A comparative study of some priority dispatching rules under different shop loads

Priority dispatching rules and shop load affect job-shop performance. This paper evaluates ten different priority dispatching rules with respect to six different performance criteria under light, medium and heavy shop loads. Simulation was used as a tool to determine the rankings of the dispatching rules for a given shop load and performance criteria. A comparative study was conducted to investigate the performance of these rules. Two rules, ‘shortest processing time” and ‘least work remaining’, performed well under criteria related to the processing time. It was found that the rules that perform well in average and r.m.s. tardiness perform poorly under percentage-of-jobs-late criterion. The experimental results are conveyed with critical comments on the performance of the dispatching rules under different loading conditions of the shop.     

Dynamic selection of dispatching rules for job shop scheduling

Although the academic contribution to job shop scheduling is abundant, its impact on practice has been minimal. The most preferred approach to job shop scheduling in the industry is dispatching rules. A major criticism against dispatching rules is that there is no single universal rule. The effective choice of dispatching rules depends on the scheduling criterion and existing job shop conditions. In this paper, the authors have proposed a scheduling method based on the analytic hierarchy process, that dynamically selects the most appropriate dispatching rule from several candidate rules. The selection is based on the existing job shop conditions. This method is applied to two formal job shop problems, and the results for single dispatching rules are inferior to the method proposed in this paper.     

A STOCHASTIC DOMINANCE ORDERING OF SCHEDULING RULES

This paper applies stochastic dominance (SD) preference-ordering criteria to job shop scheduling rules. A simulation model of a hypothetical dual-constrained job shop is used to derive several measures of shop performance for a number of dispatching/due-date scheduling policies. The results presented suggest that previous research conclusions concerning the relative performance of dispatching scheduling rules may need to be reconsidered if production schedulers are risk-averse utility maximizers.     

Time completion for various dispatching rules in job shops

This study investigates the relative priority of various job shop dispatching rules for various shop utilization levels under both deterministic and stochastic assumptions with regard to processing times. The primary criterion for evaluation is that of percentage on time completion. The results indicate that an assumption of accurately predetermining actual operation times in most cases is not likely to weaken the analysis and impact of research studies which are performed using such an assumption. Also conclusions indicate that the ranking of dispatching rules according to their effectiveness varies significantly with shop utilization levels.     

The Impact of Learning and Labor Attrition on Worker Flexibility in Dual Resource Constrained Job Shops

This study investigates the impact of worker learning, worker flexibility, and labor attrition on the system performance of a dual resource constrained (DRC) job-shop. The effects of learning and labor attrition have not been previously addressed in DRC literature. Results from the study, consistent with previous literature, show that the greatest benefits are achieved when inter-departmental worker flexibility is incrementally introduced into the system. In addition, the learning environment, which depends on the initial processing time of jobs and the learning rates of workers, is shown to impact the acquisition of flexibility. The study also shows that the impact of labor attrition on system performance under certain shop conditions may be significant.     

Customer Order Scheduling in a General Job Shop Environment*

The primary objective of this study is to examine the performance of order-based dispatching rules in a general job shop, where the environmental factors are shop utilization and due date tightness. An order is defined as a collection of jobs that are shipped as a group—an order—to the customer, only on completion of the last job of the order. We specifically compare dispatching rules from past job-based studies to some rules adapted to encompass order characteristics. Standard flow time and tardiness measures are used, but in addition, we introduce measures that combine average performance with variation in an attempt to capture the performance of a majority of the orders processed in the shop. Of the 16 dispatching rules tested, our results show that four of the simple rules dominate the others. We also found that order-based rules perform better than their job-based counterparts. The study makes use of multivariate statistical analysis, in addition to the usual univariate tests, which can provide additional insight to managers using multiple criteria in their decision process.     

