Production planning and industrial scheduling: examples, case studies and applications
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Format: | Buch |
Sprache: | English |
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CRC Press
2008
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Ausgabe: | 2. ed. |
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Online-Zugang: | Inhaltsverzeichnis |
Beschreibung: | XVI, 534 S. graph. Darst. |
ISBN: | 9781420044201 1420044206 |
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250 | |a 2. ed. | ||
264 | 1 | |a Boca Raton, Fla. [u.a.] |b CRC Press |c 2008 | |
300 | |a XVI, 534 S. |b graph. Darst. | ||
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adam_text | Table of Contents
Preface............................................................................. xv
Acknowledgments................................................................. xvii
Author.............................................................................. xix
Chapter 1 Introduction to Production Planning and Scheduling.............. 1
1.1 Production Planning....................................................... 1
1.1.1 Pictorial View of a Production Planning and Control System.. 2
1.1.2 Production Systems............................................... 3
1.1.3 Characteristics of Production Systems.......................... 4
1.1.4 Response Time.................................................... 4
1.1.5 Supply Chain..................................................... 5
1.1.6 Inventory.......................................................... 6
1.2 Scheduling.................................................................. 6
1.2.1 Scheduling Examples............................................. 7
1.2.2 Scheduling on Shop Floor........................................ 8
1.3 What Is Not Included...................................................... 13
1.4 Summary................................................................... 13
1.5 Problems.................................................................... 14
References and Suggested Readings ............................................. 14
Chapter 2 Plant Locations and Capacity Determination....................... 15
2.1 Existing Production Facilities............................................. 15
2.1.1 Distribution Network with Existing Facilities .................. 15
2.1.2 Response Time Consideration................................... 18
2.1.3 Limitation on Number of Facilities.............................. 18
2.2 New Plant Locations....................................................... 21
2.2.1 New Facilities with Capacity Determination.................... 21
2.2.2 Variables in Linear Programming Initial Formulation and
Alternate Formulation............................................ 22
2.2.3 Spreadsheet Approach Using Solver Tool....................... 25
2.2.4 Single Sourcing................................................... 28
2.2.5 Time Constraints.................................................. 30
2.3 Uncertainty in Demand.................................................... 32
2.3.1 Large Plant Evaluation........................................... 35
2.3.2 Small Plant Evaluation........................................... 36
2.3.3 Revenue Evaluation.............................................. 37
vi Contents
2.3.4 Expansion in Future.............................................. 38
2.4 Summary................................................................... 39
2.5 Exercise .................................................................... 39
References and Suggested Readings ............................................. 42
Chapter 3 Forecasting and Aggregate Planning................................ 45
3.1 Forecasting................................................................. 45
3.1.1 Qualitative Forecasting........................................... 45
3.1.2 Quantitative Forecasting......................................... 46
3.1.3 Static Forecasting................................................. 47
3.1.4 Seasonal Correction.............................................. 48
3.1.5 Adaptive Forecasting............................................. 50
3.1.6 Exponential Smoothing .......................................... 50
3.1.7 Holt s and Winter s Models...................................... 52
3.1.8 Analysis of Forecasting Errors................................... 53
3.2 Aggregate Planning........................................................ 57
3.2.1 Strategies.......................................................... 58
3.2.2 Problem Description.............................................. 60
3.2.3 Other Factors ..................................................... 66
3.2.3.1 Human Factors........................................ 66
3.2.3.2 Changing Demand.................................... 66
3.2.3.3 Spreadsheet Approach................................ 67
3.3 Summary................................................................... 68
3.4 Exercise .................................................................... 68
3.4.1 Discussion and Review Questions............................... 68
References and Suggested Readings ............................................. 74
Chapter 4 Master Production Scheduling and Material Requirement
Planning.............................................................. 75
4.1 Master Production Schedule............................................... 75
4.1.1 Fixed Order Quantity (FOQ)..................................... 77
4.1.2 Periodic Order Quantity (POQ).................................. 79
4.1.3 Lot for Lot (L4L)................................................. 79
4.1.4 Least Total Cost................................................... 79
4.1.5 Incremental Cost Analysis (ICA)................................ 80
4.1.6 Available-to-Promise Chart (ATP)............................... 82
