The document discusses shop floor control in manufacturing. It covers key concepts like loading, scheduling, dispatching, and monitoring in shop floor control. Loading involves checking resource availability and assigning work orders. Scheduling develops detailed production schedules using techniques like forward/backward scheduling and priority rules. Dispatching implements schedules based on real-time shop floor status. Monitoring tracks work progress, throughput, quality and provides performance feedback using tools like dashboards and Gantt charts. Overall, the document provides an overview of the main functions and processes involved in shop floor control systems that plan and control work flow on the manufacturing plant floor.

1. Arif Rahman – The Production Systems
Slide 9
Shop Floor Control
Arif Rahman, ST MT

2. Arif Rahman – The Production Systems
Information Barriers

3. Arif Rahman – The Production Systems
Manufacturing Network Interdependencies

4. Arif Rahman – The Production Systems
System Scope Scalability

5. Arif Rahman – The Production Systems
Enterprise Resource Planning (ERP)
Manufacturing Execution System (MES)
Shop Floor Control (SFC)
ERP - MES - SFC

6. Arif Rahman – The Production Systems
ERP - MES - SFC

7. Arif Rahman – The Production Systems
ERP - MES - SFC

8. Arif Rahman – The Production Systems
ERP - MES - SFC
Business Planning
and Logistics
Manufacturing
Operations & Control
Process
Control
Enterprise
Resource
Planning
(ERP)
Manufacturing
Execution
System
(MES)
Shop Floor
Control
(SFC)
Level 4
Level 3
Level 0,1,2

9. Arif Rahman – The Production Systems
ERP - MES - SFC

10. Arif Rahman – The Production Systems
LEVEL 4:
Establishing the basic plant schedule –
production, material use, delivery and shipping;
Determining inventory level
Time frame : months, weeks, days
LEVEL 3:
Work flow, recipe control to produce the
desired end products; Maintaining records
and optimizing the production process.
Time frame : days, shifts, hours, minutesLEVEL 2:
Monitoring, supervisory control and
automated control of the production
process
Time frame : minutes, seconds
LEVEL 1:
Sensing the production
process and manipulating it
Time frame : minutes,
seconds, miliseconds
LEVEL 0:
The actual production process
Time frame : minutes, seconds,
miliseconds

11. Arif Rahman – The Production Systems
Production Planning and Shop Floor Control
Resource
planning
Sales and operations
planning
Demand
management
Master production
scheduling
Detailed material
planning
Material and
capacity plans
Shop-floor scheduling
and control (SFC)
Purchasing
Detailed capacity
planning
Vendor scheduling
and follow-up
Order release

12. Arif Rahman – The Production Systems
Purchasing is responsible for establishing
and controlling flow of raw materials into
the factory
Shop Floor Control is responsible for
planning & controlling flow of work through
the factory
Purchasing and Shop Floor Control

13. Arif Rahman – The Production Systems
Work Flow Control
WIP
Tracking
Throughput
Tracking
Status
Monitoring
Work
Forecasting
Capacity
Feedback
Quality
Control
Work Flow
Control

14. Arif Rahman – The Production Systems
Status monitoring
¤ the state of resources (inactive, idle, busy, failed)
¤ the state of order (queue, in progress, done,
postponed, cancelled)
Throughput tracking
¤ Elapsed orders
¤ Remaining orders
WIP tracking
¤ Locates the order progress
¤ Estimates remaining time for completion
¤ Indicates imbalanced production (insufficient capacity
of bottleneck)
Work Flow Control

15. Arif Rahman – The Production Systems
Quality control
¤ Performance and reliability of process
¤ Quality of products, including defect rate
Capacity feedback
¤ Scheduled time and utilization
¤ Available time and excess capacity
Work forecasting
Work Flow Control

16. Arif Rahman – The Production Systems
Schedule and monitor day-to-day production at
the factory,
Reviewed and revised daily
Also called production activity control (PAC)
Performed by production control department
¤ Loading - check availability of material, machines, and labor
¤ Scheduling - release work orders to shop and issue dispatch lists for
production lines, machines and labor
¤ Dispatching - implement the schedule taking into account the current status
of the production system (orders releasing)
¤ Monitoring - maintain progress reports on each job until it is complete
Shop Floor Control

17. Arif Rahman – The Production Systems
Shop Floor Control Platform

18. Arif Rahman – The Production Systems
Shop Floor Control - Two Sided Perspective

19. Arif Rahman – The Production Systems
Illustration of Shop Floor Control

20. Arif Rahman – The Production Systems
Data Flow in Shop Floor Control

21. Arif Rahman – The Production Systems
Shop Floor Control
Tooling available
Material available
Machine available
Labor available
Assignment & utilization
LOADING
Sequencing
Lot splitting
Route changing
Method engineering
Overlapping
SCHEDULING
Job selection
Job assignment
Priority control
Setup & exchange
Process execution
DISPATCHING
WIP track
Progress monitor
Quality control
Troughput evaluate
Completion estimate
MONITORING
Status reporting
Performance achievement
Deviations
Unexpected matter
Changed situation
FEEDBACK
SHOP
FLOOR
CONTROL

