Mahindra University

École Centrale School of Engineering

Minor-I
Program: B. Tech. Branch: All branches Year: 4th Semester: I
Subject: Industrial Engineering (EE4125 & ME4105)

Date:19-Sep-2023 Start Time: 10:00 AM

Time Duration: 1.5 Hours Max. Marks: 100

Instructions:
1) Attempt all four question all question carry equal marks.
2) Electronic Scientific Calculators are permitted.

Marks 25
Question-1 (Johnson’s Method for scheduling 2-Machine Flow-Shop problem)

(2-Marks)
a) Briefly state the characteristics of the following type of shops, use a sketch to discuss
different types if required:
i. Flow Shop;
ii. Job Shop;
iii. Open Shop.

(23-Marks)
b) A flow shop contains two machines which process the jobs in a fixed order. There
are five jobs to be processed on the two machines. The process times of the five
jobs are given below. Here 𝒑𝟏𝒋 & 𝒑𝟐𝒋 indicates the process time of jth job on
Machine-1 and Machine-2 respectively. Work out the optimum sequence of
processing the jobs in the order Machine-1 and then Machine-2 for the optimum
value of Makespan using Johnson’s Method.

Process time 𝒑𝒊𝒋 of the Jobs 𝒋𝒋

Job (j) 𝒋𝟏 𝒋𝟐 𝒋𝟑 𝒋𝟒 𝒋𝟓

𝒑𝟏𝒋 4 7 5 1 6

𝒑𝟐𝒋 6 5 5 3 3

Arrange the following sets based on the above-mentioned process data and state
the following particulars:
 (i) Form the Leading Set-1, Trailing Set-2 and the Tie-set;
(ii) Combine the Tie-Set with the Leading Set-1 and sort the entries of 𝒑𝟏𝒋 as
per the Shortest-Processing-Time (SPT) rule;
(iii) Sort the Trailing Set-2 as per the entries of 𝒑𝟐𝒋 according to the Largest-
Processing-Time (LPT) rule;
(iv) Hence, form the Optimally Sequenced set;
(v) Work out the Directed Graph and state the value of the optimum
Makespan, 𝑪𝒎𝒂𝒙 ;
(vi) Work out the Gantt Chart indicating the idle-times. Hence indicate the
total idle-time of Machine-2.

(Marks 25)
Question-2: (Palmer’s Heuristic-Method)
(15-Marks)
a) A flow shop consists of 3-Machines on which 4-Jobs have to be scheduled in a
fixed order. The process times of the four jobs are given in the table below. In this
table 𝑝1𝑗 , 𝑝2𝑗 𝑎𝑛𝑑 𝑝3𝑗 indicate the process time of the 𝑗𝑡ℎ job on Machine-1,
Machine-2 and Machine-3 respectively. Work out a near-optimum sequence for
processing the jobs, adopting heuristically minimizing method of Makespan using
Palmer’s Method. First check the Johnson’s criteria for 3-Machine.

Job (j) J1 J2 J3 J4
p1j 7 5 8 10
p2j 9 1 6 5
p3j 4 8 4 8

Hence, calculate the following:

(i) Calculate the Minimum and the Maximum Processing Times on the 3-machines
and hence conclude whether the machines satisfy the Johnson’s criteria for 3-
machines or not.
(ii) If the Johnson’s criteria is not satisfied then calculate the slope-index and hence
decide the heuristic optimal sequence;
(iii) Hence calculate the value of Makespan, Cmax.
𝑚

𝑆𝑙𝑜𝑝𝑒 𝑖𝑛𝑑𝑒𝑥: 𝐴𝑗 = − ∑{𝑚 − (2𝑖 − 1)} 𝑝𝑖𝑗

𝑖=1

2
 (10-Marks)
b) A single machine shop has 5-jobs available at the start-of-the-day with the process
times and the due date (times) mentioned below:

J1 J2 J3 J4 J5
pj 5 7 10 6 9
dj 30 35 37 31 34

Sequence the jobs such that the Flowtime is minimized. Hence calculate the
following:
i. The Flowtime;
ii. The total amount of Tardiness.
𝐹 = 𝑛𝑝1 + (𝑛 − 1)𝑝2 + (𝑛 − 3)𝑝3 + ⋯ + 2𝑝(𝑛−1) + 𝑝𝑛

(Marks 25)
Question-3 (Inventory of Multiple-Items)
a) Consider the case of multiple item inventory where two items are ordered on the
same vendor with the following data: the yearly demand, D1, is 13,000 items per
year, and the yearly demand, D2, is 26,000 items per year, the ordering cost, Co,
of Rs.250 per order, the item costs, C1, is Rs.30 per item and the item costs, C2,
is Rs.20 per item; and the carrying cost is given in percentage value of the item
cost, i=20%, the shortage costs is also Rs.25. There is a constraint of 25 number
of ordering cycles.
b) Consider another case of multiple item inventory when the constraint is on the total
𝑄𝑗 𝐶𝑗
cost. Consider the average value of item cost to be . Hence limit the value of
2
the total cost to be maintained at Rs. 25,000/-.

