CAD
• Flexible manufacturing systems (FMS)
©
• Computer integrated manufacturing (CIM) 1995
Corel
© 1995 Corel Corp. Corp.
After completion of this session one can able to understand the details of
manufacturing tools, systems, processes, routing and their importance

Contents can be covered are as follows:

 Evolution of Manufacturing System tools

 Changes in manufacturing methods, tools and techniques

 Different Production systems and their layouts

 Changes in Manufacturing Methods
 Manual Systems

HAND CRAFTS

 Semi Manual Systems

 Single Product Planning
 Material requirement and planning
 Manufacturing Resource Planning
Eli Whitney’s cotton gin
machine
 Automated Machines
 Just in Time manufacturing
 Enterprise resource planning
 Enterprise resource management

NC Machine tools

 Intelligent Machines

 Strategic ERM
 Lean and Agile MFG
 E-Manufacturing
3D Printer
 Methods of Production

Mass Production

 Flow Line Production

 Quantity Production

Batch Production

Job shop Production https://www.youtube.com/watch?v=DTWnQDAhp9k

 Production Layout‟s
Layout:
The layout of an operation is concerned with the
physical location of its transforming resources, that is
deciding where to put the facilities, machines,
equipment and staff in the operation.

Layout types:
1) Fixed position layout
2) Process layout
3) Cell layout
4) Product layout
 Fixed Position Layout

Fixed position layout

1) In a fixed position layout, the transformed resource does not
move between its transforming resources.

2) Equipment, machinery, plant and people who do the

processing move as necessary because the product or
customer is either:
i. Too large
ii. Too delicate or
iii. Objects being moved
Fixed Position Layout
 Process Layout

1) In a process layout, similar processes or processes with

similar needs are located together because:
i. It is convenient to group them together or
ii. The utilization of the transforming resource is
improved

2) Different products of customer have different requirements

therefore they may take different routes within the process.

3) The flow in a process layout can be very complex.

Process Layout
 Manufacturing Process Layout

Milling
Lathe Department Department Drilling Department
M M D D D D
L L
M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly

© Wiley 2010 18
 Product Layout

• Mass production where variety is small

and production volumes are very high. L M D G

•More efficient, but less flexible than

„functional‟ layout. A
S
• Work in progress is minimised, and jobs S
are easily tracked. E
L M D G
M
• Investment in specialised capital
B
equipment is high, so a reliable and LY
steady demand is required.
• Very sensitive to machine breakdown or
disruption to material supply.
L M D G
 Product Layout
In

Out
 Hybrid Layout

• Combine elements of both product & process

layouts
– Maintain some of the efficiencies of product layouts
– Maintain some of the flexibility of process layouts
• Examples:
– Group technology & manufacturing cells
– Grocery stores
Original Process Layout Revised Cellular Layout

Assembly Assembly

8 10 9 12
4 6 7 9
11
5 8 4 Cell 1 Cell 26 Cell 3
7
2 10 12

1 3 2 1 3 5
11

A C B
A B CRaw materials Raw materials
Before GT and after GT in process flows
Group Technology (CELL) Layouts
 Comparison of Product vs. Product Layouts

Process Layouts Product Layouts

Products Large in Variety High in Efficiency

Resources General purpose Specialized

Facilities More labor intensive More capital intensive

Flexibility Greater relative to market Lower relative to market

Processing Rates Slower Faster

Handling costs High Low

Space requirements Higher Lower

Library showing the path of just one customer

Loan books in subject order

On-line and
CD-ROM
access room

Study desks To
journal

Company reports
sack
Enquiries

Current
journals

Reference
section
Reserve
collection
Store Counter staff
room Copying area

Entrance Exit
 The ground floor plan of a department store
showing the sports goods shop-within-a-shop

Books
and
videos Footwear Sports shop Menswear

Perfume
& jewellery

Confectionery, Elevators
newspaper,
magazines and Women’s clothes
stationery

Luggage
and gifts
Entrance
An army Induction centre
 A restaurant complex with all four basic
layout types
Line layout cafeteria

Cell layout buffet

Fixed-position layout
service restaurant

Desert

Starter
buffet

buffet
Main course
buffet Service line
Preparation

Oven
Process layout kitchen
Cool room
Freezer Vegetable prep Grill
Machine-matrix
 Rank order clustering