22. Arif Rahman – The Production Systems
Loading

23. Arif Rahman – The Production Systems
Notice the work order releases from monthly or
weekly production planning
Check availability of material, machines, and
labor
Process of assigning work to available resources
Perform work with most efficient resources
Loading

24. Arif Rahman – The Production Systems
Routing specifies the operation, its duration, and the
work center performing the work
Lead times typically consist of four elements
¤ Run time
¤ Setup time
¤ Loading-unloading time
¤ Transfer and handling time
Inventory and purchasing order presents the
availability of material
Availability of resources are illustrated by :
¤ On-going schedule or previous schedule
¤ Maintenance schedule
¤ Employee leave calendar
Loading - Basic Input

25. Arif Rahman – The Production Systems
Use assignment method of operation research to
determine allocation
Hungarian Algorithm
Loading - Assignment
1. Perform row reductions
– subtract minimum value in each row
from all other row values
2. Perform column reductions
– subtract minimum value in each
column from all other column values
3. Cross out all zeros in matrix
– use minimum number of horizontal
and vertical lines
4. If number of lines equals number of
rows in matrix, then optimum
solution has been found. Make
assignments where zeros appear
‾ Else modify matrix:
‾ subtract minimum uncrossed value
from all uncrossed values
‾ add it to all cells where two lines
intersect
‾ other values in matrix remain
unchanged
4. Repeat steps 3 and 4 until
optimum solution is reached

26. Arif Rahman – The Production Systems
Initial Matrix
Row Reduction
Loading - Assignment
Order
Resource O1 O2 O3 O4
R1 10 5 6 10
R2 6 2 4 6
R3 7 6 5 6
R4 9 5 4 10
Order
Resource O1 O2 O3 O4
R1 5 0 1 5
R2 4 0 2 4
R3 2 1 0 1
R4 5 1 0 6

27. Arif Rahman – The Production Systems
Column reduction
Cover all zeros
Loading - Assignment
Order
Resource O1 O2 O3 O4
R1 3 0 1 4
R2 2 0 2 3
R3 0 1 0 0
R4 3 1 0 5
Order
Resource O1 O2 O3 O4
R1 3 0 1 4
R2 2 0 2 3
R3 0 1 0 0
R4 3 1 0 5
+2

28. Arif Rahman – The Production Systems
Modify Matrix
Cover all zeros
Loading - Assignment
Order
Resource O1 O2 O3 O4
R1 3 0 1 4
R2 2 0 2 3
R3 2 3 2 2
R4 3 1 0 5
Order
Resource O1 O2 O3 O4
R1 1 0 1 2
R2 0 0 2 1
R3 0 3 2 0
R4 1 1 0 3

29. Arif Rahman – The Production Systems
Final Matrix
Solution
Loading - Assignment
Order
Resource O1 O2 O3 O4
R1 1 0 1 2
R2 0 0 2 1
R3 0 3 2 0
R4 1 1 0 3
Order
Resource O1 O2 O3 O4
R1 10 5 6 10
R2 6 2 4 6
R3 7 6 5 6
R4 9 5 4 10

30. Arif Rahman – The Production Systems
Loading - Assignment

31. Arif Rahman – The Production Systems
The allocation of jobs to work centers is
called shop loading
Loading methods :
¤ Infinite loading – It does not take into consideration
the limited capacity of the facility. Scheduling with
unlimited capacity
¤ Finite loading – assigns jobs to work centers
without regard to capacity limitations. Scheduling with
limited capacity. It takes into consideration the limited
capacity of each work center.
Shop Loading

32. Arif Rahman – The Production Systems
Infinite loading
¤ Assigns jobs to work centers without regard to
capacity
¤ Unless excessive capacity exists, long queues
occur
Finite loading
¤ Uses work center capacity to schedule orders
¤ Popular scheduling approach
¤ Integral part of CRP
Shop Loading

33. Arif Rahman – The Production Systems
Shop Loading
Capacity
Time period651 2 3 4
under
over
INFINITE LOADING (without regard for capacity)

34. Arif Rahman – The Production Systems
Shop Loading
FINITE LOADING (never to exceed capacity)
Capacity
Time perid651 2 3 4

35. Arif Rahman – The Production Systems
Scheduling

36. Arif Rahman – The Production Systems
Developing detailed schedule based on
timely knowledge and data which will
ensure that all the production
requirements are fulfilled
Allocating orders, equipment, and
personnel to work center or other specified
locations
Scheduling

37. Arif Rahman – The Production Systems
Scheduling Objectives
Meet the due dates
Minimize lateness
Minimize response time
Minimize completion time
Minimize time in the
system
Minimize overtime
Maximize machine or
labor utilization
Minimize idle time
Minimize work-in-process
inventory

38. Arif Rahman – The Production Systems
Flow time (completion time)
¤ Time for a job to flow through system
Makespan
¤ Time for a group of jobs to be completed
Tardiness
¤ Difference between a late job’s due date and
its completion time
Number of tardy jobs
¤ The number of late jobs exceed due date
Scheduling Performance Measures

