2nd Edition

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

ISBN 9781420044201
Published October 16, 2007 by CRC Press
560 Pages 44 B/W Illustrations

USD $130.00

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Book Description

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.

Table of Contents

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

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"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