4.1.7 Concluding Remarks on MPS ................................... 82
4.2 Material Requirement Planning and Other Techniques.................. 83
4.2.1 Least Unit Cost Purchase Policy................................. 87
4.2.2 General Considerations........................................... 91
4.2.2.1 Planning Period........................................ 91
4.2.2.2 Product Structure...................................... 92
4.2.2.3 Manufacturing Resource Planning................... 92
4.2.2.4 Enterprise Resource Planning........................ 92
Contents vii
4.2.3 Distribution Requirement Planning.............................. 93
4.2.3.1 DRPExample ......................................... 93
4.3 Summary................................................................... 94
4.4 Exercise .................................................................... 95
References and Suggested Readings............................................. 97
Chapters Inventory and Capacity Planning................................... 99
5.1 Inventory Planning......................................................... 99
5.1.1 Economic Order Quantity........................................ 99
5.2 Safety Stock Determination............................................... 102
5.2.1 Fixed Quantity-Varying Cycle System.......................... 104
5.2.2 Periodic Review System......................................... 104
5.2.3 Safety Stock with Substitute Products........................... 105
5.3 Quantity Discounts......................................................... 106
5.3.1 All Unit Quantity Discount....................................... 107
5.3.2 Marginal Unit Quantity Discount................................ 109
5.3.3 One-Time Unit Price Discount................................... Ill
5.3.4 Multiple Products Order Jointly................................. 113
5.4 Single Period Planning.................................................... 117
5.4.1 Discrete Order Quantity.......................................... 117
5.4.2 Single Period Ordering with Continuous Demand.............. 119
5.4.3 Buyback Policy................................................... 121
5.4.4 Effect of Reduction in a ......................................... 121
5.5 Consumption during Production.......................................... 124
5.6 JIT Inventory System...................................................... 124
5.6.1 Distribution Strategy............................................. 125
5.6.1.1 Day 1 Evaluation...................................... 128
5.6.1.2 Day 2 Evaluation...................................... 129
5.6.1.3 Day 3 Evaluation...................................... 130
5.6.1.4 Day 4 Evaluation...................................... 130
5.6.1.5 Day 5 Evaluation...................................... 132
5.6.1.6 Day 6 Evaluation...................................... 132
5.6.1.7 Day 7 Evaluation...................................... 132
5.6.2 Backward Check.................................................. 134
5.7 Recourse Center Capacity Planning....................................... 135
5.7.1 Rough Cut Planning.............................................. 135
5.7.2 Capacity Bills..................................................... 136
5.7.3 Number of Machines Needed.................................... 138
5.8 Theory of Constraints...................................................... 139
5.9 Summary................................................................... 140
5.10 Exercise .................................................................... 140
References and Suggested Readings ............................................. 146
Chapter 6 Single Machine Scheduling......................................... 147
6.1 Tardiness Problem......................................................... 148
vi!j Contents
6.2 Survey of Exact Methods for Single-Machine Scheduling Problem .... 148
6.2.1 Exhaustive Enumeration......................................... 148
6.2.2 Branch-and-Bound Algorithm................................... 149
6.2.2.1 Illustrative Example 1................................. 149
6.3 Commonly Used Heuristic Rules......................................... 150
6.3.1 Earliest Due Date Rule........................................... 152
6.3.2 Cost Over Time (COVERT) Rule................................ 152
6.3.3 Shortest Processing Time (SPT) Rule........................... 152
6.3.4 Largest Penalty per Unit Length (LPUL) Rule.................. 152
6.3.5 Shortest Processing Time and LPUL Rule...................... 153
6.3.6 Shortest Weighted Processing Time (SWPT) Rule............. 153
6.3.7 Largest Weight (WT) and LPUL Rule........................... 153
6.3.8 Critical Ratio (CR) Rule......................................... 153
6.3.8.1 Illustrative Example 1................................. 153
6.4 Description of an Efficient Heuristic...................................... 156
6.4.1 Backward Phase.................................................. 156
6.4.2 Forward Phase.................................................... 158
6.4.3 An Illustrative Example Using the Heuristic Algorithm........ 158
6.4.4 Validity of the Heuristic and Conclusions....................... 160
6.5 Single Machine Problem with Early and Late Penalties................. 162
6.5.1 Backward Phase.................................................. 163
6.5.1.1 Illustrative Example 2................................. 163
6.5.1.2 Modified Background Phase When Early Penalties
and Present............................................ 164
6.5.2 Validity of the Heuristic.......................................... 166
6.6 Some Weil-Known Theorems............................................. 167
6.7 Summary................................................................... 168
6.8 Problems.................................................................... 168
