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7 Routing, Scheduling, Dispatching-1

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37

Routing, Scheduling, Despatching and Follow-Up

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.

The Manufacturing Order


Issuing of the manufacturing order production order is to give the authorization to
or
order are:
commence production. The objectives of issuing the manufacturing or production
(a) to convey information to customer and promise time to delivery.
as a tool for cost etc., for the order as a whole or for the individual
(6) tosupply estimating
components, and for any operation to be performed.
c) to showa starting point for the control system.
Such orders
Further, with the production order some other orders are also to be issued.
are

known as secondary or subsidiary orders.

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*******

Order for...********************* ********************ssdstppeeu nsusereasesapl


+eursess***srt***0"se**"e*v"
Pattern.. srmegs ***************
Material... * * * 0 0 0 * * 0 0 t 0 i 4 1 0 4 G i 4 u i e d t u i i s d i i d i t i i t u i 1 0 0

Finish... *********ess***********eesesaassasm n enendsssgsntvunsoosssssssggggeed


Customer Order no....
******************************seessneesinndseeneen nunsnustseissosstud0eds4do6sesd
With date...
*********"***************ssssnnnn*ssatassnsessen s smmssnussossdsslesie
***************************** *******00004 *****"****°********010000t0010009tiitdio4010099'111051r020000""*"*

Machining. ****** ...6689.. rossdsseederneereuddunneutnated001606606"e*"

Machine No..**************.************** Man..... 141sdi0d4400400001100tedtieistd95ss66/

Started. Finished..
***********************

Pcs received. *svsormes*********DP)


SpO1led...uusus doidsdgsd4000000u itiiip dd0000055'17707

Pes. good.. **************'***************"***********0******issd!edssstes satdesesodeo*000007""""

Inspection report..
**************************************************seeo41eessee seeestosssd*****0600s**e*00d0t"""**

Casting 6699
MachineNo.. *****************************. M a n . . . 04tdqu4sduudunuuuvunn44uu
... tiut1tvd

Started. ******************************
Finished.. "*"***********°*"****"""*****'***°°**

Pes received. *********************


Spoiled.. **r*eddernssstuseotso*eore*************"***"*d"**"""

Pes.good.. ****************essrorseen***********osesaosoeosssneru**sdsessseoteoesses**tdss***********"*"****

Inspection report....

tore 6699
* * * * * * * * * ' * * * " * * * * * * e "

***.********o*************************e*************** ************"*"*****"*

Recd.by.. ****e******************************* Time.. ********* e***************°*******°***************"|

Flg. 37.1. Production and Job order with fixed routing


customer's namne,
Another type of manufacturing order is shown in Fig. 37.2. This includes
for cost data.
specification of parts, date of delivery etc. In this typical form, there is space
a

ROUTING

part product each of the will follow


Routing may be defined as the selection of path which
while being transformed from raw materialsto finished products. Path
of the product will also
give sequence of operation to be adopted while being manufactured. to be followed from
In other words, routingmeans determination of most advantageous path
raw material gets its final shape.
department to department and machine to machine till
Thus routing is a technique which involvesthe analysis of:
(a) Type of work to be done on product or its parts.

(6) Operations required todo the work.


(c) Sequence of operations.
(d) Where the work will be done.
and the machine for doing the work.
(e) A proper classification about the personnel required
For effective production control of a well managed industry with 8tandard conditions, the
routing plays an important role, so as to get best results obtained from available plant capacity.
Thus routing provides the basis for scheduling, dispatching and follow-up.
PRODUCTION MANAGEMENT SYSTEMS
976
Industrial Machine Corporation
Produetion Order
Lathe Machine
Job Order No..
Customer Stock Order No..
|Address
Entered
Model 87 mty Machine no. Range Pka Date
Max. 7%x 7%... Min. 7/8 x 7/8 By

Inventory Quantity Item Specification


Ordered Shipped Drive Molor| Make IP /4 Volts 440

CYL 60 PH3 RP 1760 AC-DC


Mark Local No. 870 Bore 3/4 Key Wny
V.Pully
V.IBelt Make Dunlop No. B-61

Make H.P. 1/3 Volu 230 V


Coolent
motor

Cyl 60 PH1 RPM 1260 AC-DC


Motor Make S.No.
L18 M122 Tapor Turning Attachment
L-20m 222 Micrometer stand
L-22m110 Tailatroxke
L40 m 420 Tool Accesaory Box

86L-20 m Adustable work support


66 m- 2C- Foundation Bolts

Shipping
Promised Date

One Week Office Shipped


Flg. 37.2. Manufacturlng:Order.

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.