Effects of Erroneous Estimation of Activity Durations on Scheduling and Dispatching a Single Project*

This research examines the effects of erroneous estimation of activity durations on two different approaches for executing a resource-constrained project. The two approaches are scheduling and dispatching. This research is conducted in two phases. Phase one examines the performance of scheduling and dispatching rules in a variety of project environments. These project environments are categorized by three different factors, namely, the order strength of the precedence relationship, the level of resource availability and the size of errors in estimating the activity durations. The results show that scheduling generally produces a shorter project completion time than the heuristic dispatching rules. The results also indicate that project environment affects only the relative performance differences of the scheduling and dispatching rules but not their ranking. Phase two examines the effect of rescheduling. The results show that frequent rescheduling improves the project completion time, while the timing of rescheduling has little impact on the improvement in the project completion time. The results also identify the project environments where rescheduling is beneficial.     

Priority dispatching rules in job shops with assembly operations and random delays

The article reports the results of an experimental investigation into priority dispatching rules for a job shop with assembly operations. A job is made up of several parts, where parts are individual entities requiring several operations in different machine centres. The study was directed towards rules which attempt to co-ordinate the completion time of parts required in the same job. This mainly involves rules that utilise job status information such as operation float, number of parts completed, and number of operations remaining on each part. Results indicate that job status information improves most of the measures of performance used.     

Evaluation of scheduling strategies for a dynamic job shop in a tool-shared,flexible manufacturing environment

A two-phase approach is used to examine the impact of job scheduling rules and tool selection policies for a dynamic job shop system in a tool-shared, flexible manufacturing environment. The first phase develops a generalized simulation model and analyses 'simple' job scheduling rules and tool selection policies under various operating scenarios. The results from this investigation are then used to develop and analyse various bi-criteria rules in the second phase of this study. The results show that the scheduling rules have the most significant impact on system performance, particularly at high shop load levels. Tool selection policies affect some of the performance measures, most notably, proportion of tardy jobs, to a lesser degree. Higher machine utilizations can be obtained at higher tool duplication levels but at the expense of increased tooling costs and lower tool utilization. The results also show that using different processing time distributions may have a significant impact on shop performance.     

EVALUATING ORDER RELEASE MECHANISMS IN A JOB SHOP WITH SEQUENCE-DEPENDENT SETUP TIMES

Job-release mechanisms in job-shop control are receiving increased recognition in recent research. However, there is considerable disagreement over the benefits of sophisticated job-release mechanisms, and they remain to be tested in various operating environments. In our study, we extend previous job-releasing research by examining several job-release mechanisms in a different operating environment-a sequence-dependent setup job shop. We tested these release mechanisms, originally developed for a machine-constrained job shop, in conjunction with two groups of sequencing rules-ordinary and setup-oriented sequencing rules. We measured shop performance in terms of total cost, the sum of inventory-holding and late-penalty costs. We developed a simulation model of a nine-machine job shop for our experiment.     

AN EVALUATION OF ORDER RELEASE MECHANISMS IN A JOB-SHOP ENVIRONMENT

Controlling the flow of material on the shop floor involves releasing and dispatching jobs to meet customer due-date requirements while attempting to keep operating costs low. This report presents an evaluation of five releasing mechanisms and four dispatching rules under various levels of aggregate due-date tightness, shop cost structure, and machine utilization using simulation. The performance criteria of total shop cost, jobs on shop floor, deviation from due dates, and job queue time are collected to demonstrate the interactive nature of releasing and dispatching on shop performance.     

TWO DESIGN PRINCIPLES FOR KNOWLEDGE-BASED SYSTEMS*

This paper discusses two principles that have become increasingly important in the design of knowledge-based systems: domain-specific knowledge used to support opportunistic reasoning and hierarchical organization structure used to control and coordinate problem-solving activity. We propose a design framework that embodies these two principles and describe how this framework has been used to develop a knowledge-based job-shop scheduling system. This system, called OPIS 0, has undergone limited testing in an experimental environment modeled after an actual job shop. Its performance has been very good compared to ISIS and to the more traditional approach of constructing a schedule by dispatching jobs using the COVERT priority rule. The resulting design also shows potential for use in a decision support role.     

