CHAPTER -4

PROBLEM DESCRIPTION

4.1 Motivation to Present Work

In the preliminary investigation, it was observed that most of the machines are
idle. The reasons for the most of the machines to remain idle have been investigated
through the work sampling approach. Pilot study with 95% confidence level and ±5%
margin of error is considered. Initial random observations for pilot study is taken as
100 to get percentage of working (q) and idle times (p). Using the values obtained
from pilot study i.e. percentage of working and idle times and margin of error, actual
no. of. observations required for random study is computed for the central job shop,
to get the existing performance of the job shop and was observed that the maximum
machine utilization for most of the machines is less than 45%.
It was found that the allotment of jobs on the machines is not proper in most of
the cases. The jobs are being loaded randomly as and when they arrive without taking
into consideration the better scheduling rules for given conditions. Due to this most of
the jobs are delayed at the same time most of the machines also remain idle.
The present project makes an attempt to provide better scheduling rule by making
use of inter-arrival time patterns, processing times, due date settings data observed in
the job shop while conducting work sampling study. The inter-arrival times,
processing times, pilot study and random study are shown in the following tables.

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 OBSERVATIONS

TABLE-1

ARRIVAL TIMES OF JOBS BETWEEN 9:00AM TO 5:00 PM

S.NO WORK ORDER DESCRIPTION DATE OF TIME OF ARRIVAL

NO. ARRIVAL ARRIVAL PATTERN
(MIN)
1 BF-333 Flange coupling of Auxiliary Hoist 02-02-2006 9:33AM 33
2 BF-1041 Coupling for M-41 Fan 02-02-2006 10;02 AM 29
3 BF-1079 Worm Shaft (POS-7) 02-02-2006 10:35 AM 33
4 BF-1080 Worm Shaft (POS-6) 02-02-2006 11:06 AM 31
5 BF-1091 KA-1 Through G/Box input pinion shaft 02-02-2006 11:36 AM 30
6 MMSM-109 Driving Axle for D710 Wheel 02-02-2006 12:O7 AM 31
7 MMSM-475 Turbine Shaft Repair 02-02-2006 12:39 AM 32
8 CCCD-904 Repair of conveyer pulleys 02-02-2006 01:11 PM 30
9 CRMP-280 Modified extended Tongue (Left) 02-02-2006 01:41 PM 30
10 EMD-183 DN600 Sliphon Flange 02-02-2006 02:12 PM 31
11 ENMD-299 Motor side coupling 02-02-2006 02:43 PM 31
12 ENMD-300 Pump side coupling 02-02-2006 03:15 PM 32
13 ENMD-175 Shaft for Impeller Fan DE-11.1 02-02-2006 03:47 PM 32
14 ESF-149 Hammer Pallets Machining 02-02-2006 04:18 PM 31
15 ESF-300 Machining of Power Hack saw Drive Wheel 02-02-2006 04:48 PM 30
16 LMMM-195 Hub For U Shaft of BV5 03-02-2006 9:32 AM 32
17 LMMM-737 Liner for Modified Base Frame 03-02-2006 10:04 AM 32
18 RMHP-1003 Machining of Bore for Body Structure 03-02-2006 10:36 AM 31
19 RMHP-1004 Manufacturing Sleeve for Bogie 03-02-2006 11:07 AM 31
20 RMHP-1005 Manufacturing Distance piece for Bogie 03-02-2006 11:37 AM 30

TOTAL 622

MEAN
31.1 min

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 TABLE-2

PROCESSING TIMES OF JOBS

S.NO WORK ORDER DESCRIPTION PROCESSING

NO. TIMES
(MIN)
1 BF-333 Flange coupling of Auxiliary Hoist 22
2 BF-1041 Coupling for M-41 Fan 24
3 BF-1079 Worm Shaft (POS-7) 23
4 BF-1080 Worm Shaft (POS-6) 19
5 BF-1091 KA-1 Through G/Box input pinion shaft 18
6 MMSM-109 Driving Axle for D710 Wheel 21
7 MMSM-475 Turbine Shaft Repair 23
8 CCCD-904 Repair of conveyer pulleys 20
9 CRMP-280 Modified extended Tongue (Left) 15
10 EMD-183 DN600 Sliphon Flange 17
11 ENMD-299 Motor side coupling 18
12 ENMD-300 Pump side coupling 20
13 ENMD-175 Shaft for Impeller Fan DE-11.1 21
14 ESF-149 Hammer Pallets Machining 15
15 ESF-300 Machining of Power Hack saw Drive Wheel 20
16 LMMM-195 Hub For U Shaft of BV5 17
17 LMMM-737 Liner for Modified Base Frame 19
18 RMHP-1003 Machining of Bore for Body Structure 17
19 RMHP-1004 Manufacturing Sleeve for Bogie 18
20 RMHP-1005 Manufacturing Distance piece for Bogie 26

