7 Routing, Scheduling, Dispatching-1
7 Routing, Scheduling, Dispatching-1
7 Routing, Scheduling, Dispatching-1
should be evolved.
To achieve good production control, a proper mechanism or procedure
Under this mechanism, to provide necessary information, a system ofissuing of number offorms
and orders are dealt
of instructions and orders are used. All the forms used for instructions
under the following headings
1. Authorization to commence production. i.e. the manufacturing order.
2. Routing
3. Scheduling, including machine loading and sequencing.
4. Dispatching.
5. Follow up or expediting.
Secondary Orders
With the issue of production order a series of secondary orders are also prepared such as in
case of aachine shop work, the secondary ordersissued may be pattern and casting orders,
tools, fixtures and jigs making orders, processing orjob orders. In addition to these, some
secondaryorders like materials requisitions, storesissue orders, tool is_ue orders, move orders,
inspection orders and replacement orders are also issued by control department.
Insmallindustries, with fixed processes, sometimes manufacturing orders are combined
with routing and scheduling. Fig. 37.1 shows one such type of order. In this, each sheet is
removed at perforated lines by the production man as soon as each operation is performed. The
top most portion of the order represent the manufacturing order and the lower ones are the job
orders. The bottom one is always material issue order which is first to be removed.
ROUTING, SCHEDULING, DESPATCHING AND FOLLOW-UP 975
Date... . L0 be shipped on.. oosenesosne osssuersusesstsseeeea
Customer...************ssreese nevneonre0b03...arpoeppedte*neessse"rensann
6689.
Shipping instruction.. ********************** esurdss esoreds44d9oed001007*******
Started. Finished..
***********************
Inspection report..
**************************************************seeo41eessee seeestosssd*****0600s**e*00d0t"""**
Casting 6699
MachineNo.. *****************************. M a n . . . 04tdqu4sduudunuuuvunn44uu
... tiut1tvd
Started. ******************************
Finished.. "*"***********°*"****"""*****'***°°**
Pes.good.. ****************essrorseen***********osesaosoeosssneru**sdsessseoteoesses**tdss***********"*"****
Inspection report....
tore 6699
* * * * * * * * * ' * * * " * * * * * * e "
***.********o*************************e*************** ************"*"*****"*
ROUTING
Shipping
Promised Date
Technique of Routing9
While converting raw material into required goods, different operations are to be performed
and the selection of a particular path of operations for each piece is termed as 'Routing. This
selection of a particular path, ie. sequence of operations must be the best and cheapest to have
the lowest cost of the final product.
ROUTING IN INDUSTRIES
Routing in industries depends upon the nature and type ofindustry, as explained below
(a) Continuous Industry. Such industries are almost automatic, therefore, the problem of
routingin them is very simple. The plan of industry is laid during its erection time for a
particular sequence of operations. Therefore, when raw materials enter the plant, it will
automatically move through different processestillit get final shape. Therefore, once the route
isdecidediîn the beginning, no further control over the route is generally needed.
n e examples of such industries are cycle, scooter, car, radio, type- writer, watch ete. These
S i e s require much attention for routing. In thesc industries, a work-flow sheet for every
cmponentis prepared. This gives full particulars about the processes, machines, and the
sequencein which parts will reach at a particular place and time. As this type of routing
be
requires good technical knowledge, the staff of the production control department must
qualitied and experienced one.
c) Job Order Industry. Suchindustries handle different products, therefore, afterreceiv
ingthemanufacturing orders, the planning department has to prepare a detailed drawing and
in
planning each time. This will indicate the proper sequence of routes for the job. Therefore,
such industries, the production planning and control department should be very expert in their
Drawing No...
Part
No. Symbol. Lot Size
Machine Jigs and fix | Set-up time Time per Time per lot Labour rate
Operation Shop Piece
tures re
Number
quired
No. Description
Cause of scrap No. Scraped Cost
MAT
LAB
Inspection Total
Route Sheet
sheets. One sheet is
Tt dealswith specific production order generally made, from operation
required for each part or component of the order. This includes the following:
1. Number and other identification of order
2. Symbol and identification of part.
3. Number of pieces to be made.
4. Number of pieces in each lot if put through in lots.
5. Operation data, which includes:
(a) list of operation on the part.
(6) department in which operations are to be performed.
(c) machine to be used for each operation.
(d) fixed sequence of operation, if any.
6. Date at which the job must be completed, determined from the operation sheet.
LFLLING HOLE
BORAINING HOLE
Move Order
document needed for production control, it is never used for Routing
Though this is only a
System.
On this the quantity passed
Move orderis prepared for each operation as per operation sheet.
are recorded. It is returned to planning office when the
forward, scrapped and to be rectified
operation is typical move order is shown ir. Fig. 37.7.
completed. A
980 PRODUCTION MANAGEMENT SYSTEMS
Route Sheet
Order no.. . Dateof Completion.. *** ************************.
Order Tool Operation Nachine Time allowance Due date Move Piece
order Good
No. Making | Issue Per Lot Setting|TotalStart Finish
order piece
Move Order
Customer Quantity Description Part No. Job No.
