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Simulating and Scheduling the Job Shop
CreateASoft, Inc.
The Process Improvement Company
  • Joint Development

The Ohio State University
CreateASoft, Inc.

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Properties of a Job Shop
  • High Mix – Custom orders
    -- One of a kind.
    -- Customized specifications.
  • Skilled resources.
  • Relatively Low Volume.
  • Variable Demand.
  • High machine utilizations.
  • A constant struggle to meet delivery schedules.
Why Schedule?
  • Better utilization of equipment / resources.
  • Predictable lead time.
    -- When can I deliver?
  • Improve efficiency/reduce change ove.r
    -- Part grouping
  • Manufacturing cost reduction.
  • Improved workforce moral.
We are lean, do we needto schedule ?
  • What’s in the shop ?
    -- A pull system ?
    -- A 5S system ?
    -- Single piece/kanban pull, ….
  • Job shop lean is different than Toyota lean
  • A leaner environment provides
    -- Cost reduction
    -- Lower WIP
  • Does that translate to a better schedule?
Schedule Requirement
  • What is required to create a schedule?
    -- Current state of the shop
    -- Resource and equipment status
    -- Future orders
        - Future orders
        - Quantity
  • Shop Layout
  • Outside services, raw material availability
  • Historical equipment performance (MTBF/MTBR)
What to expect?
  • A scheduler should generate
    -- Sequence of orders in the shop
    -- State of the shop at different time intervals
    -- Gantt chart with respective delivery dates
    -- Expected Process activity
    -- Expected resource load

Types of schedule
  • Static scheduling
    -- Based on historical data of the equipment
    -- Does not include resource efficiency
    -- Based on averages or distributions.
    -- Not very reliable.
    -- In use in most shops.
    -- Does not use current equipment loading/WIP as part of the schedule
    -- Dependent on Resource data entry
Active Scheduling
  • Active Scheduling includes:
    -- Work orders to be processed
    -- Active WIP, what’s happening in the shop
    -- Current Downtimes
    -- Run daily or weekly
    -- Extensive, time consuming operation
Dynamic Scheduling
  • Constant view of the shop
    -- Live monitoring of activities
    -- Automatic pull of data
    -- Automatic look ahead for potential problems and machine downtime
    -- Dynamic reroute of parts if machine is down
    -- Constant update of forecasted delivery date.
    -- Most accurate, minimum user interaction
Achieving dynamic scheduling
  • Requires an environment that can forecast the future based on current data
    -- Simulation….
    -- With dynamic connectivity to existing systems
       - For orders, current status, WIP levels, locations…
  • Must get accurate representation of the shop data with minimum reliance on personnel
    -- Active RFID / Wi-Fi based tags with minimum overhead.
Implementing Dynamic Scheduling
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CreateASoft, Inc.
The Process Improvement Company
Simulating and Scheduling the Job Shop.
Q & A

Hosni Adra
CreateASoft, Inc.
(630) 428-2850 x205

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