References and Suggested Readings............................................. 170
Chapter 7 Other Objectives in Single-Machine Scheduling................... 171
7.1 Common Due Date ........................................................ 171
7.1.1 Illustrative Example 7.1.......................................... 172
7.2 Common Due Date Specified by a Customer............................. 174
7.3 Early and Late Due Dates................................................. 174
7.3.1 Illustrative Example 7.2.......................................... 175
7.4 Quadratic or Nonlinear Penalty Function................................. 177
7.4.1 Illustrative Example 7.3.......................................... 178
7.5 Minimization of the Average Delay....................................... 178
7.6 Minimization of the Maximum Delay.................................... 179
7.7 Minimize the Number of Jobs That Are Delayed........................ 179
7.7.1 Illustrative Example 7.4.......................................... 180
7.8 Maximize the Number of Jobs Processed When the Available Time Is
Less than Total Processing Time.......................................... 181
7.8.1 Illustrative Example 7.5.......................................... 181
Contents ix
7.9 Sequence-Dependent Jobs................................................. 182
7.9.1 Illustrative Example 7.6.......................................... 182
7.9.2 Forward Phase.................................................... 184
7.10 Sequence-Dependent Jobs with Minimum/Maximum Separations...... 184
7.10.1 Illustrative Example 7.7.......................................... 185
7.11 Minimize Variation of Flow Time......................................... 185
7.11.1 Illustrative Example 7.8.......................................... 186
7.12 Sequence-Dependent Setup Times........................................ 186
7.12.1 Illustrative Example 7.10......................................... 186
7.13 DualCriteria ............................................................... 187
7.13.1 Illustrative Example 7.11......................................... 187
7.14 Delay of Early Completing Jobs.......................................... 188
7.14.1 Phase I. Slack Introduction....................................... 189
7.14.2 Phase U. Optimal Sequence Search.............................. 191
7.14.3 Illustrative Example 7.12......................................... 191
7.14.4 Phase II: Optimal Sequence Search.............................. 195
7.15 Jobs Arriving at Different Times.......................................... 198
7.16 Summary................................................................... 206
7.17 Problems.................................................................... 206
References and Suggested Readings ............................................. 210
Chapter 8 Flowshop Problems.................................................. 213
8.1 Two-Machine Problem..................................................... 213
8.1.1 Illustrative Example 8.1.......................................... 214
8.2 Three-Machine Problem................................................... 216
8.2.1 Illustrative Example 8.2.......................................... 216
8.3 Setup/Processing and Removal Times Separated: Another Extension
of Johnson s Algorithm.................................................... 218
8.4 Two-Machine Flowshop with Travel Time between Machines.......... 219
8.4.1 Relationships for Makespan Calculations....................... 220
8.4.2 Illustrative Example 8.3.......................................... 221
8.4.3 Makespan Calculations........................................... 222
8.5 n Jobs/m-Machines Problem .............................................. 222
8.5.1 Minimize Machine Idle Time Method........................... 223
8.5.1.1 Procedure.............................................. 224
8.5.1.2 Illustrative Example................................... 224
8.5.2 Palmer Procedure................................................. 227
8.5.3 Nawaz Heuristic.................................................. 227
8.5.4 Campbell, Dudek, and Smith (CDS) Procedure................. 229
8.6 n-Job//n-Machine Problem: Jobs Arriving at Different Times........... 229
8.6.1 Example........................................................... 230
8.6.2 Result.............................................................. 233
8.7 Summary................................................................... 233
x Contents
8.8 Problems.................................................................... 234
References and Suggested Readings ............................................. 236
Chapter 9 Parallel Processing and Batch Sequencing......................... 237
9.1 Parallel Processing......................................................... 237
9.1.1 Jobs with Equal Weight and No Due Dates..................... 237
9.1.1.1 Procedure.............................................. 237
9.1.1.2 Illustrative Example................................... 238
9.1.2 Jobs with Priorities Ranked by Weights......................... 240
9.1.3 Jobs with Due Dates.............................................. 241
9.1.3.1 Illustrative Example................................... 242
9.2 Single Operation Job-Related Earliness/Tardiness Penalties with
Machine Activation Cost.................................................. 248
9.2.1 Example........................................................... 250
9.2.2 Single Machine................................................... 250
9.2.3 TwoMachines.................................................... 252
9.3 Nonidentical Parallel Processors.......................................... 254
9.3.1 Procedure......................................................... 254
9.4 Parallel Machines in a Flowshop.......................................... 259
