Developing an improved production planning method for a machining cell using an active-nondelay hybrid scheduling technique

Abstract

We examine the production planning and scheduling of a job shop environment of a machining cell in a manufacturing facility. This thesis addresses the scheduling limitations in the machining cell that can result in unbalanced loading and idling of machines as well as longer manufacturing lead times. A method was developed to use Microsoft Project 2007 as a tool to enable dynamic production planning and control in the shop floor. In order for a proper model to be set up, relevant observations were made and required data collected. In Microsoft Project, work orders were scheduled using an active-nondelay hybrid scheduling technique. This technique resulted in short makespan with high machine utilization, low average waiting time, and low WIP. Simulated manufacturing lead times were also reduced to an average of 1.5 weeks compared to current manufacturing lead times of about 3 - 4 weeks, showing significant improvement. Further observations revealed that machine utilizations could not be balanced further than what was achieved without changing the machine routings of the components. Alternatively, if process times on the bottleneck machine could be reduced, more balanced loads could be achieved as well. If recommendations to the company were implemented, we expect that there will be an increase in the overall machining cell output capacity and a reduction in overall manufacturing lead times and WIP levels due to shorter processing times, higher machine utilizations, and better production planning.