ADVANCED DECISION MODELLING

Unit – V
Sequencing Problems
Introduction, Notations, Terminology and Assumptions, Processing n Jobs Through Two
Machines, Processing n Jobs Through Three Machines, Processing n Jobs Through m
Machines, Processing Two Jobs Through m Machines

Introduction
The optimal order (sequence) shows the minimum time in which jobs, equipment, people,
materials, facilities and all other resources are arranged to support the production schedules to
give low costs and high utilizations. Other objectives of calculating optimal production
schedule are minimizing customers waiting time for a product or service, meeting promised
delivery dates, keeping stock levels low providing preferred working pattern, and so on.

If n jobs are to be performed, one at a time, on each of m machines, where sequence (order) of
the machines in which each job should be performed, and the actual (or expected) time required
by the jobs on each of the machines are given, then the general sequencing problem is to find
a sequence out of (n!)m possible sequences, which minimize the total elapsed time between the
start of the job on first machine and the completion of the last job on the last machine.

In particular, if there are n = 3 jobs to be performed and m = 3 machines are to be used, then
the total number of possible sequences will be (3!)3 = 216. Theoretically, it may be possible to
find the optimum sequence but this would require a lot of computational time. Thus, one should
adopt the sequencing technique.

Notations
tij = Processing time (time required) for job i on machine j.
T = Total elapsed time for processing all the jobs. This includes idle time, if any.
Iij = Idle time on machine j from the end of job (i – 1) to the start of job i.

Terminology
 Number of Machines The number of machines refer to the number of service facilities
through which a job must pass before it is assumed to be completed.
 Processing Time This is the time required by a job on each machine.
 Processing Order This refers to the order (sequence) in which machines are required
for completing the job.
 Idle Time on a Machine This is the time during which a machine does not have a job to
process, i.e. idle time from the end of job (i – 1) to the start of job i.
 Total Elapsed Time This is the time interval between starting the first job and
completing the last job, including the idle time (if any), in a particular order by the
given set of machines.
 No Passing Rule This refers to the rule of maintaining the order in which jobs are to be
processed on given machines. For example, if n jobs are to be processed on two
machines, M1 and M2 in the order M1M2, then each job should go first to machine M1
and then to M2.

Assumptions:
1. No machine can process more than one operation at a time.
2. Each operation once started must be performed till completion.
3. Each operation must be completed before starting any other operation.
4. Time intervals for processing are independent of the order in which operations are
performed.

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5. There is only one machine of each type.

6. A job is processed as soon as possible, subject to the ordering requirements.
7. All jobs are known and are ready for processing, before the period under consideration
begins.
8. The time required to transfer the jobs between machines is negligible.
Processing n Jobs Through Two Machines:
 Processing 𝑛 jobs through two machines is a classic sequencing problem in operations
research, often addressed using Johnson’s Rule for optimal job sequencing. This
problem falls under the category of two-machine flow shop scheduling and is typically
framed to minimize the makespan, or total time required to complete all jobs.

Let there be n jobs, each of which is to be processed through two machines, M1 and M2 in the
order M 1 M 2, i.e. each job has to pass through the same sequence of operations. In other words,
a job is assigned on machine M 1 first and once processing is over on machine M 1, it is assigned
to machine M 2. If the machine M 2 is not free for processing the same job, then the job is placed
in waiting line for its turn on machine M 2, i.e. passing is not allowed.

Since passing is not allowed, therefore, machine M1 will remain busy in processing all the n
jobs one by – one, while machine M2 may remain idle waiting for the jobs to come from M1.
The idle time for both M1 and M2 may be reduced by determining an optimal sequence of n
jobs to be processed on two machines M1 and M2. The procedure suggested by Johnson for
determining the optimal sequence is summarized as follows:

Johnson Procedure:
Step 1: List the jobs along with their processing times in a table as shown below:
Processing Time Job Number
on Machine 1 2 3 … n
M1 t11 t12 t13 … t1n
M2 t21 t21 t21 … t2n

Step 2: Examine the processing times on machines M1 and M2, in each column of the table and
find the shortest processing time, i.e. find out, min. (t1j, t2j) for all j.

Step 3(a): If the shortest processing time is on machine M1, then place the job in the first
available position in the sequence. If the processing time is on machine M2, then
place the job in the last available position in the sequence.
(b) If there is a tie in selecting the minimum of all the processing times, then the following
three situations may arise:
i. If minimum processing time is same on both machines, i.e. min (t1j, t2j) = t1k = t2r, then
process the kth job first and the rth job last.
ii. If minimum processing times, t1j on machine M1 are same for more than two jobs, then
select the job corresponding to the smallest job subscript, j first.
iii. If minimum processing times, t2j on machine M2 are same for more than two jobs, then
select the job corresponding to the largest job subscript, j last.