9.5 Batch Scheduling for a Limited-Capacity, Fixed-Period Process
Problem..................................................................... 262
9.5.1 Integer Programming Model..................................... 263
9.5.2 Heuristic Approach............................................... 265
9.5.3 Illustrative Example.............................................. 266
9.6 Batch Scheduling for Limited-Capacity Processors in Sequence with
Varying Job Requirements................................................. 267
9.6.1 Illustrative Example.............................................. 267
9.6.2 Improvement Routine............................................ 269
9.7 Batch Sequencing.......................................................... 271
9.7.1 Procedure and Analysis .......................................... 272
9.7.2 Application........................................................ 273
9.8 Summary................................................................... 275
9.9 Problems.................................................................... 275
References and Suggested Readings............................................. 278
Chapter 10 Network-Based Scheduling........................................ 281
10.1 Critical Path Method....................................................... 281
10.2 Scheduling a Network of Jobs on a Specified Number of Parallel
Processors.................................................................. 284
10.2.1 Solution Procedure............................................... 285
10.2.1.1 Illustrated Example.................................... 287
10.3 Scheduling n Jobs on m Parallel Machines When Each Job Can Be
Scheduled on p Machines, p Being a Subset of m, That Is, p m.... 293
10.3.1 Solution Procedure............................................... 293
10.3.2 Illustrated Example............................................... 295
Contents xi
10.4 Assembly Line Balancing ................................................. 296
10.4.1 Largest Candidate Rule........................................... 296
10.4.2 Ranked Positional Weight Method .............................. 299
10.4.3 Cycle Time Less than Task Time................................ 301
10.5 Mixed-Model Assembly Line Balancing................................. 302
10.5.1 Procedure and an Illustrative Example.......................... 302
10.5.2 Effects of Other Ways of Balancing (Grouping)................ 307
10.5.2.1 An Assembly Line for Each Model................... 307
10.5.2.2 A Single Assembly Line for All Models ............. 307
10.5.3 Advantages of the Suggested Approach......................... 308
10.5.3.1 Problem Areas......................................... 308
10.6 Mixed-Model Assembly—Method to Minimize Stations................ 308
10.6.1 Procedure......................................................... 309
10.6.2 Numerical Illustration............................................ 310
10.6.2.1 Solution................................................ 310
10.7 Network Scheduling with Resource Constraint.......................... 313
10.7.1 Illustrative Example.............................................. 314
10.7.2 Multiple Resources............................................... 317
10.8 Summary................................................................... 319
10.9 Problems.................................................................... 319
References and Suggested Readings ............................................. 324
Chapter 11 Job Shop Scheduling............................................... 325
11.1 Job Shop.................................................................... 325
11.2 Job Shop Scheduling to Minimize Makespan (SPT)..................... 327
11.2.1 Shortest Processing Rule......................................... 328
11.3 Network Approach to Job Shop Scheduling.............................. 329
11.3.1 The Modified Shifting Bottleneck Heuristic .................... 331
11.3.1.1 Illustrative Example................................... 333
11.3.2 Two-Stage Job Shop Scheduling Heuristic...................... 340
11.3.2.1 Illustrative Example................................... 342
11.4 Job Shop Scheduling to Minimize Tardiness............................. 346
11.4.1 The CEXSPT Rule ............................................... 347
11.4.2 Minimizing Penalty Using Modified Shifting Bottleneck
Procedure......................................................... 349
11.4.3 Optimizing Total Penalty and Makespan Using MODSB
(Dual Criteria).................................................... 359
11.5 Summary................................................................... 361
11.6 Problems.................................................................... 361
References and Suggested Readings ............................................. 365
Chapter 12 Open-Shop Scheduling............................................. 367
12.1 Minimize Makespan: Two-Machine Problem............................ 367
12.2 Minimize Makespan: Multiple-Machine Problem ....................... 368
12.2.1 Illustrative Example.............................................. 371
xjj Contents
12.3 Minimization of Total Tardiness-Open Shop (MTT-OP)................ 378
12.3.1 Solution Procedure............................................... 378
12.3.2 Initial Assignment................................................ 378
12.3.3 Special Cases..................................................... 380
12.3.4 Subsequent Assignments......................................... 380
12.3.5 Illustrative Example.............................................. 381
12.3.6 Special Cases..................................................... 385
12.3.6.1 Special Case 1 (Example)............................. 385
12.3.6.2 Special Case 2 (Example)............................. 387
12.4 Minimization of Total Weighted Tardiness Penalties-Open Shop
