Production Planning and Industrial Scheduling: Examples, Case Studies and Applications, Second Edition

556 Pages·2007·3.79 MB·English

by  Dileep R. Sule

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Table of Contents
Preface ............................................................................. xv
Acknowledgments................................................................. xvii
Author.............................................................................. xix
Chapter1 IntroductiontoProductionPlanningandScheduling.............. 1
1.1 ProductionPlanning ....................................................... 1
1.1.1 PictorialViewofaProductionPlanningandControlSystem.. 2
1.1.2 ProductionSystems............................................... 3
1.1.3 CharacteristicsofProductionSystems .......................... 4
1.1.4 ResponseTime.................................................... 4
1.1.5 SupplyChain ..................................................... 5
1.1.6 Inventory.......................................................... 6
1.2 Scheduling.................................................................. 6
1.2.1 SchedulingExamples............................................. 7
1.2.2 SchedulingonShopFloor........................................ 8
1.3 WhatIsNotIncluded...................................................... 13
1.4 Summary ................................................................... 13
1.5 Problems.................................................................... 14
ReferencesandSuggestedReadings ............................................. 14
Chapter2 PlantLocationsandCapacityDetermination....................... 15
2.1 ExistingProductionFacilities............................................. 15
2.1.1 DistributionNetworkwithExistingFacilities .................. 15
2.1.2 ResponseTimeConsideration ................................... 18
2.1.3 LimitationonNumberofFacilities.............................. 18
2.2 NewPlantLocations....................................................... 21
2.2.1 NewFacilitieswithCapacityDetermination.................... 21
2.2.2 VariablesinLinearProgrammingInitialFormulationand
AlternateFormulation............................................ 22
2.2.3 SpreadsheetApproachUsingSolverTool....................... 25
2.2.4 SingleSourcing................................................... 28
2.2.5 TimeConstraints.................................................. 30
2.3 UncertaintyinDemand.................................................... 32
2.3.1 LargePlantEvaluation........................................... 35
2.3.2 SmallPlantEvaluation........................................... 36
2.3.3 RevenueEvaluation .............................................. 37
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2.3.4 ExpansioninFuture.............................................. 38
2.4 Summary ................................................................... 39
2.5 Exercise .................................................................... 39
ReferencesandSuggestedReadings ............................................. 42
Chapter3 ForecastingandAggregatePlanning................................ 45
3.1 Forecasting................................................................. 45
3.1.1 QualitativeForecasting........................................... 45
3.1.2 QuantitativeForecasting ......................................... 46
3.1.3 StaticForecasting................................................. 47
3.1.4 SeasonalCorrection .............................................. 48
3.1.5 AdaptiveForecasting............................................. 50
3.1.6 ExponentialSmoothing .......................................... 50
3.1.7 Holt’sandWinter’sModels...................................... 52
3.1.8 AnalysisofForecastingErrors................................... 53
3.2 AggregatePlanning........................................................ 57
3.2.1 Strategies.......................................................... 58
3.2.2 ProblemDescription.............................................. 60
3.2.3 OtherFactors ..................................................... 66
3.2.3.1 HumanFactors ........................................ 66
3.2.3.2 ChangingDemand .................................... 66
3.2.3.3 SpreadsheetApproach ................................ 67
3.3 Summary ................................................................... 68
3.4 Exercise .................................................................... 68
3.4.1 DiscussionandReviewQuestions............................... 68
ReferencesandSuggestedReadings ............................................. 74
Chapter4 MasterProductionSchedulingandMaterialRequirement
Planning.............................................................. 75
4.1 MasterProductionSchedule............................................... 75
4.1.1 FixedOrderQuantity(FOQ)..................................... 77
4.1.2 PeriodicOrderQuantity(POQ).................................. 79
4.1.3 LotforLot(L4L)................................................. 79
4.1.4 LeastTotalCost................................................... 79
