Proceedings of the 2013 Industrial and Systems Engineering Research Conference

A. Krishnamurthy and W.K.V. Chan, eds.

EVALUATION OF PRODUCTION ORDERS SPLIT IN

ELECTROSTATIC PAINTING COMPANY
Abstract ID: 125
Abstract
This article aims to make a diagnosis to production scheduling system in a company dedicated to metal coating with
electrostatic paint. One of the most common problems in the operation management is to determinate the optimal
sequence to execute in a command set or in an order batch (order lots) seeking to minimize the times of use and set
up of each machine. Considering the efficient allocation, this problem concerns to schedule a set of tasks that needs
to be done for one or a group of machines arranged in correct sequence; this Sequencing problem considered a NP
(complex) when the number of machines is greater than or equal to 3. Every single task follows the same route of
manufacturing; where a machine cannot process more than one task at the same time.
The assessment of production orders with subdivisions, provides the initial stage of the characterization and
diagnosis of the production; under this conception those tasks that minimize the speed of the production flow were
identified (Bottleneck). The research results show that there are problems in the processing and delivery of the
finished material.

Keywords
Sequencing, subdivision, machine setups, Flow-Shop, Scheduling

1. Introduction
The most important part of an organization is the system behind the product, production systems are classified
according to the layout of machinery and departments within the organization. The types of production systems can
be classified by Job Shop and Flow Shop. For these cases the variables are the number of different products
manufactured by a company, the types of orders, sales volume and the frequency of repeat orders, and strongly
influence which would be a more efficient production system for a specific company.
Flow Shop System or continuous production are characterized as those in which all jobs are processed in the same
order on all machines, this is the typical situation of continuous mass production but not unique to this type of
production, the production process of a specific item can be interrupted, setup machine and restart the manufacture
of another article of the same family. Thats known as batch production.
The batch production, the production system is used by companies that produce a limited amount of a product each
time, with increasing amounts beyond the few that are made to start the company; the work can be done in this way.
That amount is called limited production lot. These methods require that the work relating to any product to be split
into parts or operations, and each operation is completed for the entire lot before taking the next step. It is in batch
production where the production control department can produce the greatest benefits, but is also in this type of
production where the greatest difficulties to organize the effective operation of the production control department.
During the manufacturing batch materials are always at rest while the batch finishes processing. Rest periods of any
unit in a lot of 'n' units added (n-1) / nx 100 percent of the total production time per batch. This is characteristic of
batch production, where the work content of the material increases irregularly and gives rise to a substantial amount
of work in process.

2. Research Overview
2.1. Objective
Characterize and evaluate programming problem and the sizing of production orders in a manufacturing system,
which works in a Flow Shop, considering the time and cost of setup machines, termination costs early or late, and
fractionating batches according to the determined sequence.

No Author 1, 2, or 3 Last Name Yet

2.2. Problem Description
AMI and Industrial Metal Finishing born in 2007 with the goal of providing innovative applications in the process of
electrostatic powder coating, allowing customers to have new options to complete their manufacturing processes.
Currently has an excellent infrastructure to advance processes 700 m2 "Just in time", complying at all times quality
parameters demanding customers. Because production orders are received where most times the color pattern
changes for each structure to paint and terms (time) of delivery are different, you may not be achieved with the
proposed delivery requirement.
2.3. Problem formulation
How can you optimize the functionality of a production system using fractions of lots of purchase orders?
2.4. Process Characteristics
The production process of electrostatic painting represents a Flow-Shop problem, each machine performs a single
task and work at the same time work (pieces) go through each machine once, the order of the machines will always
be the same.
For the specific case of this process is important to consider that the rate of the production line is constant, the
number of pieces that can feed the line is limited and the only machine that needs changes associated with each
production order is the camera of paint.

Figure 1: Diagram Production process electrostatic paint

Consider the following workflow:

Product:
o Large batches to allow continuous production.
o Sequential inflow
o Variation in the characteristics of the product is low.
o Input volume (amount) is high.
o The type of market is large (mass production).
Labor
o Type of repetitive task.

No Author 1, 2, or 3 Last Name Yet

o The skill required to perform the tasks is low.

Capital
o Investment in machinery and raw materials is high.
o They keep inventory levels low (paintings) depend on customer requirements.
o The equipment used is unique for a special purpose.
Objectives
o The cost of maintenance and supply is low.
o The quality of the final product is constant.
o The service is high as long as the production schedule.
Verification
o The production control, inventory quality and is easy to perform.
o The planning depends on the amount of production orders entered.