(6) Assembly Industry. Such industries require various components to be assenmbled at a


particular time. Therefore,it is necessary that no component should fail to reach at the proper
time and proper place in required quantity otherwise whole of the production line will be held
up, resulting wastage oftime and production delay.
ROUTING, sCHEDULING, DESPATCHING AND FOLLOW-UP 977

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

work so that planning can be made after receiving manufacturing orders.

Factors Responsible for Proper Routing


a) Process analysis should be done.
done.
(6) In of assembly, product analysis of different components should be
case
(c) Analysis of material required should be done.
d) Analysis for the quantity required for eachcomponent.
e) Order of preference of various products must be found out.
different stages o
) Findingout the of operation and operations to be performed at
place
operation.
g)Knowledge ofthe machines and operations to be used.
consumed in different stages with regard
(h) Knowledge about the quantity of material to be for material
to the time consumed in different operations and space requirement
movement.

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

Flg. 37.3. (a) Route card.

Route Card the material


with the job throughout the operations. This indicates
This card accompanies to another. The particulars
and their progress from
one operation
used during manufacturing the details of scrap and good-work
produced
37.3. In addition to this,
the card are shown Fig.
in
of
are also recorded.
978 PRODUCTION MANAGEMENT SYSTEMS
Scrap Note No. 3202

Date. Part. Part No. . . . Jobor M/cNo......


s**************
.. Account No..
********************

Deptt. . . . Check No. . .


NAMe Operation at which scraped
sneeeasa
.

No. Description
Cause of scrap No. Scraped Cost

MAT

LAB

Reissue of Material Inspected by 0. head


Authorised Foreman

Inspection Total

Material Reqd. Amount Issued Date

Fig. 37.3. (6)


Work Sheet
Tt contains : (i) Specifications to.be followed.while manufacturing.
) Instructions regarding routing of every part with identification, number of machines and
work place of operation.
Work areas 1, 2 Type of Machine Card Time 15 Starting Time Ref. No.
Card Machine XYZ No. 4
No. 26 SCOOTER
Work Unit Code
Men Work System| Sub Sys- Inspection require-|
Reqd. area tem or ment Electric Power
Part
OFF ON
2. 1. |1. Lubricate as per requirement indicated on back side of card using table oflubricant for
reference.
(a) Shock-absorbers-onlywhen not working satisfactory,
6) ) Drain oil from gearbox through draining hole. (i) Refil oil in the Gear Box.
c) Grease the front hub.
(d) Lubricate thecontrolcable.
Table of Lubrication
Part lubricated Type
1 a Shell-donex A-1
2 b Shell X-10030
3. C Grease hub
4. d Shell Retinax -A
Fig. 37.4. One slde of work sheet.
979
ROUTING, SCHEDULING, DESPATCHING AND FOLLOW-UP

While preparing for


nis for manufacturing as well as for maintenance.
sheet is made
be
the actual part to
alntenance work, the reverse of the sheet illustrates diagramatically
repaired. A such sheet of this type is shown in Figs. 37.4 and 37.5.

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

Flg. 37.5. Reverse slde of worksheet.


the same as that
The number of pieces specified on the route sheet may not necessarily be
allowance for spoilage is added. Many times these
of manufacturing order. In most cases, an
on future demands
additional pieces create a reserve stock and can be delivered immediately
or further repairs etc.
In Fig. 37.6, a route sheet generally adopted for metal work is shown.

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.. *** ************************.

Description of Part. ******** ******°*****


. P a r t s y m b o l . .sao*****************"************"*****

Number of pieces on order or on Lot.. Spoilage allowance.. * * *********************** ******

Extrastocksllowance.. .Total to make...


*********************************** **** ************

Materislsymbol.. Description.... Quantity allotted....


soom***** *******************

Purchssedorder no... ***Due.. oeesesusssStoresissueorderno..... * * * * * * * *


... Move...
* *
***********"*****

Order Tool Operation Nachine Time allowance Due date Move Piece
order Good
No. Making | Issue Per Lot Setting|TotalStart Finish
order piece

Fig. 37.6. Route-Sheet.

Move Order
Customer Quantity Description Part No. Job No.

Schedule Date issue Material Released Special Instruction Date Due

Progress Op.No.| Deptt M/C or Operation Jig, Tool, Labour Time Allowed
Group No. Gauge Grade Setup Hrs.
Per 100

Stores Operator Name Quantity Passed And Rectification Inspectorr


Control Send Forward No. Cause

Check No. Scrap No. To Date


No. Cause Pay For

Fig. 37.7. Move order.

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."