4.1.5 IncrementalCostAnalysis(ICA)................................ 80
4.1.6 Available-to-PromiseChart(ATP)............................... 82
4.1.7 ConcludingRemarksonMPS ................................... 82
4.2 MaterialRequirementPlanningandOtherTechniques .................. 83
4.2.1 LeastUnitCostPurchasePolicy................................. 87
4.2.2 GeneralConsiderations........................................... 91
4.2.2.1 PlanningPeriod........................................ 91
4.2.2.2 ProductStructure...................................... 92
4.2.2.3 ManufacturingResourcePlanning ................... 92
4.2.2.4 EnterpriseResourcePlanning ........................ 92
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4.2.3 DistributionRequirementPlanning.............................. 93
4.2.3.1 DRPExample ......................................... 93
4.3 Summary ................................................................... 94
4.4 Exercise .................................................................... 95
ReferencesandSuggestedReadings ............................................. 97
Chapter5 InventoryandCapacityPlanning ................................... 99
5.1 InventoryPlanning......................................................... 99
5.1.1 EconomicOrderQuantity........................................ 99
5.2 SafetyStockDetermination ............................................... 102
5.2.1 FixedQuantity–VaryingCycleSystem.......................... 104
5.2.2 PeriodicReviewSystem ......................................... 104
5.2.3 SafetyStockwithSubstituteProducts........................... 105
5.3 QuantityDiscounts......................................................... 106
5.3.1 AllUnitQuantityDiscount....................................... 107
5.3.2 MarginalUnitQuantityDiscount................................ 109
5.3.3 One-TimeUnitPriceDiscount................................... 111
5.3.4 MultipleProductsOrderJointly ................................. 113
5.4 SinglePeriodPlanning .................................................... 117
5.4.1 DiscreteOrderQuantity.......................................... 117
5.4.2 SinglePeriodOrderingwithContinuousDemand.............. 119
5.4.3 BuybackPolicy................................................... 121
5.4.4 EffectofReductioninσ ......................................... 121
5.5 ConsumptionduringProduction .......................................... 124
5.6 JITInventorySystem...................................................... 124
5.6.1 DistributionStrategy ............................................. 125
5.6.1.1 Day1Evaluation...................................... 128
5.6.1.2 Day2Evaluation...................................... 129
5.6.1.3 Day3Evaluation...................................... 130
5.6.1.4 Day4Evaluation...................................... 130
5.6.1.5 Day5Evaluation...................................... 132
5.6.1.6 Day6Evaluation...................................... 132
5.6.1.7 Day7Evaluation...................................... 132
5.6.2 BackwardCheck.................................................. 134
5.7 RecourseCenterCapacityPlanning....................................... 135
5.7.1 RoughCutPlanning.............................................. 135
5.7.2 CapacityBills..................................................... 136
5.7.3 NumberofMachinesNeeded.................................... 138
5.8 TheoryofConstraints...................................................... 139
5.9 Summary ................................................................... 140
5.10 Exercise .................................................................... 140
ReferencesandSuggestedReadings ............................................. 146
Chapter6 SingleMachineScheduling ......................................... 147
6.1 TardinessProblem ......................................................... 148
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6.2 SurveyofExactMethodsforSingle-MachineSchedulingProblem .... 148
6.2.1 ExhaustiveEnumeration ......................................... 148
6.2.2 Branch-and-BoundAlgorithm ................................... 149
6.2.2.1 IllustrativeExample1................................. 149
6.3 CommonlyUsedHeuristicRules ......................................... 150
6.3.1 EarliestDueDateRule........................................... 152
6.3.2 CostOverTime(COVERT)Rule................................ 152
6.3.3 ShortestProcessingTime(SPT)Rule ........................... 152
6.3.4 LargestPenaltyperUnitLength(LPUL)Rule.................. 152
6.3.5 ShortestProcessingTimeandLPULRule ...................... 153
6.3.6 ShortestWeightedProcessingTime(SWPT)Rule ............. 153
6.3.7 LargestWeight(WT)andLPULRule........................... 153
6.3.8 CriticalRatio(CR)Rule ......................................... 153
6.3.8.1 IllustrativeExample1................................. 153
6.4 DescriptionofanEfficientHeuristic...................................... 156
6.4.1 BackwardPhase .................................................. 156
6.4.2 ForwardPhase.................................................... 158