2.5. Methodology
There are n orders where each Kn consists Product number n, which must be processed on m machines whose
processing times per unit of output are Tij, where i and j corresponds to the machine product, orders can be executed
partially, however when a processing unit starts a machine must finish, the order fractionation means cannot
generate product fractionation beyond the maximum permissible amount is equal to the product requested by the
request. The problem is to achieve minimize the processing time of all jobs, indicating how many and what size are
the subdivisions of each order. For the production chain of AMI is to explain if optimal working with split
production orders (lots of the same order) to meet delivery times set with the customer.
Model Formulation
n_i = number jobs of type i
=

(i,j) = denote the J^th job of product i i=1,,N;j=1,,n_i

P(i,j) = time of job process j of product i
d(i,j) = delivery time j of product i
h(i,j) = keeping cost the unit of job j of product i at the in inventory per unit time
TCU(i,j) = penalty for finishing after the delivery date units job j per unit time
SC(imp) = prepare cost of moving the produce i to product g
ST(imp) = prepare time to moving the produce i to product g
Decision Variable

= ((
,(
,,(
, ! " "#
(
=
$
%
C(i,j) = completion time of job (i,j)
T(i,j) = completion time after the delivery date of job (i,j)
E(i,j) = completion time before the delivery date of job (i,j)
=

Objective Function
= " [!

& '(

[ *, [ *#

+ ,-!

[ *, [ *#

,!

[ *, [ *#

+ /-(

[ *, [ *

(1)

Subject to
-! [
6! [
,! [

0 *, [ 0 * #
*, [
*, [

*# +
*# +

+ 1! [ *, [ * # + /! [ *, [ * # -! [ *, [ * # 3 = 1, , 5
7!0, [ ( [ *, [ * # -! [ *, [ * #* 3 = 1, , 5
7!0, [-( [ *, [ * # ! [ *, [ * #* 3 = 1, , 5

(2)
(3)
(4)

No Author 1, 2, or 3 Last Name Yet

2.6. Information production orders
Consider the following information to four production orders:
The paint change in the system takes for roughly 7200 seconds. For each production order is determined by the
quantity, color, and delivery time and admission date.
Table 1. Information of the respective delivery dates and number of units outstanding for each order at the beginning of the planning period.

No Order
1
1
1
2
2
2
3
3
4

Quantity
1000
650
800
1200
1000
500
1200
1000
900

Color (i)
Red
Green
Black
Black
Blue
White
White
Black
Black

Delivery time (d)

2
2
2
3
3
3
1
1
2

Admission date
1
1
1
2
2
2
2
2
3

Table 2. Info time (in seconds) that an item remains in each section of the paint line.

Job
Pick up
Cleaning
Drying
Painting
Oven
Take down
Quality

Input (Seg)
0
720
1825
2810
3285
4270
4479

Out (Seg)
1620
2605
3080
4065
4274
6279

3. Result
We considered two scenarios with the data of table 1., in which were two political programming to meet scheduled
delivery time. In the first case, starts the production of each order according to their order of arrival, time data are
recorded below:
Table 3. Review of production orders. Case 1

No Order
1
1
1
2
2
2
3
3
4

Quantity
1000
650
800
1200
1000
500
1200
1000
900

Total hours: 29,98666667

Total days: 3,748333333

Color (i)
Red
Green
Black
Black
Blue
White
White
Black
Black

Delivery time (d)

2
2
2
3
3
3
1
1
2

Admission date
1
1
1
2
2
2
2
2
3

Duration seg
14478
28606
42884
7478
21956
35934
7478
21956
7178

Total duration (h)

4,02
7,95
11,91
2,08
6,10
9,98
2,08
6,10
1,99

No Author 1, 2, or 3 Last Name Yet

Order 1
Order 1
Order 1
Order 2
Order 2
Order 2
Order 3
Order 3
Order 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Figure 2. Total time consumed (Hours). Case 1.

For the second assessment case, the same production orders, are considered but are grouped by color regardless of
the order they belong but sorts its input to the production line with next delivery date. The results are reported
below:
Table 4. Review of production orders. Case 2

No Order
3
1
4
2
3
2
1
1
2

Quantity
1000
800
900
1200
1200
500
650
1000
1000

Color (i)
Black
Black
Black
Black
White
White
Green
Red
Blue

Delivery time (d)

1
2
2
3
1
3
2
2
3

Admission date
2
1
3
2
2
2
1
1
2

Table 5. Grouping color

Color
Black
White
Green
Red
Blue

Start
0,00
4,83
4,02
2,18
4,22

Duration seg
17378
15178
7849
14478
14478

Duration hours
4,83
4,22
2,18
4,02
4,02

Total hours: 19,26694444

Total days: 2,408368056

Black
White
Green
Red
Blue
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Figure 3. Total time consumed (Hours). Case 2.

4. Conclusion
The present investigation was able to determine the sequencing of jobs (tasks) in AMI production systems from
available resources (machinery, equipment, materials, supplies, facilities) for processing production orders. With the
above, it does minimize manufacturing downtime affecting production rates and promise to comply with customers.

No Author 1, 2, or 3 Last Name Yet

Furthermore, fractionation of production orders (following batch planning) can run jobs in less time with greater
efficiency, increasing productivity and reducing the delay, which brings benefits to AMI in use of resources
manufacturing (manpower, machinery and plant) and the increased productivity of the manufacturing line, the
company associated with this was an improvement in the yield of 35.74%, which reduces operating costs and
increases the benefit corporate.
Finally it can shown that the production strategies that are developed under flow shop techniques are useful when it
comes to problems with work areas complete tasks that can be split, providing improved solutions without major
investments in technology resources, infrastructure or knowledge management.

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