Jonson's rule with examples up to four machine multi jobs

1. (Dr. M K Manik)
HOD.mechccetb@gmail.com

2. What is Production structure tree
Or
Bill of materials (BOM)
It is a hierarchical Classification of
a product
A bill of materials (BOM) is a
critical product information record
That lists the
 Raw materials
Assemblies
Components
 Parts and
The quantities of each needed to manufacture

3. Product structure tree defines the systematic sub
assemblies/Components that requires to assemble a
product

5. What are the Types of Scheduling?
Forward scheduling is planning the tasks from the
date resources become available to determine the
shipping date or the due date.
Backward scheduling is planning the tasks from the
due date or delivery date to determine the start date
and/or any changes in capacity
What is the function of production, planning and
Control (PPC)?
This functions of PPC are as follows:
Efficient utilization of material resources, people
and facilities in any undertaking through planning
Coordinating and controlling the production
activities that transform the raw material into
finished products or components as a most optimal

6. Backward schedul
ing

7. Types of Scheduling

8. What is the principle of Material-handling?
There are three basic principles of material handling
as given below:
Gravity principle: Utilize gravity to move
a material wherever practicable it will generate low
cost.
Material flow principle: Plan an operation sequence
and equipment arrangement to optimize material flow.
Simplification principle: Reduce combine or

9. What do you mean by aggregate planning
Aggregate planning: is the process of developing,
analyzing, and maintaining a preliminary,
approximate schedule of the overall operations of an
organization.
The aggregate plan generally contains:
Targeted sales forecasts,
Production levels,
Inventory levels,
And customer backlogs.
Generally speaking, aggregate planning is connected to the
budgeting process.
 Finally, aggregate planning is important because
it can help synchronize flow throughout the supply chain;
It affects costs, equipment utilization, employment levels,

10. Difference between aggregate planning and Master
scheduling

12. . So, if I make a pen,
It has a cap,
A barrel,
A spring.
And a refill.
Based on the
definition above,
the pen is an MPS
item. The cap,
barrel, spring and
refill are MRP
items.

14. Problem1. using Jonson’s sequencing algorithm, solve n-jobs× 2 machine
problem with reference to table below
Job J1 J2 J3 J4 J5
Machine-1(hrs) 7 4 3 5 2
Machine-2 (hrs) 6 2 8 9 1
i)Calculate total elapsed
time
ii)Idle time for machine two
iii)Optimal sequence
J3 J4 J1 J2 J5
Here the processing time are given as 1, 2, 3, 4, 5, 6, 7 and 8 hrs in the different
jobs worked in different machines
As per Jonson's rule lowest possible time is only 1 Hour and highest possible
process time is 8 hrs
To find out the optimal sequence time for processing all the jobs as follows:

16. As job are scheduled as per follows but now it is the time to find out the
machining time to processJob J3 J4 J1 J2 J5
Machine-1(hrs) 3 5 7 4 2
Machine-2 (hrs) 8 9 6 2 1
Machining will be starting with J3 whose process time is 3 hrs in M1 and 8 hrs in M2
•Workshop open and same time operator of M1 and M2 arrived, the operators of machine
M2
Will be seating idle till 1st job of machine M1 is not processed, They will start the job when M1 complete the
1st job.
•After completing the 1st job M1 will take 2nd job i.e. J4 just after three hours, though they will complete the
job
after 8 hrs but M2 personal till they will be busy with 1st job of J1 ,after completing that job at 11 hrs
they will
catch the 2nd Job J4 and similarly all the job will be processed till the Job J5 is not processed.

17. Problem2. using Jonson’s sequencing algorithm, solve n-jobs× 2 machine problem
with reference to table below
Job J1 J2 J3 J4 J5
Machine-1(hrs) 3 8 7 5 4
Machine-2 (hrs) 4 5 1 2 3
Machine-3 (hrs) 7 9 5 6 10
Solution: Johnson condition
1)Minimum processing time of extreme row ≥ Max. processing
time of middle row 2)Here
minimum process time of extremes row are 3 or 5
And Max. processing time of middle row 5
Hence 3 or 5 ≥ 5 then the condition is satisfied
3) Then above three machines scheduled to be converted into two
machine scheduled as per process.
i)Calculate total elapsed
time
ii)Idle time for machine
Two, Three
iii)Optimal sequence

18. As per the rule lowest processing time in M1 will be scheduled first and the lowest
time in M2 will scheduled at the end of the processing.
Hence the above jobs will be scheduled as per
As J4 job is to be processed 1st , Hence processing of all the job will be as per given
below
Jo
b
M1
(In
)
M1(out) M2(In
)
M2(out) M3(In
)
M3(out) Remarks
J4 00 0+5=5 5 5+2 =7 7 7+6=13 M2 idle for initial 5 hrs & M3
idle for initial 7 hrs
J1 5 5+3=8 8 8+4=12 13 13+7=20 M2 idle for initial 8-7=1hrs
J5 8 8+4=12 12 12+3=1
5
20 20+10=3
0
J2 12 12+8=2
0
20 20+5=2
5
30 30+9=39 M2 idle for (20-15= 5 hrs)
J3 20 20+7=2
7
27 27+1=2
8
39 39+5=44 M1 machine idle for(44-27)
17Hrs & M2 for 27-25=2 HrsTotal elapsed time is 44 hrs, M1 for 17 hrs, M2 for 13 hrs and M3 for 7 hrs were idle in