Types of Schedules. Schedules are of the following types


(A) Master Schedule. It shows the dates on which important production items are to be
leted. It is weekly or monthly break-up ofthe production requirements for each product.
Whenever any order is received, it is accommodated first in the Master Schedule considering
the availability of the machines and labour.
Thus, it helps Production Manager for advance planning and to have check over the
production rate and efficiency.
(B) Shop or Manufacturing Schedule. After preparing master schedule, shop schedules
are prepared. It assigns a definite period of time to a particular shop for manufacturing products
in required quantity. It shows how much products are to be prepared and on what day or week
etc.

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

Maximum labour utilisation.


-

Maximum utilisation of plant capacity.


-

Maximum customer satisfaction.

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

(1) Flow Process chart. (2) Gantt chart.


(3) Line of Balance. (4) Linear programming.
(5) Network Techniques.

1. Flow process chert. This has been


explained under Follow-up' in this chapter.
2. Gantt chart. When number of activities become too
large with the increase in size of the
job, it becomes impossible to plan in that minute details, therefore it becomes necessary for the
management to plan in greater detail. In such cases, management need a timely and correct
information about the status of all the significant activities, and effect of these on the total
project. Management may also require rescheduling and expediting the activities to minimise
the adverse effect of delays on the entire project cost and duration.
Gantt charts (also known as Bar charts) are used in such
eases, for simultaneous presentation
of these informations in a logical manner. Gantt charts are the
simple charts which display the
schedule as well as make a comparison between actual performance and the
A Milestone chart is similar to Bar chart
original schedule.
except that it displays the Milestone rather than
bars.
Gantt charts are explained in detail in a separate
chapter titled as "Network Techniques".
3. Line of Balance. In a continuous
manufacturing process, a product moves down a line
past successive work stations, where one operation after another operation is done while product
takes form. This is a line production. The work is done either manually or through a machine
ROUTING, sCHEDULING, DESPATCHING AND FOLLOW-UP 985

at the workstation and it may move manually or through a


to
handling device from one workstation
another. In this system of production, if a line stops, all the men and machine becomes 1ae
and this results in heavy loss. Thus it becomes most essential to balance the workload of the
men and
machine along the line. If these are not balanced, i.e., if the work is not nearly
the
same tor all the men in line, as that of the busiest man, then there is wastage of time on the
part ot each man. For example, one man has a job of one minute and others 50 seconds then the

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.

Balancing Procedure. Balancing is done in following stages


The task should be splitted into
() Making a of every minor job required for assembly.
list
is noted.
elements of 5 to 10 seconds, and time required for each such element
the number of units
(ii) Determine the workload ofthe line. This can be computed by knowing hour
unit. This will give total man-hours per
required per hour and the elemental time for each then
hour and each unit takes 1 man hour,
for the line. For example, if we require 20 units per
are perfectly
we have to provide 20 man hours per
hour on the line. Therefore, if all the jobs
of about 75% to 80% is achieved, and
balanced, 20 m e n shall be required. Generally balancing
therefore, we shall need 25 to 27 men. then
Number of stations in each line are
(iii) Decide number of work stations required.
decided. from one
the work, elements which can be transferred
(iu) Start balancing. While balancing
to be performed in
also determined, as some elements are necessary
station to another are

others can be transferred.


sequence, while a problem of
A smoothly working industry may suddenly face
4. Linear Programming. due to market
r e s o u r c e s available with
the firm. This situation may arise
reallocation oflimited a new capacity, major
breakdown

situation, change of priorities,


change in demand, installing be men,
need reallocation or scheduling may
that
equipment. The resources
in one or m o r e
or time. Since the management
objective is to maximise gain
machines, money, space circumstances is
material, of gain under the changed
therefore maximising
out of available resources,
linear programming. A product-mix
problems
Such problems are solved through
also desired. Linear programming is a
also be solved through linear programming.
to maximise profit
can
limited r e s c u r c e s .
best solution to a problem involving
mathematical model to get in section on Operation
in detail in a separate chapter
Linear programming
is given
estimated
Research consists of assigning an

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

associated with each activity


Cost, availability of work crews, materials and other
resources

must be considered with reference to start and finish times.


These informations when analysed
used for manpower
establish limiting boundary times for each activity. The time charts are

levelling, resource allocation, and for cost analysis.


Thus network technique is not only used for planning, scheduling
and controlling but also
also helps in rescheduling,
helpsin optimization in the use of available resources. This technique
as per revised resource availability from time to time.
This Network technique has been explained in separate chapter in this book.

Factors affecting Scheduling


These factors are given hereunder
- Customer's demand
- Customer's delivery dates.
Stock already lying with dealers
- Stock already lying with the firm.
-- How much time available and how much time is required for manufacture.
--

Availability of machinery and otherfacilities


- Availability of raw materials
-

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.

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