A comparison of dispatching rules for executing a resource-constrained project with estimated activity durations

This research examines the performance of 13 dispatching rules for executing a resource-constrained project whose estimated activity durations may differ from the actual activity durations. The dispatching rules are tested in environments characterized by three factors, namely, the order strength of the precedence relationship, the level of resource availability and the level of estimation errors in the activity durations. The results show that project environment affects only the performance differences but not the grouping of the better dispatching rules. The greatest number of successors, rank positional weight, greatest cumulative resource requirement and minimum activity slack dispatching rules consistently perform better than the other dispatching rules, unaffected by the accuracy of the estimated activity durations. This finding validates the results of many past studies in the deterministic project environment for choosing the right dispatching rule for both projects with and without well-estimated activity durations.     

A MODEL FOR SWITCHING DISPATCHING RULES IN REAL TIME IN A FLEXIBLE MANUFACTURING CELL

We model choice of dispatching rules in real time (system state dependent) as a pattern recognition problem, using a modified version of Data Envelopment Analysis. A data base of system state and performance values is created from extensive simulation, and this data base is used to train the pattern-recognition model. Our results show that the model is very effective in choosing a mix of dispatching rules over a period of time, varying the mix with system objectives, and performing better than the strategy of using fixed rules. We show how “If-Then” decision rules can be created from the model and portrayed in a decision-tree-like diagram. Since such decision rules are based on rigorous mathematical foundations, optimization will be ensured in our approach.     

Workload Control and Order Release: A Lean Solution for Make‐to‐Order Companies

Protecting throughput from variance is the key to achieving lean. Workload control (WLC) accomplishes this in complex make‐to‐order job shops by controlling lead times, capacity, and work‐in‐process (WIP). However, the concept has been dismissed by many authors who believe its order release mechanism reduces the effectiveness of shop floor dispatching and increases work center idleness, thereby also increasing job tardiness results. We show that these problems have been overcome. A WLC order release method known as “LUMS OR” (Lancaster University Management School order release) combines continuous with periodic release, allowing the release of work to be triggered between periodic releases if a work center is starving. This paper refines the method based on the literature (creating “LUMS COR” [Lancaster University Management School corrected order release]) before comparing its performance against the best‐performing purely periodic and continuous release rules across a range of flow directions, from the pure job shop to the general flow shop. Results demonstrate that LUMS COR and the continuous WLC release methods consistently outperform purely periodic release and Constant WIP. LUMS COR is considered the best solution in practice due to its excellent performance and ease of implementation. Findings have significant implications for research and practice: throughput times and job tardiness results can be improved simultaneously and order release and dispatching rules can complement each other. Thus, WLC represents an effective means of implementing lean principles in a make‐to‐order context.     

Measures of backtracking and bi-directional flow in one dimensional machine location problems

In many modern manufacturing settings, management simplifies the workflow of jobs to the greatest extent possible by avoiding a job-shop structure in favour of a generalized flow line (GFL) in which all jobs flow in a single direction (Conway et al., 1967, Theory of Scheduling (Addison-Wcsley)). Heuristics may be used to assign machines to appropriate locations in the attempt to achieve a GFL. Materials that must be transported upstream in a production line are said to ‘backtrack’. Since no backtracking occurs in a GFL, the relative amount of backtracking that does occur is an indication of the degree to which the ideal (and most productive) case is achieved. Several measures of the backtracking of materials are developed in this paper to assess the degree to which a configuration approaches the GFL. The measure for backtracking is extended to bi-directional flow problems which may occur when a GFL is not achievable because of the job routing.     

OPERATING POLICIES FOR SCHEDULING ASSEMBLED PRODUCTS

This paper describes a simulation study of the relative impact of different operating policies on performance of a hypothetical multistage production system that produces assembled products. The main objective of this study is to examine the impact of operating policy rules on system performance. Several performance criteria, including flow time and earliness and tardiness measures, were used to evaluate system performance. Results show that performance of the production system is significantly influenced by the operating policy rules, although the relative impact of the rules is dependent on the performance measure considered. Interactions between and among policy rules were also found to be important in several cases. Overall, the results indicate that much previous research in non-assembly systems can be generalized to assembly systems. Subject Areas: Scheduling, Material Requirements Planning, and Simulation.     