20. Solution: Four Jobs 1,2,3&4 are to be processed in each
of the four machines such as a, b ,c and d in the order given
below Process time is given in Hrs. Find minimum elapsed
time for processing all the Jobs and idle time for the
machines.JOB Ma Mb Mc Md
1 54 14 14 18
2 30 10 18 32
3 28 12 16 44
4 14 16 12 42
Solution: Johnson condition
1)Minimum processing time of extreme column ≥ Max.
processing
time of middle column.
2) Here minimum process time of extremes column are 14 or18
And Max. processing time of middle column 18
Hence 14 or18 ≥ 18 then the condition is satisfied
3) Then four machine scheduled to be converted into two
machine scheduled as per process.

22. Flow process Chart
The Flow process Chart is a simple half-text, half-picture
used for showing the steps in a process,
Using symbols to indicate the type of action being taken
and text to give details of the action.
The chart can selectively be used to show what happens to
selected people, materials or equipment.

24. Flow Process Chart

25. Bar chart or bar graph
A bar chart or bar graph is a
Chart or graph that presents categorical data with
rectangular bars with heights or lengths proportional to the
values that they represent.
The bars can be plotted vertically or horizontally.
A vertical bar chart is sometimes called a line graph.

27. Gantt chart
A Gantt chart is a type of bar chart that illustrates a project schedule.
This chart lists the tasks to be performed on the vertical axis, and time intervals
on the horizontal axis.
The width of the horizontal bars in the graph shows the duration of each activity

29. Material-handling equipment.
 Material handling equipment is
mechanical equipment used for:
 The movement,
Storage,
Control and protection of materials,
Goods and products to be shifted for the process of
manufacturing,
Distribution,
Consumption and disposal.

30. Vertical screw
Automatic Robotic Palletizing System
Static/ Co robotic operation

31. 4 Types of Materials Handling Equipment
Examples of storage and handling equipment
include:
• Racks: such as pallet racks, drive-through or drive-in racks, push-back racks, and
sliding racks
• Stacking frames: these are interlocking units that enable stacking of a load so crushing
doesn’t occur
• Shelves
• Bins and drawers
• Mezzanines: elevated floor systems that are installed between the production floor and
ceiling in order to provide additional storage space
Engineered Systems
•AS/RS: Automated Storage and Retrieval that involves racks, aisles and
shelves that are accessible by a type of mechanized shuttle system for the quick
retrieval of items.
• Conveyor systems: Automated conveyor systems carry heavy materials to
specified destinations using belts, flexible chain. It is a highly efficient equipment
to move large volumes of material quickly.
• Robotic delivery systems– These automated systems are ideal for moving
products on an assembly line or transporting goods throughout a plant or

32. Conveyer system motion contro
automatic storage and retrieval systems
Automated guided vehicle

33. Industrial Trucks
Powered industrial trucks, such as forklifts, are used to move large materials or
large quantities of materials around the manufacturing floor.
• Hand trucks– Also known as a dolly, or box cart. Hand trucks are l-shaped
box-moving handcarts with handles at one end, wheels at the base, and a
ledge to set objects on.
• Pallet jacks– These are tools are the most basic form of a forklift and used to
lift and move pallets within a warehouse.
• Pallet trucks– Manual operated or powered industrial forklifts.
• Walkie stackers– A pedestrian walk-behind stacker with a mast for lifting
pallets to heights.
• Platform trucks– These are similar to a two wheeled dolly, but with an
extended deck.
• Order picker– An electric lift truck specifically designed for filling individual
customer orders. This requires piece-part picking rather than selecting full
pallets or unit loads.
• Side loader– Automated tool similar to a fork lift that loads and unloads from
the side of the machine rather than the front.
• Automatic guided vehicles

34. Bulk Material Handling Equipment
Equipment that deals with bulk handling aids in the control and transportation of
large volumes of material either in bulk or loose form. In general the equipment
is used to move loose parts from one area of the production floor to another.
Examples of bulk material handling equipment are:
• Conveyor belts
• Stackers– Similar to forklifts, stackers help to lift and stack heavy loads on the
dock or in the warehouse.
• Reclaimers– These are large machines used to recover bulk materials from a
stockpile.
• Bucket elevators– Also known as a grain leg. These elevators haul flow able
bulk materials vertically.
• Grain elevators– This type of equipment is used to store and move grain and
other similar materials throughout a production pathway.
• Hoppers– Hoppers are a container for bulk material such as grain, that tapers
and discharges it’s materials at the bottom.
• Silos– A tower used to store grain and other materials such as coal, sawdust,
woodchips, and food products.

36. What are the factors are to be taken into
account while selecting the material handling
equipment?
Properties of the Material.
Layout and Characteristic of the building.
Production Flow.
Cost Considerations.
Nature of Operations.
Engineering Factors.
Equipment reliability.

37. Thank youTo
all