Progress Op.No.| Deptt M/C or Operation Jig, Tool, Labour Time Allowed
Group No. Gauge Grade Setup Hrs.
Per 100
Product Sequencing
During production, manytimes a probler arises when several products are to be manufac-
turedoncertainmachines according tothe determined sequence of operation. In such cases, a
problem arises that how to havebest machineutilization, i.e. minimum machine idle time, and
tosatisfythecustomers, i.e.to deliver the goods at the righttime. Such problems can be solved
on the basis of cost ratios.
ROUTING, sCHEDULING, DESPATCHING AND 983
FOLLOW-UP
n e shortest possible route is through product 4th having shortost time = 40+28 = 68 hours.
sCHEDULING
Scheduling determines the programme for the operations. In scheduling, order of sequence
of each operation and their starting and finishing time is decided so that the required materials,
machines etc. may be kopt roady as per schedule. Thus, scheduling may be defined as, "the
fixation of time and date for ench operation", as well as it determines the sequence o
operations to be followed. This programme is prepared by the planning department and
assigns timing for various operations for processes. Routing and scheduling can be easily
understood by the example of railways.
A railway map shows the routes for passengers, which the trains follow and the stations on
that route. This is what is known as Routing ? Similarly, railway time table gives the exact
timings at which all the trains start and the time theytaketo reach at various stations and how
long they halt there. Itis known as'Scheduling
Scheduling is the last step in production planning. At this stage, detailed plans are prepared,
which indicate the time schedule for each machine, at which different products will be processed.
In other words, schedulingis the time table for the production department. Production sêhedule
shouldbe prepared insuch a way that it optimises the use of all the available resourd
Scheduling can also be defined as, "illing of specific jobs into a time table so that orders can
be executed in accordance with the commitments, and that each component may arrive and
enter the assembly in the right order and at the required time."
Criteria of Scheduling
For effective scheduling following criteria are considered. Since it is neither possible nor
economical to fulfill all the criterias, therefore an optimisation should be achieved :
- Minimum production costs.
- Minimum storage costs.
- Maximum utilisation of machines or minimum idle time.
- Minimum cash out flow. When a particular item of product requires a heavy cash
investment, it is desirable to produce this item as late as possible.
984 PRODUCTION MANAGEMENT SYSTEMS
Scheduling Situations
Scheduling is required to be done for different types ofwork, therefore, there may be diferent
techniques for scheduling of different types of works. Such works (or situations) may be of
following types:
a) Where quantity, time and production rate and resources are not fixed, scheduling can
be done by adjusting all ofthem, so that most economic balance is struck between various
parameters. This is a case of mass production.
(6) Where quantity, delivery time and production rates are all fixed (either by sales
department or by customer), limited resources are required to be used effectively and
economically. This is suitable in batch production.
(c) Where, only one project is being undertaken, scheduling is done through network
technique. Resource allocation and resource levelling is done to optimise the available
resources.
d) Where optimisation is required to be done for quantities of various products produced
and resources used, a linear programming technique is used to find a product-mix.
SCHEDULING TECHNIQUES
Various techniques are used for scheduling purposes. Some common scheduling techniques
are
loss of 16%
on
with less
menlabour cost
work load are idle for 10 seconds i.e., 16% of the time, which means
on these
a
men.
Therefore, the desired rate of production is converted to a time per work station, which is
known as the balancing time or balancing factor or cycle time or station time. This balancing
factor is the reciprocal ofthe rate of production. Generally the perfect balance is hardly achievea,
there is some extra time in at least one operation. In order to balance, generally, the operator
with idle time is assigned additional work not necessary to his operation, it may be handling
label etc. Where it is difficult
material to the line, inspection of his work, applying lubrication,
to divide machine operation, the banks are introduced in line.
Techniques. Scheduling
through network terms of float
5. Network certain amount of flexibility in
in a project. A
time to each activity and are critical and have to
be
start and finish while s o m e have no float,
certain activities,
is available in has to be completed in
time.
schedule if the project
completed as per
PRODUCTION MANAGEMENT SYSTEMS
986
Availability of manpower
- Feasibility of economic production/batch size.
Uses of Scheduling
Scheduling informations are useful for different departments for their working. Some of the
examples are given below:
(i) It helps in planning the manufacturing, purchase and sale, which is also helpful for
planning by ancillary and other user industries.
(i) Ithelps the produetion department whether production is as per schedule, and ifthere
is any need for cope up the backlog.
(i) It helps in planning the personnel, extra shifts, overtime, machine repair programme
etc.
(iv) By adhering to schedules, satisfactory relations can be maintained with customers
and vendors.
Informations required for Scheduling:
For the purpose ofscheduling,
following informations are required
(i) Sequence of operations for the manufacture.
(i) Time required for each operation.
Ciii) Machine capacity and its availability per day.
(iv) Availability of material and components.
Aims of Scheduling
() Minimum production cost.
(i) Maximum customer satisfaction.
(iii) Maximum operator Morale, as he knows his programme in Timne.
v) Maximum plant utilisation.
(v) Maximum utilisation of manpower.
(vi) Minimum storage costs.