• Rank order Clustering

– This method automates the cluster study by computing Binary weights
from a machine – part matrix
– It orders parts and machine cells „automatically‟ by structuring and
computing the matrix with binary weights
– It implies a computer algorithm for solving the clustering problem
– It may not solve if machines are needed by more than one family –
forces intelligence in application and hand scanning after several
ordering iterations
 Rank Order Clustering Method:
1. For each row of the machine/part matrix (M/P/M) read the pattern of cell
entries as a binary word. Rank the rows by decreasing binary value.
Equal values stay in same order.
2. Ask if newly ranked rows in the matrix are the same as previous order? –
Yes (STOP) No (continue)
3. Re-form the M/P/M with rows in new descending order. Now rank the
columns by decreasing binary word weight. Columns of equal weight are
left where they are
4. Are current column weights the same as current column order? Yes
(STOP), No (continue)
5. Re-form the matrix column order per rank order (highest to left) and
return to #1.
Lets try it with our earlier problem:
Part ‘Number’
X 1 2 3 4 5 6
A 1 1
Machine ID

B 1 1
C 1 1
D 1 1 1
E 1 1 1
 Step 1:
Part Numbers
1 2 3 4 5 6

B. Wt: 25 24 23 22 21 20
Machine ID

A 1 1

B 1 1

C 1 1

D 1 1 1

E 1 1 1

Step 2: Must Reorder!

 Step 3:
Part Number
B. WT. 1 2 3 4 5 6
E 24 1 1 1
Machine ID

C 23 1 1
D 22 1 1 1
B 21 1 1
A 20 1 1

Step 4: Must Reorder

 Back at Step 1:Great
Cluster
Result!

Part Number D. Eqv Rank

1 4 6 3 2 5
B Wt: 25 24 23 22 21 20
25+24+
E 1 1 1 1
23=56
Machine ID

25+24=
C 1 1 2
48
22+21+
D 1 1 1 3
20 = 7
B 1 1 22+21=6 4
A 1 1 22+20=5 5

Order stays the same: STOP!

 Issues in Clustering
• R/O clustering oscillations indicating need of machine
replication (happens often!)
• Presence of Outliers and/or Voids in the finished clusters
• Outliers indicate the need of machine replication
• Voids indicate „skipped‟ machines in a cell
• Generally speaking, these clustering algorithms are designed
to convert existing routes for facility re-organization
• They require a previous engineering study to be
performed to develop a series of routers on a core
sample of parts that represent most of the production
in the shop
 Practice Problem
Part ‘Number’
X 1 2 3 4 5 6
A 1 1 1
Machine ID

B 1 1
C 1 1
D 1 1
E 1
F 1 1
Sequencing and Scheduling
Sequencing and Scheduling
 Issues in Scheduling (sequencing of Jobs)

• Based on Established Job Priorities and the way arrivals are

treated:
• Static Arrival means we only enter jobs into
consideration at fixed points in time – uses job
accumulation
• Dynamic Scheduling means that jobs are dispatched as
they arrive with continuously revised job priorities
• Types and numbers of workers and machines available
• Most scheduling algorithms are machine-limited
(assumes labor is always available but machine time is
the problem)
• Newer algorithms are studying Labor-limited systems
(due to cells and multi-tasking workers)
• Internal Flow patterns
• Priority Rules for job allocation
Typical (Common) Sequencing Rules that we should
consider

FCFS. First Come First Served. Jobs processed in the

order they come to the shop.
SPT. Shortest Processing Time. Jobs with the shortest
processing time are scheduled first.
EDD. Earliest Due Date. Jobs are sequenced according
to their due dates.
CR. Critical Ratio. Compute the ratio of processing time
of the job and remaining time until the due date.
Schedule the job with the smallest CR value next.
Examining the scheduling of n on 1 – or the handling of the
bottleneck machine

• We will examine several approaches and select

ones that best meet varying priority decision
making
• Like Min. Mean Flow Time
• Average Job tardiness
• Number of Tardy Jobs
• Let‟s try FCFS, SPT, EDD and CR
 Example
• Machine shop has 5 unprocessed jobs (J1, J2, J3, J4, J5) numbers
by order they entered Bottleneck machines queue:

Job # Process Time Due Date

1 11 61

2 29 45

3 31 31

4 1 33

5 2 32
Using FCFS
Sequence Comp. Time D. Date Tardiness
J1 11 61 0
J2 40 45 0
J3 71 31 40
J4 72 33 39
J5 74 32 42
Totals 268 121

• Mean Flow Time: (268)/5 = 53.4

• Avg Tardiness: (121)/5 = 24.2
• # Tardy Jobs: 3
SPT
Sequence Comp. Time D. Date Tardiness
J4 1 61 0
J5 3 45 0
J1 14 31 0
J2 43 33 10
J3 74 32 42
Totals 135 52