(MTWT-OP)................................................................ 388
12.4.1 Initial Assignment................................................ 388
12.4.2 Subsequent Assignments......................................... 389
12.4.3 Illustration Example.............................................. 390
12.5 Summary................................................................... 394
12.6 Problems.................................................................... 394
References and Suggested Readings ............................................. 396
Chapter 13 Manpower Scheduling ............................................. 397
13.1 Consecutive Days-Off Scheduling........................................ 398
13.1.1 Illustrative Example.............................................. 399
13.2 Rotating Days (Weekends) Off............................................ 401
13.2.1 Illustrative Example.............................................. 403
13.3 Monroe s Algorithm....................................................... 406
13.3.1 Illustrative Example II............................................ 408
13.3.2 Illustrative Example ffl........................................... 409
13.3.3 Realignment of a Worker......................................... 409
13.3.4 Increasing the Workforce......................................... 410
13.3.5 Assigning Nonconsecutive Days Off............................ 411
13.4 Tour Scheduling............................................................ 412
13.4.1 Procedure......................................................... 412
13.4.2 Illustrative Example.............................................. 413
13.4.3 Other Variations.................................................. 416
13.5 Three Consecutive Days Off.............................................. 416
13.5.1 Assign Nonconsecutive Days Off................................ 421
13.5.2 Special Case and Further Discussion............................ 422
13.6 Summary................................................................... 423
13.7 Problems.................................................................... 424
References and Suggested Readings............................................. 427
Chapter 14 Industrial Sequencing I: Scheduling on NC Machines........... 429
14.1 Tabular Approach in Group Forming..................................... 429
14.2 Job Sequencing to Minimize Tool Changeovers in Flexible
Manufacturing Systems.................................................... 435
14.2.1 Assumptions and Problem Statement............................ 435
Contents xiii
14.2.2 Solution Procedure............................................... 437
14.2.3 Illustrative Example.............................................. 439
14.3 Heuristic to Minimize Throughput Time on an NC Machine............ 442
14.3.1 Problem Definition and Assumptions............................ 444
14.3.2 Heuristic Procedure and Its Application......................... 445
14.3.3 Alternative 1: Start with a Job Having the Largest Demand__ 446
14.3.3.1 Discussion of the Procedure.......................... 446
14.3.3.2 Applications of Steps 3 through 5 to the Illustrative
Example ............................................... 450
14.3.4 Alternative 2: Minimize the External Tool Changes............ 452
14.3.5 Select the Best Alternative....................................... 452
14.3.5.1 Further Comments .................................... 452
14.4 Summary................................................................... 453
14.5 Problems.................................................................... 453
References and Suggested Readings ............................................. 456
Chapter 15 Industrial Sequencing II: Electronic Assemblies: Component
Tape Assemblies on a Sequencer.................................... 457
15.1 A Heuristic Procedure for Tape Assembling on a Sequencer............ 458
15.1.1 Problem Statement................................................ 459
15.1.2 Solution Procedure............................................... 459
15.1.3 Phase II: Scheduling.............................................. 462
15.1.4 Solution to the Example Problem................................ 466
15.2 Summary................................................................... 471
15.3 Problems.................................................................... 471
References and Suggested Readings ............................................. 473
Chapter 16 Industrial Sequencing III: Sequencing Feeder for Component
Tape Assembly....................................................... 475
16.1 Problem Description....................................................... 476
16.2 Heuristic Procedure........................................................ 478
16.2.1 Developing Basic Component Assignments to the Slots....... 478
16.2.2 Developing the Initial Assignment............................... 483
16.2.2.1 Calculation of Priorities for Locations............... 483
16.2.2.2 Location Assignments................................. 483
16.2.3 Smoothing the Assignment....................................... 487
16.2.4 Improving the Assignment....................................... 488
16.2.5 Check for Improvement.......................................... 492
16.3 Problems.................................................................... 494
References and Suggested Readings ............................................. 495
Chapter 17 Industrial Sequencing IV: Scheduling in Flexible Manufacturing 497
17.1 A CDS-Based, Two-Phase Algorithm for Group Scheduling with
Group-Dependent Setup Times............................................ 497
17.1.1 Introduction....................................................... 497
xiv Contents
17.1.2 Heuristic .......................................................... 497
17.1.2.1 Phase I: Preliminary Sequence....................... 497