Data given is summarized in the table below:

Parameter Item-1 Item-2 Unit

Annual demand, Dj 13,000 26,000 Nos.
Order cost, Co 250 250 Rs. Per order
Carrying cost percent, i% 20 20 % of item cost
Cost of each item, Cj 30 20 Rs./item
Shortage cost, Cs 25 25
(i) Constraint on total number of cycles, N 25 Nos.
(ii) Constraint on total cost, B 25,000 Rs.

Calculate the following:

Part (a): Marks (15)
(i) Calculate the Economic Order Quantity of both items without constraints;

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 (ii) Calculate the Economic Order Quantity for both items with backorder
without constraints;
(iii) For the number-constraint, calculate the Lagrange Multiplier value, 𝜆;
(iv) Calculate the order quantity for item-1 and the item-2 when the number-
constraint is imposed;
(v) Hence calculate the number of orders for Item-1 and Item-2, N1 & N2 using
the Lagrange Multiplier method when number constraint is imposed;
(vi) Does the total quantity ordered meet the constraint of N-numbers?

Part (b): Marks (10)

(i) For the total-cost constraint, calculate the Lagrange Multiplier value, 𝜆;
(ii) Calculate the order quantity for item-1 and the item-2 when the cost-
constraint is imposed;
(iii) Calculate the total cost of the items.
(iv) Does the total quantity ordered satisfy the cost-constraint?
2
𝑛
𝑖 2𝐷𝑘
𝑁𝑢𝑚𝑏𝑒𝑟 𝑐𝑜𝑛𝑠𝑡𝑟𝑎𝑖𝑛𝑡: 𝜆 = (∑ √𝐷𝑗 𝐶𝑗 ) − 𝐶𝑜 ; 𝑄𝑘 = √ (𝐶 + 𝜆); ∀ (1 ≤ 𝑘 ≤ 𝑛)
2𝑁 2 𝑖𝐶𝑘 𝑜
𝑗=1

2
𝑛
𝐶𝑜 2𝐷𝑘 𝐶𝑜
𝐶𝑜𝑠𝑡 𝑐𝑜𝑛𝑠𝑡𝑟𝑎𝑖𝑛𝑡: 𝜆 = (∑ √𝐷𝑗 𝐶𝑗 ) − 𝑖; 𝑄𝑘 = √ ; ∀ (1 ≤ 𝑘 ≤ 𝑛)
2𝐵 2 (𝑖 + 𝜆)𝐶𝑘
𝑗=1

𝐷 𝑄𝑗 𝐶𝑗 2𝐷 𝐶0
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑡𝑒𝑚𝑠, 𝑁𝑖 = 𝑄𝑖 ; 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑖𝑡𝑒𝑚𝑠 𝐵 = ∑ 𝑄∗ = √ ;
𝑖 2 𝐶𝑐

2𝐷𝐶0 (𝐶𝑠 +𝐶𝑐 ) 2𝐷𝐶0 𝐶𝑐

𝑄∗ = √ ; 𝑠∗ = √
𝐶𝑠 𝐶𝑐 𝐶𝑠 (𝐶𝑠 +𝐶𝑐)

(Marks 25)
Question-4: (Cellular Manufacturing by Rank order clustering method)
(2-Marks)
a) What should be the type of manufacturing layout for a mass-scale manufacturing
and the type of manufacturing layout for a batch-type manufacturing; discuss, in a
couple of sentences sketching the Variety-vs-Volume graph.

(23-Marks)
b) A manufacturing system was originally laid out for facilitating mass production
with a Functional Layout. A change in the business strategy requires a Cellular
Layout system to be implemented which needs the machines to be clustered.

There are, in total, 7-Machines and 8-Part Families being produced in the
manufacturing unit. Earlier the seven machines were laid out to implement the
4
 Functional Layout and are denoted as machines M1 to M7 in the incidence matrix
below. The part-families being manufactured are denoted as P1 to P8. The layout
of the machines and parts are denoted conventionally by an incidence matrix given
below:
INCIDENCE MATRIX
Part Families
P1 P2 P3 P4 P5 P6 P7 P8
M1 1 1
M2 1 1 1 1
M3
Machines

1 1 1
M4 1 1 1
M5 1 1
M6 1 1 1 1
M7 1 1

The incidence matrix is a binary matrix and the entries of the matrix are unity
where the parts visit the machine, as shown above. Therefore, the part-P1 visits
the machine M2, hence the entry in the corresponding cell of M2-P1 is 1. If the part
does not visit a particular machine then the entry is a blank.

Use the Rank Order Clustering method to cluster the incidence matrix which will
be suitable for Cellular Manufacturing process. Hence calculate the following:

(i) Work out the weights for ordering the Machines using the 2’s exponents;
(ii) Reorder the machines by sorting the weights in descending order from top to bottom;
(iii) Next work out the weights for the Part Families adopting the same method;
(iv) Reorder the Part Families by sorting the column-weights in descending order from
left to right;
(v) Hence work out the Cellular Manufacturing layout and indicate how many cells are
required;
(vi) Indicate which machines are going to be assigned to which cell and which Part
Families will be manufactured in those cells.
(vii) Are there any inter-cell moves? If yes what is the remedy?

END OF QUESTION PAPER