Fundamental Insights into Part Family Scheduling: The Single Machine Case

A simulation study was conducted to investigate the behavior of family scheduling procedures in a dynamic dispatching environment. Two scheduling rules that incorporate setup avoidance mechanisms (FCFS-F and SPT-F) and two that do not (FCFS and SPT) were applied to a single machine. The scheduling environment was varied by controlling several important factors: the machine utilization, the number of setup configurations (families), the size of the family setup times relative to the job run times, the frequency by which members of the part families were released for processing, and the distribution of job interarrival and job run times. The major results from the study are the following: (1) The degree of stability in the system is the most influential factor with respect to mean flow time and flow time variance. Under low variance service and interarrival time distributions, the impact of scheduling rule selection is minor. (2) Conversely, under unstable scheduling situations, family scheduling procedures can have a substantial impact. (3) Clear interaction effects are noticed between all factors. The environment most conducive to family scheduling is characterized by high resource utilization, low setup-to-run time ratio, few part families, and erratic job arrivals. (4) Under conditions favorable to family scheduling, setup avoiding procedures can be used to increase output while at the same time reduce the mean and variance of flow time. (5) The shortest processing time rule (SPT) performs well with respect to mean flow time when relative setup times are small. Overall, however, SPT-F generates the lowest mean flow time while FCFS-F produces the lowest flow time variance. This study shows that scheduling procedures that consider setups in their structure can outperform rules that do not under many different operating conditions. However, the magnitude of this advantage very much depends on the scheduling environment. The results also highlight the fact that it may be better to try to reshape the manufacturing environment than worry about selecting the correct scheduling rule. If the environment cannot be stabilized, then the choice of a setup avoiding procedure, allocation of families to machines, and setup reduction become important issues.     

Heterogeneous dispatching rules in job and flow shops

This paper reports the results of a study of the use of heterogeneous dispatching rules for the scheduling of work in a job shop. The methodology employed included discrete event simulation, using rule combinations determined by prior genetic algorithm searches and generalization using neural networks. Eight dispatching rules were considered, including first in first out (FIFO), earliest due date ( EDD), shortest processing time (SPT), slack/ number of operations (SLK), critical ratio (CR), modified due date (MDD), modified operation due date (MOD), and apparent tardiness cost (ATC). A three-machine job shop was studied, in which three work organizations were employed, pure flow (fixed sequence), pure job shop ( random sequence), and a hybrid shop where flow is random but with unequal probabilities. Three levels of machine loading were used and average tardiness was used as the performance measure. In most cases, modified due date and apparent tardiness cost were the best rules. The application of the best rules effected the results primarily when applied to bottleneck machines or the first machine in a pure flow shop. Nearly any other rule was acceptable on non-botdeneck machines except FIFO and CR, which consistently perform poorly. No major advantage of mixing rules was found.     

Efficient jobshop dispatching rules: Further developments

Many dispatching rules for scheduling in dynamic jobshops have been proposed over many years. The research issues in jobshop scheduling seem to be still open in the sense that no single rule has been found to be the best under all shopfloor conditions even with respect to one single measure of performance. Added to this problem, there are several measures of performance, e.g. the minimizations of mean, maximum and variance of flowtime, percentage of tardy jobs, and mean, maximum and variance of tardiness of jobs. Recent studies have reported the development of more efficient dispatching rules than the popular rules, e.g. SPT, COVERT, MOD and ATC. This study is an attempt to improve some of the recently reported dispatching rules. An extensive simulation study reveals that the improved rules developed in the present study appear to be quite effective in minimizing mean flowtime, and maximum tardiness and variance of tardiness of jobs.