17.1.2.2 Phase II: Makespan Reduction by Minimizing the
Machine Idle Time.................................... 498
17.1.3 Illustrative Example.............................................. 498
17.1.3.1 Phase I: Preliminary Sequence....................... 499
17.1.3.2 Phase II: Makespan Reduction by Minimizing the
Machine Idle Time.................................... 501
17.1.4 Results ............................................................ 503
17.2 Multiple Robot in Assembly Operations.................................. 505
17.2.1 Illustrative Example.............................................. 507
17.2.2 More than Two Robots........................................... 509
References and Suggested Readings ............................................. 510
Appendix: Computer Program Description...................................... 513
Index............................................................................... 527
|
adam_txt |
Table of Contents
Preface. xv
Acknowledgments. xvii
Author. xix
Chapter 1 Introduction to Production Planning and Scheduling. 1
1.1 Production Planning. 1
1.1.1 Pictorial View of a Production Planning and Control System. 2
1.1.2 Production Systems. 3
1.1.3 Characteristics of Production Systems. 4
1.1.4 Response Time. 4
1.1.5 Supply Chain. 5
1.1.6 Inventory. 6
1.2 Scheduling. 6
1.2.1 Scheduling Examples. 7
1.2.2 Scheduling on Shop Floor. 8
1.3 What Is Not Included. 13
1.4 Summary. 13
1.5 Problems. 14
References and Suggested Readings . 14
Chapter 2 Plant Locations and Capacity Determination. 15
2.1 Existing Production Facilities. 15
2.1.1 Distribution Network with Existing Facilities . 15
2.1.2 Response Time Consideration. 18
2.1.3 Limitation on Number of Facilities. 18
2.2 New Plant Locations. 21
2.2.1 New Facilities with Capacity Determination. 21
2.2.2 Variables in Linear Programming Initial Formulation and
Alternate Formulation. 22
2.2.3 Spreadsheet Approach Using Solver Tool. 25
2.2.4 Single Sourcing. 28
2.2.5 Time Constraints. 30
2.3 Uncertainty in Demand. 32
2.3.1 Large Plant Evaluation. 35
2.3.2 Small Plant Evaluation. 36
2.3.3 Revenue Evaluation. 37
vi Contents
2.3.4 Expansion in Future. 38
2.4 Summary. 39
2.5 Exercise . 39
References and Suggested Readings . 42
Chapter 3 Forecasting and Aggregate Planning. 45
3.1 Forecasting. 45
3.1.1 Qualitative Forecasting. 45
3.1.2 Quantitative Forecasting. 46
3.1.3 Static Forecasting. 47
3.1.4 Seasonal Correction. 48
3.1.5 Adaptive Forecasting. 50
3.1.6 Exponential Smoothing . 50
3.1.7 Holt's and Winter's Models. 52
3.1.8 Analysis of Forecasting Errors. 53
3.2 Aggregate Planning. 57
3.2.1 Strategies. 58
3.2.2 Problem Description. 60
3.2.3 Other Factors . 66
3.2.3.1 Human Factors. 66
3.2.3.2 Changing Demand. 66
3.2.3.3 Spreadsheet Approach. 67
3.3 Summary. 68
3.4 Exercise . 68
3.4.1 Discussion and Review Questions. 68
References and Suggested Readings . 74
Chapter 4 Master Production Scheduling and Material Requirement
Planning. 75
4.1 Master Production Schedule. 75
4.1.1 Fixed Order Quantity (FOQ). 77
4.1.2 Periodic Order Quantity (POQ). 79
4.1.3 Lot for Lot (L4L). 79
4.1.4 Least Total Cost. 79
4.1.5 Incremental Cost Analysis (ICA). 80
4.1.6 Available-to-Promise Chart (ATP). 82
4.1.7 Concluding Remarks on MPS . 82
4.2 Material Requirement Planning and Other Techniques. 83
4.2.1 Least Unit Cost Purchase Policy. 87
4.2.2 General Considerations. 91
4.2.2.1 Planning Period. 91
4.2.2.2 Product Structure. 92
4.2.2.3 Manufacturing Resource Planning. 92
4.2.2.4 Enterprise Resource Planning. 92
Contents vii
4.2.3 Distribution Requirement Planning. 93
4.2.3.1 DRPExample . 93
4.3 Summary. 94
4.4 Exercise . 95
References and Suggested Readings. 97
Chapters Inventory and Capacity Planning. 99
5.1 Inventory Planning. 99
5.1.1 Economic Order Quantity. 99
5.2 Safety Stock Determination. 102
5.2.1 Fixed Quantity-Varying Cycle System. 104
5.2.2 Periodic Review System. 104
5.2.3 Safety Stock with Substitute Products. 105
5.3 Quantity Discounts. 106
5.3.1 All Unit Quantity Discount. 107
5.3.2 Marginal Unit Quantity Discount. 109
5.3.3 One-Time Unit Price Discount. Ill
5.3.4 Multiple Products Order Jointly. 113
5.4 Single Period Planning. 117
5.4.1 Discrete Order Quantity. 117
5.4.2 Single Period Ordering with Continuous Demand. 119
5.4.3 Buyback Policy. 121
5.4.4 Effect of Reduction in a . 121
5.5 Consumption during Production. 124
5.6 JIT Inventory System. 124
5.6.1 Distribution Strategy. 125
5.6.1.1 Day 1 Evaluation. 128
5.6.1.2 Day 2 Evaluation. 129
5.6.1.3 Day 3 Evaluation. 130
5.6.1.4 Day 4 Evaluation. 130
5.6.1.5 Day 5 Evaluation. 132
5.6.1.6 Day 6 Evaluation. 132
5.6.1.7 Day 7 Evaluation. 132
5.6.2 Backward Check. 134
5.7 Recourse Center Capacity Planning. 135
5.7.1 Rough Cut Planning. 135
5.7.2 Capacity Bills. 136
5.7.3 Number of Machines Needed. 138
5.8 Theory of Constraints. 139
5.9 Summary. 140
5.10 Exercise . 140
References and Suggested Readings . 146
Chapter 6 Single Machine Scheduling. 147
6.1 Tardiness Problem. 148
vi!j Contents
6.2 Survey of Exact Methods for Single-Machine Scheduling Problem . 148
6.2.1 Exhaustive Enumeration. 148
6.2.2 Branch-and-Bound Algorithm. 149
6.2.2.1 Illustrative Example 1. 149
6.3 Commonly Used Heuristic Rules. 150
6.3.1 Earliest Due Date Rule. 152
6.3.2 Cost Over Time (COVERT) Rule. 152
6.3.3 Shortest Processing Time (SPT) Rule. 152
6.3.4 Largest Penalty per Unit Length (LPUL) Rule. 152
6.3.5 Shortest Processing Time and LPUL Rule. 153
6.3.6 Shortest Weighted Processing Time (SWPT) Rule. 153
6.3.7 Largest Weight (WT) and LPUL Rule. 153
6.3.8 Critical Ratio (CR) Rule. 153
6.3.8.1 Illustrative Example 1. 153
6.4 Description of an Efficient Heuristic. 156
6.4.1 Backward Phase. 156
6.4.2 Forward Phase. 158
6.4.3 An Illustrative Example Using the Heuristic Algorithm. 158
6.4.4 Validity of the Heuristic and Conclusions. 160
6.5 Single Machine Problem with Early and Late Penalties. 162