6.4.3 AnIllustrativeExampleUsingtheHeuristicAlgorithm........ 158
6.4.4 ValidityoftheHeuristicandConclusions....................... 160
6.5 SingleMachineProblemwithEarlyandLatePenalties ................. 162
6.5.1 BackwardPhase .................................................. 163
6.5.1.1 IllustrativeExample2................................. 163
6.5.1.2 ModifiedBackgroundPhaseWhenEarlyPenalties
andPresent ............................................ 164
6.5.2 ValidityoftheHeuristic.......................................... 166
6.6 SomeWell-KnownTheorems............................................. 167
6.7 Summary ................................................................... 168
6.8 Problems.................................................................... 168
ReferencesandSuggestedReadings ............................................. 170
Chapter7 OtherObjectivesinSingle-MachineScheduling................... 171
7.1 CommonDueDate ........................................................ 171
7.1.1 IllustrativeExample7.1.......................................... 172
7.2 CommonDueDateSpecifiedbyaCustomer............................. 174
7.3 EarlyandLateDueDates ................................................. 174
7.3.1 IllustrativeExample7.2.......................................... 175
7.4 QuadraticorNonlinearPenaltyFunction................................. 177
7.4.1 IllustrativeExample7.3.......................................... 178
7.5 MinimizationoftheAverageDelay....................................... 178
7.6 MinimizationoftheMaximumDelay .................................... 179
7.7 MinimizetheNumberofJobsThatAreDelayed ........................ 179
7.7.1 IllustrativeExample7.4.......................................... 180
7.8 MaximizetheNumberofJobsProcessedWhentheAvailableTimeIs
LessthanTotalProcessingTime.......................................... 181
7.8.1 IllustrativeExample7.5.......................................... 181
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7.9 Sequence-DependentJobs................................................. 182
7.9.1 IllustrativeExample7.6.......................................... 182
7.9.2 ForwardPhase.................................................... 184
7.10 Sequence-DependentJobswithMinimum/MaximumSeparations...... 184
7.10.1 IllustrativeExample7.7.......................................... 185
7.11 MinimizeVariationofFlowTime......................................... 185
7.11.1 IllustrativeExample7.8.......................................... 186
7.12 Sequence-DependentSetupTimes........................................ 186
7.12.1 IllustrativeExample7.10......................................... 186
7.13 DualCriteria ............................................................... 187
7.13.1 IllustrativeExample7.11......................................... 187
7.14 DelayofEarlyCompletingJobs .......................................... 188
7.14.1 PhaseI.SlackIntroduction....................................... 189
7.14.2 PhaseII.OptimalSequenceSearch.............................. 191
7.14.3 IllustrativeExample7.12......................................... 191
7.14.4 PhaseII:OptimalSequenceSearch.............................. 195
7.15 JobsArrivingatDifferentTimes.......................................... 198
7.16 Summary ................................................................... 206
7.17 Problems.................................................................... 206
ReferencesandSuggestedReadings ............................................. 210
Chapter8 FlowshopProblems.................................................. 213
8.1 Two-MachineProblem..................................................... 213
8.1.1 IllustrativeExample8.1.......................................... 214
8.2 Three-MachineProblem................................................... 216
8.2.1 IllustrativeExample8.2.......................................... 216
8.3 Setup/ProcessingandRemovalTimesSeparated:AnotherExtension
ofJohnson’sAlgorithm.................................................... 218
8.4 Two-MachineFlowshopwithTravelTimebetweenMachines.......... 219
8.4.1 RelationshipsforMakespanCalculations....................... 220
8.4.2 IllustrativeExample8.3.......................................... 221
8.4.3 MakespanCalculations........................................... 222
8.5 nJobs/m-MachinesProblem .............................................. 222
8.5.1 MinimizeMachineIdleTimeMethod........................... 223
8.5.1.1 Procedure.............................................. 224
8.5.1.2 IllustrativeExample................................... 224
8.5.2 PalmerProcedure................................................. 227
8.5.3 NawazHeuristic.................................................. 227
8.5.4 Campbell,Dudek,andSmith(CDS)Procedure................. 229
8.6 n-Job/m-MachineProblem:JobsArrivingatDifferentTimes........... 229
8.6.1 Example........................................................... 230
8.6.2 Result.............................................................. 233
8.7 Summary ................................................................... 233
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