39. Arif Rahman – The Production Systems
ASAP (as soon as possible) or ALAP (as late as possible)
List scheduling
Force directed algorithms
Path based
Enumerative methods
Heuristic algorithm
Heuristic search techniques (percolation algorithms,
simulated annealing, tabu search, genetic algorithm,
artificial intelligence and others)
Analytical models (linear programming, dynamic
programming, queueing model, simulation)
Resource or Time Constrained Approach

40. Arif Rahman – The Production Systems
FCFS - first-come, first-served
LCFS - last come, first served
CUSTPR - highest customer priority
SETUP - similar required setups
SPT - shortest processing time
LPT - longest processing time
EDD - earliest due date
SLACK - Minimum slack
CR - smallest critical ratio
Random order
Priority Rule of Scheduling

41. Arif Rahman – The Production Systems
Minimum Slack
Smallest Critical Ratio
Priority Rule of Scheduling
Slack = time remaining – processing time
= (due date – today’s date) – processing time
Critical Ratio =
time remaining
processing time
=
(due date – today’s date)
processing time

42. Arif Rahman – The Production Systems
There are two scheduling techniques to assigning
due dates to specific jobs:
Forward scheduling – an approach to scheduling that
starts from the present time and schedules each job to
start at the earliest possible moment.
¤ Advantages: time buffers,
¤ Disadvantages: increase work in process inventory
Backward scheduling – an approach to scheduling
that starts from desired due date and works backward.
¤ Advantages: decrease the work in process inventory;
¤ Disadvantages: no time buffers
Forward - Backward Scheduling

43. Arif Rahman – The Production Systems
Forward scheduling
¤ Jobs are given earliest available time slot in operation
¤ excessive WIP usually results
Backward scheduling
¤ Start with promise date and work backward through
operations reviewing lead times to determine when a
job has to pass through each operation
¤ Less WIP but must have accurate lead times
Forward - Backward Scheduling

44. Arif Rahman – The Production Systems
Forward - Backward Scheduling
Today Due Date
B
Forward Scheduling
Today Due Date
B E
Backward Scheduling
E

45. Arif Rahman – The Production Systems
Visual scheduling tool
Graphical representation of scheduling
information
Show dependencies between tasks,
personnel, and other resources allocations
Track progress towards completion
Gantt Chart

46. Arif Rahman – The Production Systems
Gantt Chart
Task 1
Task 2
Task 3
Time
Resource 3
Resource 2
Resource 1
J1
J1
J1
Time
J2
J2
J2
Resource 3
Resource 2
Resource 1
J3
J1 J4
Time
J2 J5
J6
J7
J8
J9
Less Information of Resources
Serial Resources
Parallel Resources
Multi stage with Parallel Resources each Stage
Resource 3
Resource 2
Resource 1
J3
J1 J4
Time
J2 J5
J6
J7
J8
J9
Resource 3
Resource 2
Resource 1
J3
J1
J4
Time
J2
J5
J6 J7
J8 J9
duration

47. Arif Rahman – The Production Systems
Gantt Chart
Task Dependencies :
¤ Start to Start (SS). Predecessor must start
before Successor can start.
¤ Finish to Start (FS). Predecessor must finish
before Successor can start.
¤ Start to Finish (SF). Predecessor must start
before Successor can finish.
¤ Finish to Finish (FF). Predecessor must
finish before Successor can finish.

48. Arif Rahman – The Production Systems
Gantt Chart

49. Arif Rahman – The Production Systems
Lag is the amount of time whereby a
successor activity will be delayed with
respect to a predecessor activity.
Lead is the amount of time whereby a
successor activity can be advanced with
respect to a predecessor activity.
Gantt Chart

50. Arif Rahman – The Production Systems
Dispatching

51. Arif Rahman – The Production Systems
Dispatching is sending the order to a
particular resource or destination for a
particular reason to execute and finish it
quickly and efficiently without wasting
time.
It implements the schedule taking into
account the current status of the
production system
Dispatching

52. Arif Rahman – The Production Systems
Local rule. It is concerned with the local available
information.
Global rule. It is used to dispatch jobs using all
information available on the shop floor.
Static rule. It do not change over time, and ignore the
status of the shop floor.
Dynamic rule. It is time dependent, and change
according to the status of the shop floor.
Forecast rule. It is used to give priority to jobs
according to what the job is going to come across in the
future and according to the situation at the local
machine.
Dispatching Rule

53. Arif Rahman – The Production Systems
Timely Production Board

54. Arif Rahman – The Production Systems
To Do List Board

55. Arif Rahman – The Production Systems
Monitoring

56. Arif Rahman – The Production Systems
Information System
Performance Dashboard
Gantt Chart
Monitoring

57. Arif Rahman – The Production Systems
Information System

58. Arif Rahman – The Production Systems
Performance Dashboard

59. Arif Rahman – The Production Systems
Gantt Chart

60. Arif Rahman – The Production Systems 60
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