6.5.1 Backward Phase. 163
6.5.1.1 Illustrative Example 2. 163
6.5.1.2 Modified Background Phase When Early Penalties
and Present. 164
6.5.2 Validity of the Heuristic. 166
6.6 Some Weil-Known Theorems. 167
6.7 Summary. 168
6.8 Problems. 168
References and Suggested Readings. 170
Chapter 7 Other Objectives in Single-Machine Scheduling. 171
7.1 Common Due Date . 171
7.1.1 Illustrative Example 7.1. 172
7.2 Common Due Date Specified by a Customer. 174
7.3 Early and Late Due Dates. 174
7.3.1 Illustrative Example 7.2. 175
7.4 Quadratic or Nonlinear Penalty Function. 177
7.4.1 Illustrative Example 7.3. 178
7.5 Minimization of the Average Delay. 178
7.6 Minimization of the Maximum Delay. 179
7.7 Minimize the Number of Jobs That Are Delayed. 179
7.7.1 Illustrative Example 7.4. 180
7.8 Maximize the Number of Jobs Processed When the Available Time Is
Less than Total Processing Time. 181
7.8.1 Illustrative Example 7.5. 181
Contents ix
7.9 Sequence-Dependent Jobs. 182
7.9.1 Illustrative Example 7.6. 182
7.9.2 Forward Phase. 184
7.10 Sequence-Dependent Jobs with Minimum/Maximum Separations. 184
7.10.1 Illustrative Example 7.7. 185
7.11 Minimize Variation of Flow Time. 185
7.11.1 Illustrative Example 7.8. 186
7.12 Sequence-Dependent Setup Times. 186
7.12.1 Illustrative Example 7.10. 186
7.13 DualCriteria . 187
7.13.1 Illustrative Example 7.11. 187
7.14 Delay of Early Completing Jobs. 188
7.14.1 Phase I. Slack Introduction. 189
7.14.2 Phase U. Optimal Sequence Search. 191
7.14.3 Illustrative Example 7.12. 191
7.14.4 Phase II: Optimal Sequence Search. 195
7.15 Jobs Arriving at Different Times. 198
7.16 Summary. 206
7.17 Problems. 206
References and Suggested Readings . 210
Chapter 8 Flowshop Problems. 213
8.1 Two-Machine Problem. 213
8.1.1 Illustrative Example 8.1. 214
8.2 Three-Machine Problem. 216
8.2.1 Illustrative Example 8.2. 216
8.3 Setup/Processing and Removal Times Separated: Another Extension
of Johnson's Algorithm. 218
8.4 Two-Machine Flowshop with Travel Time between Machines. 219
8.4.1 Relationships for Makespan Calculations. 220
8.4.2 Illustrative Example 8.3. 221
8.4.3 Makespan Calculations. 222
8.5 n Jobs/m-Machines Problem . 222
8.5.1 Minimize Machine Idle Time Method. 223
8.5.1.1 Procedure. 224
8.5.1.2 Illustrative Example. 224
8.5.2 Palmer Procedure. 227
8.5.3 Nawaz Heuristic. 227
8.5.4 Campbell, Dudek, and Smith (CDS) Procedure. 229
8.6 n-Job//n-Machine Problem: Jobs Arriving at Different Times. 229
8.6.1 Example. 230
8.6.2 Result. 233
8.7 Summary. 233
x Contents
8.8 Problems. 234
References and Suggested Readings . 236
Chapter 9 Parallel Processing and Batch Sequencing. 237
9.1 Parallel Processing. 237
9.1.1 Jobs with Equal Weight and No Due Dates. 237
9.1.1.1 Procedure. 237
9.1.1.2 Illustrative Example. 238
9.1.2 Jobs with Priorities Ranked by Weights. 240
9.1.3 Jobs with Due Dates. 241
9.1.3.1 Illustrative Example. 242
9.2 Single Operation Job-Related Earliness/Tardiness Penalties with
Machine Activation Cost. 248
9.2.1 Example. 250
9.2.2 Single Machine. 250
9.2.3 TwoMachines. 252
9.3 Nonidentical Parallel Processors. 254
9.3.1 Procedure. 254
9.4 Parallel Machines in a Flowshop. 259
9.5 Batch Scheduling for a Limited-Capacity, Fixed-Period Process
Problem. 262
9.5.1 Integer Programming Model. 263
9.5.2 Heuristic Approach. 265
9.5.3 Illustrative Example. 266
9.6 Batch Scheduling for Limited-Capacity Processors in Sequence with
Varying Job Requirements. 267
9.6.1 Illustrative Example. 267
9.6.2 Improvement Routine. 269
9.7 Batch Sequencing. 271
9.7.1 Procedure and Analysis . 272
9.7.2 Application. 273
9.8 Summary. 275
9.9 Problems. 275
References and Suggested Readings. 278
Chapter 10 Network-Based Scheduling. 281
10.1 Critical Path Method. 281
10.2 Scheduling a Network of Jobs on a Specified Number of Parallel
Processors. 284
10.2.1 Solution Procedure. 285
10.2.1.1 Illustrated Example. 287
10.3 Scheduling n Jobs on m Parallel Machines When Each Job Can Be
Scheduled on p Machines, "p" Being a Subset of m, That Is, p m. 293
10.3.1 Solution Procedure. 293
10.3.2 Illustrated Example. 295
Contents xi
10.4 Assembly Line Balancing . 296
10.4.1 Largest Candidate Rule. 296
10.4.2 Ranked Positional Weight Method . 299
10.4.3 Cycle Time Less than Task Time. 301
10.5 Mixed-Model Assembly Line Balancing. 302
10.5.1 Procedure and an Illustrative Example. 302
10.5.2 Effects of Other Ways of Balancing (Grouping). 307
10.5.2.1 An Assembly Line for Each Model. 307
10.5.2.2 A Single Assembly Line for All Models . 307
10.5.3 Advantages of the Suggested Approach. 308
10.5.3.1 Problem Areas. 308
10.6 Mixed-Model Assembly—Method to Minimize Stations. 308
10.6.1 Procedure. 309
10.6.2 Numerical Illustration. 310
10.6.2.1 Solution. 310
10.7 Network Scheduling with Resource Constraint. 313
10.7.1 Illustrative Example. 314
10.7.2 Multiple Resources. 317
10.8 Summary. 319
10.9 Problems. 319
References and Suggested Readings . 324
Chapter 11 Job Shop Scheduling. 325
11.1 Job Shop. 325
11.2 Job Shop Scheduling to Minimize Makespan (SPT). 327
11.2.1 Shortest Processing Rule. 328
11.3 Network Approach to Job Shop Scheduling. 329
11.3.1 The Modified Shifting Bottleneck Heuristic . 331
11.3.1.1 Illustrative Example. 333
11.3.2 Two-Stage Job Shop Scheduling Heuristic. 340
11.3.2.1 Illustrative Example. 342
11.4 Job Shop Scheduling to Minimize Tardiness. 346
11.4.1 The CEXSPT Rule . 347
11.4.2 Minimizing Penalty Using Modified Shifting Bottleneck
Procedure. 349
11.4.3 Optimizing Total Penalty and Makespan Using MODSB
(Dual Criteria). 359
11.5 Summary. 361
11.6 Problems. 361
References and Suggested Readings . 365
Chapter 12 Open-Shop Scheduling. 367
12.1 Minimize Makespan: Two-Machine Problem. 367
12.2 Minimize Makespan: Multiple-Machine Problem . 368
12.2.1 Illustrative Example. 371
xjj Contents
12.3 Minimization of Total Tardiness-Open Shop (MTT-OP). 378
12.3.1 Solution Procedure. 378
12.3.2 Initial Assignment. 378
12.3.3 Special Cases. 380
