2nd Edition

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

By Dileep R. Sule Copyright 2007
    556 Pages 44 B/W Illustrations
    by CRC Press

    554 Pages 44 B/W Illustrations
    by CRC Press

    In today's extremely competitive manufacturing market, effective production planning and scheduling processes are critical to streamlining production and increasing profits. Success in these areas means increased efficiency, capacity utilization, and reduced time required to complete jobs. From the initial stages of plant location and capacity determination to plant operations and manpower scheduling, Production Planning and Industrial Scheduling, Second Edition presents a cohesive outlook on optimization and planning. The author provides a focus on practical applications and integrates logistics and planning in the areas of production and scheduling.

    Critical Techniques for Optimizing Operational Productivity

    Starting with the strategic development of plant locations and capacities, the book lays out a clear process for creating an effective production plan with considerations for existing production facilities. It discusses forecasting and aggregate planning, which can predict demands under scenarios. In addition, the book introduces techniques to improve plant efficiencies in various areas, as well as material requirement and inventory and capacity planning. This expanded second edition features new information on safety stock determination, uncertainty in demand, and resource center capacity planning. The problem-specific case studies illustrate the effect of different procedures on the entire system and stress coordination between independent techniques to help achieve optimal efficiency.

    With the aid of this reference and the proper application of its concepts, industrial managers and engineers can reduce their manufacturing cost, succeed in fulfilling their customers' demands in a timely manner, and attain superior planning and overall control of manufacturing operations.

    Introduction to Production Planning and Scheduling

    Production Planning


    What is not included

    Plant Locations and Capacity Determination

    Existing Production Facilities

    New Plant Locations

    Uncertainty in Demand

    Forecasting and Aggregate Planning


    Aggregate Planning

    Master Pproduction Scheduling and Material Requirement Planning

    Master Production Schedule

    Material Requirement Planning and Other Techniques

    Inventory and Capacity Planning

    Inventory Planning

    Safety Stock Determination

    Quantity Discounts

    Single Period Planning

    Consumption during Production

    JIT Inventory System

    Recourse Center Capacity Planning

    Theory of Constraints

    A Single Machine Scheduling

    The Tardiness Problem

    A Survey of Exact Methods for Single Machine Scheduling Problem

    Commonly Used Heuristic Rules

    Description of an Efficient Heuristic

    A Single Machine Problem with Early and Late Penalties

    Some Well-Known Theorems

    Other Objectives in Single-Machine Scheduling

    Common Due Date

    Common Due Date Specified by a Customer

    Early and Late Due Dates

    Quadratic or Nonlinear Penalty Function

    Minimization of the Average Delay

    Minimization of the Maximum Delay

    Minimize the Number of Jobs that are Delayed

    Illustrative Example

    Maximize the Number of Jobs Processed when the Available Time is Less than Total Processing Time

    Sequence-Dependent Jobs

    Sequence-Dependent Jobs with Minimum/Maximum


    Minimize Variation of Flow Time

    Sequence-Dependent Setup Times

    Dual Criteria

    Delay of Early Completing Jobs

    Jobs Arriving at Different Times

    Flowshop Problems

    Two-Machine Problem

    Three-Machine Problem

    Setup/Processing and Removal Times Separated: Another Extension of Johnson's Algorithm

    Two-Machine Flowshop with Travel time Between Machines

    n Jobs/m-Machines Problem

    n-Job/m-Machine Problem: Jobs Arriving at Different Times



    Parallel Processing and Batch Sequencing

    Parallel Processing

    Single Operation Job Related Earliness/Tardiness Penalties With
    Machine Activation Cost

    Nonidentical Parallel Processors

    Parallel Machines in a Flowshop

    Batch Scheduling for a Limited-Capacity Fixed-Period Process


    Batch Scheduling for Limited-Capacity Processors, in Sequence with Varying Job Requirements

    Batch Sequencing

    Network-Based Scheduling

    Critical Path Method

    To Schedule a Network of Jobs on a Specified Number of Parallel Processors

    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

    Assembly Line Balancing

    Mixed Model Assembly Line Balancing

    Mixed-Model Assembly-Method to Minimize Stations

    Network Scheduling with Resource Constraint

    Job Shop Scheduling

    Job Shop

    Job Shop Scheduling to Minimize Makespan (SPT)

    Network Approach to Job Shop Scheduling

    Job Shop Scheduling to Minimize Tardiness

    Open-Shop Scheduling

    Minimize Makespan: Two-Machine Problem

    Minimize Makespan: Multiple-Machine Problem

    Minimization of Total Tardiness-Open Shop (MTT-OP)

    Minimization of Total Weighted Tardiness Penalties-Open Shop

    Manpower Scheduling

    Consecutive Days-off Scheduling

    Rotating days (Weekends) off

    Monroe's Algorithm

    Tour Scheduling

    Three Consecutive Days Off

    Industrial Sequencing I: Scheduling on NC Machines

    Tabular Approach in Group Forming

    Job Sequencing to Minimize Tool Changeovers in Flexible

    Manufacturing Systems

    Heuristic to Minimize Throughput Time on an NC Machine

    Problem Definition and Assumptions

    Industrial Sequencing II: Electronic Assemblies:

    Tape Assemblies on a Sequencer

    A Heuristic Procedure for Tape Assembling on a Sequencer

    Industrial Sequencing III: Sequencing Feeder for

    Tape Assembly

    Problem Description

    Heuristic Procedure

    Industrial Scheduling IV: Scheduling in Flexible Manufacturing

    A CDS-Based Two-Phase Algorithm for Group Scheduling with
    Multiple Robots in Assembly Operations

    APPENDIX: Computer Program Description


    Each Chapter includes a summary and bibliography


    Dileep R. Sule

    "It is a competent text book on these topics, and can be useful for the lecturers and students in industrial engineering and operations management. It also can serve a reference for various relevant models and solution techniques . . . covers practical algorithms of planning and scheduling, the descriptions of each algorithm is formalized at a right level, many numerical examples are provided."

    – Vitaly A. Strusevich, in Zentralblatt MATH, 2008