• Mean Flow Time: (135)/5 = 27

• Avg Tardiness: (52)/5 = 10.4
• # Tardy: 2
EDD

Sequence Comp. Time D. Date Tardiness

J3 31 31 0
J5 33 32 1
J4 34 33 1
J2 63 45 18
J1 74 61 13
Totals 235 33

• Mean Flow Time: (235)/5 = 47

• Avg Tardiness: (33)/5 = 6.6
• # Tardy: 4
CR: This is an Iterative Process using this model

• Set Current Time (sum of time of all scheduled jobs so far)

• Compute: CR 
 Due _ Date    Cur _ Time 
Pr._ Work _ Re maining

• Model Starts with current time = 0

• Current time updates after each selection by adding
scheduled Process Time to current time
 Try it:
Pr. D. Pr. D.
JOB CR JOB CR
Time Date Time Date
Current Time = 0
Current Time = 31
1 11 61 5.546
1 11 61 2.727
2 29 45 1.552
2 29 45 .483
3 31 31 1.00

4 1 33 33 4 1 33 2

5 2 32 16 5 2 32 0.5
 Continuing (CR)
Pr. D. C. D.
JOB CR JOB Tardy
Time Date Time Date
Summary
Current Time = 60
0.091 3 31 61 0
1 11 61
do last 2 60 45 15
4 1 33 -27* 4 61 31 28
5 2 32 -14** 5 63 33 31

1 74 32 13

Total: 289 87

• Mean F. Time: (289)/5 = 57.8

• Mean Tardiness: (87)/5 = 17.4
• # Tardy: 4
 Comparing the Algorithm‟s for Bottleneck
Sequencing:
• Total Makespan is independent of sequencing algorithm
• SPT will guarantee minimum Mean Flow time
• Minimize Maximum lateness with EDD model
• Minimize # Tardy jobs starts with EDD, see text – Moore‟s
Algorithm – for rule to do this.
• Minimizing Mean Tardiness uses Wilkerson-Irwin
Algorthim
 Looking at the Serial Machine Problem

• In the 2-machine problem with „n‟ different products, we have

potentially: (n!)2 different schedules – therefore, full enumeration
is (usually) impossible
• Rules used in making decisions:
• Minimizing Makespan (time from start of 1st job on M1 to
completion of last job on M2)
• Minimizing Mean Flow time
• Minimize Mean Idle
• Minimize measures of Tardiness
In the Serial Problem, Various Schedules are Compared with
Gantt Charts:

• True if „n‟ is 25 or less else the chart is unreadable!

• Lets try a simple 2 parts example (2!)2 = 4 potential
schedules – lets fully enumerate!

M1 M2

Job 1 4 2

Job 2 1 4
 Potential Schedule 1 of 4

Tue Apr 25
ID Task Name Start Finish Duration
8 9 10 11 12 1 2 3 4 5 6 7

1 J1 M1 4/25/2006 4/25/2006 4h

2 J2 M1 4/25/2006 4/25/2006 1h

3 J1 M2 4/25/2006 4/25/2006 2h

4 J1 M2 4/25/2006 4/25/2006 4h

• Makespan = 10 units
• Mean Flow = (4.5+8)/2 = 6.25
• Mean Idle = (4+5)/2 = 4.5
 Potential Schedule 2 of 4

Tue Apr 25
ID Task Name Start Finish Duration
7 8 9 10 11 12 1 2 3 4 5 6 7 8 9

1 J1 M1 4/25/2006 4/25/2006 4h

2 J2 M1 4/25/2006 4/25/2006 1h

3 J2 M2 4/25/2006 4/25/2006 4h

4 J1 M2 4/25/2006 4/25/2006 2h

• Makespan: 7
• Mean Flow: (3+6)/2 = 4.5
• Mean Idle: (1+2)/2 = 1.5
 Potential Schedule 3 of 4

Tue Apr 25
ID Task Name Start Finish Duration
9 10 11 12 1 2 3 4 5 6 7 8 9

1 J2 M1 4/25/2006 4/25/2006 .99h

2 J1 M1 4/25/2006 4/25/2006 4h

3 J1 M2 4/25/2006 4/25/2006 2h

4 J2 M2 4/25/2006 4/25/2006 4h

• Makespan = 11
• Mean Flow = (3+9)/2 = 7.75
• Mean Idle = (6+5)/2 = 5.5
 Potential Schedule 4 of 4