12.3.4 Subsequent Assignments. 380
12.3.5 Illustrative Example. 381
12.3.6 Special Cases. 385
12.3.6.1 Special Case 1 (Example). 385
12.3.6.2 Special Case 2 (Example). 387
12.4 Minimization of Total Weighted Tardiness Penalties-Open Shop
(MTWT-OP). 388
12.4.1 Initial Assignment. 388
12.4.2 Subsequent Assignments. 389
12.4.3 Illustration Example. 390
12.5 Summary. 394
12.6 Problems. 394
References and Suggested Readings . 396
Chapter 13 Manpower Scheduling . 397
13.1 Consecutive Days-Off Scheduling. 398
13.1.1 Illustrative Example. 399
13.2 Rotating Days (Weekends) Off. 401
13.2.1 Illustrative Example. 403
13.3 Monroe's Algorithm. 406
13.3.1 Illustrative Example II. 408
13.3.2 Illustrative Example ffl. 409
13.3.3 Realignment of a Worker. 409
13.3.4 Increasing the Workforce. 410
13.3.5 Assigning Nonconsecutive Days Off. 411
13.4 Tour Scheduling. 412
13.4.1 Procedure. 412
13.4.2 Illustrative Example. 413
13.4.3 Other Variations. 416
13.5 Three Consecutive Days Off. 416
13.5.1 Assign Nonconsecutive Days Off. 421
13.5.2 Special Case and Further Discussion. 422
13.6 Summary. 423
13.7 Problems. 424
References and Suggested Readings. 427
Chapter 14 Industrial Sequencing I: Scheduling on NC Machines. 429
14.1 Tabular Approach in Group Forming. 429
14.2 Job Sequencing to Minimize Tool Changeovers in Flexible
Manufacturing Systems. 435
14.2.1 Assumptions and Problem Statement. 435
Contents xiii
14.2.2 Solution Procedure. 437
14.2.3 Illustrative Example. 439
14.3 Heuristic to Minimize Throughput Time on an NC Machine. 442
14.3.1 Problem Definition and Assumptions. 444
14.3.2 Heuristic Procedure and Its Application. 445
14.3.3 Alternative 1: Start with a Job Having the Largest Demand_ 446
14.3.3.1 Discussion of the Procedure. 446
14.3.3.2 Applications of Steps 3 through 5 to the Illustrative
Example . 450
14.3.4 Alternative 2: Minimize the External Tool Changes. 452
14.3.5 Select the Best Alternative. 452
14.3.5.1 Further Comments . 452
14.4 Summary. 453
14.5 Problems. 453
References and Suggested Readings . 456
Chapter 15 Industrial Sequencing II: Electronic Assemblies: Component
Tape Assemblies on a Sequencer. 457
15.1 A Heuristic Procedure for Tape Assembling on a Sequencer. 458
15.1.1 Problem Statement. 459
15.1.2 Solution Procedure. 459
15.1.3 Phase II: Scheduling. 462
15.1.4 Solution to the Example Problem. 466
15.2 Summary. 471
15.3 Problems. 471
References and Suggested Readings . 473
Chapter 16 Industrial Sequencing III: Sequencing Feeder for Component
Tape Assembly. 475
16.1 Problem Description. 476
16.2 Heuristic Procedure. 478
16.2.1 Developing Basic Component Assignments to the Slots. 478
16.2.2 Developing the Initial Assignment. 483
16.2.2.1 Calculation of Priorities for Locations. 483
16.2.2.2 Location Assignments. 483
16.2.3 Smoothing the Assignment. 487
16.2.4 Improving the Assignment. 488
16.2.5 Check for Improvement. 492
16.3 Problems. 494
References and Suggested Readings . 495
Chapter 17 Industrial Sequencing IV: Scheduling in Flexible Manufacturing 497
17.1 A CDS-Based, Two-Phase Algorithm for Group Scheduling with
Group-Dependent Setup Times. 497
17.1.1 Introduction. 497
xiv Contents
17.1.2 Heuristic . 497
17.1.2.1 Phase I: Preliminary Sequence. 497
17.1.2.2 Phase II: Makespan Reduction by Minimizing the
Machine Idle Time. 498
17.1.3 Illustrative Example. 498
17.1.3.1 Phase I: Preliminary Sequence. 499
17.1.3.2 Phase II: Makespan Reduction by Minimizing the
Machine Idle Time. 501
17.1.4 Results . 503
17.2 Multiple Robot in Assembly Operations. 505
17.2.1 Illustrative Example. 507
17.2.2 More than Two Robots. 509
References and Suggested Readings . 510
Appendix: Computer Program Description. 513
Index. 527 |
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spelling | Sule, Dileep R. Verfasser aut Production planning and industrial scheduling examples, case studies and applications Dileep R. Sule 2. ed. Boca Raton, Fla. [u.a.] CRC Press 2008 XVI, 534 S. graph. Darst. txt rdacontent n rdamedia nc rdacarrier Production scheduling Produktionsplanung (DE-588)4047360-0 gnd rswk-swf Optimierung (DE-588)4043664-0 gnd rswk-swf Produktionsplanung Produktionsplanung (DE-588)4047360-0 s Optimierung (DE-588)4043664-0 s DE-604 HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016424545&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
spellingShingle | Sule, Dileep R. Production planning and industrial scheduling examples, case studies and applications Production scheduling Produktionsplanung (DE-588)4047360-0 gnd Optimierung (DE-588)4043664-0 gnd |
subject_GND | (DE-588)4047360-0 (DE-588)4043664-0 |
title | Production planning and industrial scheduling examples, case studies and applications |
title_auth | Production planning and industrial scheduling examples, case studies and applications |
title_exact_search | Production planning and industrial scheduling examples, case studies and applications |
title_exact_search_txtP | Production planning and industrial scheduling examples, case studies and applications |
title_full | Production planning and industrial scheduling examples, case studies and applications Dileep R. Sule |
title_fullStr | Production planning and industrial scheduling examples, case studies and applications Dileep R. Sule |
title_full_unstemmed | Production planning and industrial scheduling examples, case studies and applications Dileep R. Sule |
title_short | Production planning and industrial scheduling |
title_sort | production planning and industrial scheduling examples case studies and applications |
title_sub | examples, case studies and applications |
topic | Production scheduling Produktionsplanung (DE-588)4047360-0 gnd Optimierung (DE-588)4043664-0 gnd |
topic_facet | Production scheduling Produktionsplanung Optimierung |
url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016424545&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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