• Production Activity Control and Input Output Control
Production Activity Control and Input
Output Control
Content
• Introduction
• Scheduling techniques for batch flow
• Scheduling techniques for job shop
• Technique for PAC :
Queue length Management
Operation Overlapping
Operation Splitting
• Input/Output Control
2
Introduction
• When the plan has been developed, the next step is execution of the
plan
• Production Activity Control (or often called Shop Floor Control) is to
have activities performed as planned, report on operating result, revise
plan as required.
• Techniques for scheduling different for various manufacturing systems:
– Project
– Job shop
– Batch
– Flow shop
3
Production Activity Control
Schematic
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Scheduling Batch Flow Line
• A group of similar items is manufactured on the batch line
• Batch flow lines exist in beverage , ice cream, soap powder or pharmaceutical
plants.
• The focus is to minimize changeover time
• The smaller the changeover time, the greater the scheduling flexibility
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How much to produce? Or How long the run time
will be?
• Depends on:
– Available on hand
– Demand rate
– The changeover time
– Production rate
– The sequence, if any, in which items should be run
• When the setup times are relatively small and independent of the
sequence produce first the item with smallest runout time
• Runout time is the period existing inventory will last given forecast
usage (= units in inventory / demand rate)
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Example
Item Inventory Demand R (in days) Scheduling
(units per day) priority)
A 80 20 4.0 1
B 100 10 10.0 2
C 150 12 12.5 3
D 60 4 15.0 4
Job Shop Scheduling
• Job shop production is characterized by:
– Process layout
– Many orders with different sequence of processes
– Scheduling is assigning of starting and completion times to orders (jobs) and
frequently includes the time when orders are to arrive and leave each
department.
– Sequencing is the assigning of the sequence in which orders are to be processed.
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Priority Control
• To determine the sequence in which orders should be processed
• Common Priority Rules:
– First come first served (FCFS)
– Short processing time (SPT) : results in lowest WIP, lowest MLT, and lowest
average job lateness
– EDD (Earliest due date): works well when processing times are approximately the
same
– Slack time (ST): supports the achievement of due date objectives
– Critical ratio (CR)
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Day 125 (all times are in days)
Example
Order Due Current Total MLT # Slack Critical
Date Operation Operation Remaining Operations Time Ratio
Time Time Remaining
Remaining
A 130 1.5 3.0 6.0 3 2.0 0.83
B 132 1.0 4.5 9.5 5 2.5 0.74
C 136 2.0 4.0 8.0 4 7.0 1.38
D 138 3.5 7.0 9.0 2 6.0 1.44
ST = Due Date – Present Date – Total Operations Time Remaining
Due Date – Present Date
CR = ------------------------------------------- CR = 1 means the order is on schedule
MLT Remaining
Sequencing Results
• EDD : A – B – C – D
• SPT : B – A – C – D
• ST : A – B – D – C
• CR : B – A – C – D
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Queue Length Management
• Affect WIP and manufacturing lead times
• Queues are planned to compensate uneven flow of incoming work and the
variations in work center processing times
• Difference queue: A controlled, uncontrolled, idle time
• The objective of QLM:
– To reduce WIP
– To shorten MLT
– To better utilize bottleneck resources
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Operations Overlapping
• Dividing a lot into two or
more batches
• Used to reduce MLT
SU1 1 Run 2 Run
SU2 1 Run 2 Run
To avoid idle of operation B, SU2+TAB+Q1PB>=Q2PA+TAB
Where Q = Q1+Q2
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Savings in Lead Time
Without overlapping
SU1 1 Run 2 Run SU2 1 Run 2 Run
With overlapping
SU1 1 Run 2 Run
SU2 1 Run 2 Run
Lead time savings
OPERATION SPLITTING
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INPUT/OUTPUT CONTROL
• Short-range control technique (normally daily)
• Compare scheduled input and output to actual input and output
• Effective for controlling queue, WIP, and MLT
• Enable the planner to determine the actions necessary to achieve the desired
output , WIP, and MLT
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Single Work Center Processes
ICDi ICDi 1 PIi AIi
i = Time period
PI = Planned Input
OCDi OCDi 1 POi AOi
AI = Actual Input
PO = Planned output
AO = Actual Output
PWIPi PWIPi 1 PIi POi
ICD = Input Cumulative Deviation
OCD = Output Cumulative Deviation
PWIP= ending Planned Work in
AWIPi AWIPi 1 AIi AOi Process
AWIP = Ending Actual Work In Process
WIP
LT
OutputRate
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Input / Output Control
Day
25 26 27 28 29 30
Input
Planned (PI) 16 16 16 16 16
Actual (AI) 12 19 22 10 15
Cumulative Deviation 0 -4 -1 5 -1 -2
(ICD)
Output
Planned (PO) 16 16 16 16 16
Actual (AO) 17 15 17 18 15
Cumulative Deviation 0 1 0 1 3 2
(OCD)
WIP (Ending)
Planned (PWIP) 32 32 32 32 32
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Actual (AWIP) 32 27 31 36 28 28
Normal Situation (Under Control)
• PWIP is less than 3 or 4 times of std of the ending WIP
• Acceptable deviation is about twice the standard deviation
• Typical out of control situations:
– Queues exceed upper limit due to equipment failure,
inefficient processing, and excessive input. Solution:
decreasing input or increasing process output.
– Output is below the lower limit due to equipment
failure, inefficient processing, inadequate input, or
wrong input at assembly work centers.
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How to Control I/O
• The planned output should be realistic and should represent labor and equipment
capacity .
• A planned or actual input greater than realistic output will increase WIP and
increase MLT
• All significance deviation from planned input and output indicate operational
problems that must be identified and solved.
21
Reference
Fogarty, D.W., Blackstone Jr., J.H., and Hoffmann, T.R. (1991). Production & Inventory
Management (2nd ed.). South-Western Publishing Co., Cincinnati, Ohio, USA.
22
Latihan Soal
Production planner sedang merencanakan operation splitting (pararel scheduling
dengan penambahan masing masing operasi 1 mesin) dengan data sebagai
berikut: Routing operasi A ke B ke C. Lot size 500.
Hitunglah pengurangan manufacturing Lead time dan gambarkan dalam gantt
chart apabila splitting tanpa setup offset
Operasi Set Up Operation
(jam) time
(minutes)
A 1 4
B 2 5
C 1 6
Latihan Soal
Sebuah stasiun kerja memiliki mesin ini dioperasikan dengan kapasitas penuh dengan
tenaga kerja dan utilisasi penuh. Berikut adalah performance dari mesin tersebut (jam )
Hari 1 Hari 2 Hari 3 Hari 4
Input 42 40 42 45
Output 44 38 40 46
Begining WIP = 50
a. Berapa WIP pada Hari ke 4?
b. Berapa input di Hari 3, jika kita menginginkan WIP
hari ke 4 sebesar 40?