Tue Apr 25
ID Task Name Start Finish Duration
9 10 11 12 1 2 3 4 5 6 7 8 9

1 J1 M1 4/25/2006 4/25/2006 4h

2 J2 M1 4/25/2006 4/25/2006 1h

3 J2 M2 4/25/2006 4/25/2006 4h

4 J1 M2 4/25/2006 4/25/2006 2h

• Makespan: 11
• Mean Flow = (4.5 +10)/2 = 7.25
• Mean Idle = (6+5)/2 = 5.5
 Comparing
• Upon Examination, it is obvious that Tentative Schedule 2 is the
most favorable
– Shortest Makespan, Min Mean Flow and Min Mean Idle

• Examining this schedule, we see that

– 1. the Jobs are run directly from their 1st machine to the second
upon completion
– 2. The job with the shortest time on M1 was scheduled 1st
– 3. The job with the shortest M2 time was scheduled last

• These decisions observations have been found (Johnson 1954) to

provide an optimal schedule for the 2 machine serial problem
 Johnson‟s Rule for n on 2 serial:
• Step 1: List all jobs with their M1 and M2 process times

• Step 2: Select the shortest processing time on the list

– If a M1 time, schedule job 1st
– If M2 time, schedule job LAST
– Cross this job off list

• Repeat Step 2 through rest of job (however, 1st means after

already scheduled “1sts” and last is before already scheduled lasts)

• Build optimal Schedule (Gantt Chart?) and compute Makespan,

Mean Flow and Mean Idle
 JOHNSONS ALGORITHM

The Algorithm is:

1. Find the job with minimum Pij

2. If j = 1 (machine 1) this job becomes the first job

3. If j = 2 (machine 2) this job becomes the last job

4. Remove assigned job from the list and repeat (break ties at random)
 N jobs 2 machine case
Job Machine 1 Machine 2
1 4 3

2 1 2

3 5 4

4 2 3

5 5 6

Johnson’s Algorithm
Job Sequence
2 4 5 3 1
 Example
• Suppose that Andrew and Julie work together to write reports for projects every
month. They forgot to check their calendar this month and it turned out that they
need to finish as soon as possible. Assume that Andrew writes and edits reports
while Julie collates data and draws all the necessary graphs. Julie starts her work
on a report as soon as Andrew finishes his part and Andrew works continuously.
Times for the reports (in hours) are as follows. What is the order of the tasks using
Johnson’s rule?

Projects Andrew Julie

A 4 2

B 3 5

C 5 1

D 7 3

E 8 6
Optimal Sequence
Practice Problem
 N jobs 3 machine case
Job Machine A Machine B Machine c
1 8 5 4

2 10 6 9

3 6 2 8

4 7 3 6

5 11 4 5

1. The maximum processing time on Machine M2 is at least

as great as the minimum processing time on machine M3.

and/or

2.The maximum processing time on Machine M2 is at least

as great as the minimum processing time on machine M1 .
 Job Machine G= A+B Machine H = B+C

1 8+5 = 13 5+4=9

2 10+6 = 16 6 + 9 = 15

3 6+2 = 8 2 + 8 = 10

4 7+3 = 10 3+6=9

5 11 + 4 = 15 4+5=9

Johnson’s Algorithm

Job Sequence
3 2 5 4 1
Job Machine A Machine B Machine C
Time in Time out Time in Time out Time in Time out

3 0 6 6 8 8 16

2 6 16 16 22 22 31

5 16 27 27 31 31 36

4 27 35 35 40 40 44

1 35 42 42 45 45 51
 N jobs m machines
Job Machine 1 Machine 2 Machine 3 Machine 4 Machine 5

A 7 5 2 3 9

B 6 6 4 5 10

C 5 4 5 6 8

D 8 3 3 2 6

Min (TM1, J) = 5; Min (TM5, J) = 6

Max (TM2, J; TM3,J; TM4,J) = 6,5,6;

Condition Min (TM5, J) should be greater than or equal

to Max(TM2,J;TM3,J;TM4,J)
 Job A B C D
Machine G 17 21 20 16
(M1+m2+m3+
m4)
Machine H 19 25 23 14
(M2+m3+m4+
m5)

Job Sequence
A C B D
Job Machine A Machine B Machine C Machine 4 Machine 5
Time in Time out Time in Time out Time in Time out Time in Time out Time in Time out

A 0 7 7 12 12 14 14 17 17 26

C 7 12 12 16 16 21 21 27 27 35

B 12 18 18 24 24 28 28 33 35 45

D 18 26 26 29 29 32 33 35 45 51
THANK YOU