TOTAL 393

MEAN 19.65MIN

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 TABLE-3

PILOT STUDY ON GENERAL SHIFT MACHINES

Taking Initial Random Observations as 100

Machine Bay Machine description % of % of No. Of observations (n)

No. working idle required for random
time (q) time (p) study for ±5% margin
of error
38A AB Plano milling machine, Table 45 55 396
size 4000*1600 Sqmm.
22A AB Radial Drilling Machine 12 88 169
14A BC Medium Duty Lathes, 30 70 336
Swing 1000mm*admit 3000
mm
14B BC Medium Duty Lathes, 35 65 364
Swing 1000mm*admit 3000
mm
14D BC Medium Duty Lathes, 43 57 393
Swing 1000mm*admit 3000
mm
28A BC Plano milling machine, Table 33 67 354
size 1000*3000 Sqmm.
28B BC Plano milling machine, Table 40 60 384
size 1000*3000 Sqmm.
33B BC Universal Milling machine 35 65 364
33C BC Universal Milling machine 26 74 308
46 BC Gear Hobbing machine 79 21 266
16I CD Light Duty Lathes, 21 79 266
Swing 500mm*admit 1500 mm
16J CD Light Duty Lathes, 31 69 343
Swing 500mm*admit 1500 mm
16K CD Light Duty Lathes, 21 79 266
Swing 500mm*admit 1500 mm
16P CD Light Duty Lathes, 25 75 300
Swing 500mm*admit 1500 mm
16R CD Light Duty Lathes, 34 66 359
Swing 500mm*admit 1500 mm
16O CD Light Duty Lathes, 23 77 284
Swing 500mm*admit 1500 mm
23A CD Column Drill 42 58 390
22E CD Radial Drill 30 70 336

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 TABLE-4

RANDOM STUDY ON GENERAL SHIFT MACHINES

Machine Bay Machine description No. Of observations (n) % of % of idle

No. obtained from pilot study working time (P)
for ±5% margin of error time (Q)
38A AB Plano milling machine, Table 396 42 58
size 4000*1600 Sqmm.
22A AB Radial Drilling Machine 169 15 85
14A BC Medium Duty Lathes, 336 30 70
Swing 1000mm*admit 3000
mm
14B BC Medium Duty Lathes, 364 35 65
Swing 1000mm*admit 3000
mm
14D BC Medium Duty Lathes, 393 47 53
Swing 1000mm*admit 3000
mm
28A BC Plano milling machine, Table 354 33 67
size 1000*3000 Sqmm.
28B BC Plano milling machine, Table 384 40 60
size 1000*3000 Sqmm.
33B BC Universal Milling machine 364 38 62
33C BC Universal Milling machine 308 26 74
46 BC Gear Hobbing machine 266 83 17
16I CD Light Duty Lathes, 266 21 79
Swing 500mm*admit 1500
mm
16J CD Light Duty Lathes, 343 35 65
Swing 500mm*admit 1500
mm
16K CD Light Duty Lathes, 266 21 79
Swing 500mm*admit 1500
mm
16P CD Light Duty Lathes, 300 30 70
Swing 500mm*admit 1500
mm
16R CD Light Duty Lathes, 359 37 63
Swing 500mm*admit 1500
mm
16O CD Light Duty Lathes, 284 23 77
Swing 500mm*admit 1500
mm
23A CD Column Drill 390 40 60
22E CD Radial Drill 336 30 70

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4.2 Scope of Present Work

In a dynamic job shop (chosen job shop), jobs for processing arrive at the system
at different points of times with certain specified inter-arrival time distributions such
as exponential distribution. The jobs may require a certain number of operations to be
performed in a particular sequence on specified machines.
A job proceeds to the machine for the first operation, if the machine is free, then
the processing of that job starts. Otherwise, i.e., if the machine is busy, the job joins in
the queue in front of the machine. In this manner the jobs may form queues in front of
the machines. Whenever a machine becomes free, a job from the machine’s queue is
taken up for processing based up on a scheduling rule. The scheduling rule makes use
of the attributes of the job such as operation times, due date, number of the operations
etc. In order to select the scheduling rule for optimizing a given performance
measure, detailed simulation experimentation is often required. The present project
makes an attempt in this direction.
In the present work, the scheduling problem in a general job shop production
system is considered. A comparative analysis of the relative performance of the
different sets of scheduling rules has been made.
More specifically, the present work involves the following.
 Understand the various aspects of job shop scheduling problem.
 Determine the experimental conditions such as inter-arrival time of jobs,
due date settings etc.
 Identify scheduling rules and performance measures. Totally, 8 scheduling
rules and the performance measures such as mean flow time, mean
tardiness and percentage of tardy jobs have been considered.
 Develop a simulation model using the general purpose programming
language Visual C++.
 Conduct the experiments for the various settings of experimental
conditions and using different scheduling rules.
 Perform analysis of the results obtained.

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