Integrated Approach for Job Scheduling and

Multi-Component Planning in a Production

System
 Contents

1. The company overview

2. Scenario description
3. Industrial Problem
4. The solution model
5. Results
AVTEC : OVERVIEW

 A part of USD 1.6 billion diversified CK Birla Group.

 Leading Independent Manufacturer of Power train and Precision

Engineered Products.

 Wide range of Engine & Transmission aggregates & components for

Automotive & Off-Highway Industry.

 State of the art infrastructure with four manufacturing units in India

and one Design & Batch production facility in Europe.
AVTEC : CUSTOMERS
 Scenario Description
Stores

Raw Raw
material material

Engine line Transmission line

Assembly line
Connecting rod line

Cylinder block line

Cylinder head line

ENGINE
Cam shaft line LINE
Crank Shaft line
 SCENARIO DISCRIPTION
• line consist 11 machines, each having different operation and cycle
time.
• Work in process inventory-290
• On the very first machine, 3 different components are processed out of
which 1 component is sent to different line.
• Three shifts are run: A and B are staffed with 8 operators, with the
night shift C ,is staffed with 2 operators.
• 2 supplier for camshaft line.
• Raw material inventory-200
 Process flow

CAM SHAFT LINE

F&C SPM LT-20 LATHE DURGA SPM G-18

COOPER-
SUPERFINISHING NTC FORTUNA
HOBBING M/C

RMC PHOSPHATING AMS

 Methodology
• Understand the base line of company
• Determine the industrial problem
• The Solution model
• Result
 Industry Problem
Machine Scheduling & Planning is not proper as it is
MS Excel based, due to which some of the
machines will stop due to unavailable of parts.
Does not able to fullfill the demand.
Wait!!!
again
 OBJECTIVE
To determine the optimum sequence of
product.
Reduce the makespan and increase the
utilisation of machine.
• Makespan- it is the time from when the
processing beginning on the first job in the lot
untill the last job is completed.
• Utilisation- it is defined as the percentage usage
of machine.
 The Solution model
• Solution model was prepared in witness
simulation software.
• What if scenario’s is-
o Sequencing of product
o demand
Modeling in Witness
 Results
• This solution model proposed the optimal sequence
of manufacturing products which aims at high
machine utilization and low makespan.
consider
Case1- Actual demand
Case 2- demand of 1 product inc. by 50%.
Case3-demand of products is greater than normal.
 80000 MAKESPAN
70000

60000 For MAKESPAN

Makespan (Sec)

50000 Optimal case is

CASE 1
40000 sequence 1
CASE 2
30000
CASE 3
20000

10000

0
1 2 3 4 5 6
Product Sequence(P)

50

45 MACHINE UTILIZATION
For UTILISATION 40
Optimal case is 35
sequence 2
% Utilization

30
CASE 1
25
CASE 2
20
CASE 3
15

10

0
1 2 3 4 5 6
Product Sequence (P)
 Extra features of model
We can determine the following at any time of
the month-
• production (output)
• Work in progress inventory
• Raw material inventory
THANK YOU