Step 4: Cross off assigned jobs from the table. If no job remains to be assigned, then stop the
procedure and go to Step 5. Otherwise, go to Step 2.

Step 5: Calculate the idle time for machines M1 and M2:

a. Idle time for machine M1
= (Total elapsed time) – (Time when the last job in a sequence finishes on
machine M1)
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b. Idle time for machine M2

Step 6: The total elapsed time to process all jobs through two machines is given by:
Total elapsed time = Time when the nth job in a sequence finishes on machine M2.

where M2j = Time required for processing jth job on machine M2.
I2j = Idle time for machine M2 after processing (j – 1)th job and before the start of jth
job processing.

Problems:
1. There are five jobs, each of which must go through the two machines A and B in the order
AB. Processing times are given below.
Job 1 2 3 4 5
Machine A 5 1 9 3 10
Machine B 2 6 7 8 4
Determine a sequence for the five jobs that will minimize the total elapsed time.

Solution:
The shortest processing time in the given problem is 1 on machine A. So perform job 2 in the
beginning, as shown below.
2
The reduced list of processing time becomes
Job 1 3 4 5
Machine A 5 9 3 10
Machine B 2 7 8 4
Again the shortest processing time in the reduced list is 2 for job 1 on machine B. So place
job 1 as the last.
2 1
Continuing in the same manner the next reduced list is obtained as
Job 3 4 5
Machine A 9 3 10
Machine B 7 8 4
Leading to the sequence
2 4 1
and the list
Job 3 5
Machine A 9 10
Machine B 7 4
gives rise to the sequence
2 4 5 1
Finally, the optimal sequence n is obtained as
2 4 3 5 1

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Computation of the total elapsed time and the machine’s idle time in hours.
Machine A Machine B Idle Time
Job
Time In Time Out Time In Time Out A B
2 0 0+1=1 1 1+6=7 0 1
4 1 1+3=4 7 7+8=15 0 0
3 4 4+9=13 15 15+7=22 0 0
5 13 13+10=23 23 23+4=27 0 1
1 23 23+5=28 28 28+2=30 30-28=2 28-27=1
2 1+1+1=3
From the above table we find that the total elapsed time is 30 hours and the idle time on
Machine A is 2 hours and on Machine B is 3 hours.

2. Find the sequence that minimizes the total elapsed time (in hours) required to complete the
following tasks on two machines.
Task A B C D E F G H I
Machine I 2 5 4 9 6 8 7 5 4
Machine II 6 8 7 4 3 9 3 8 11
Solution:
The shortest processing time is 2 hours on machine I for job A. Hence, process this job first.
A
Deleting these jobs, we get the reduced list of processing time.
Task B C D E F G H I
Machine I 5 4 9 6 8 7 5 4
Machine II 8 7 4 3 9 3 8 11
The next minimum processing time is same for jobs E and G on machine II. The corresponding
processing time on machine I for this job is 6 and 7. The longest processing time is 7 hours. So
sequence job G at the end and E next to it.
A E G
Deleting the jobs that are sequenced, the reduced processing list is,
Task B C D F H I
Machine I 5 4 9 8 5 4
Machine II 8 7 4 9 8 11
The minimum processing time is 4 hours for job C, I and D. For job C and I it is on machine I
and for job D it is on machine II. There is a tie in sequencing jobs C and I. To break this, we
consider the corresponding time on machine II, the longest time is 11 (eleven) hours. Hence,
sequence job I in the beginning followed by job C. For job D, as it is on machine II, sequences
it last.
A I C D E G
Deleting the jobs that are sequenced, the reduced processing list is,
Task B F H
Machine I 5 8 5
Machine II 8 9 8
The next minimum processing time is 5 hours on machine I for jobs B and H, which is again a
tie. To break this, we consider the corresponding longest time on the other machine (II) and
sequence job B or H first. Finally, job F is sequenced.
The optimal sequence for this job is,
A I C B H F D E G

The total elapsed time and idle time for both the machines are calculated from the following
table.
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Machine I Machine II Idle Time

Job
Time In Time Out Time In Time Out I II
A 0 0+2=2 2 2+6=8 0 2
I 2 2+4=6 8 8+11=19 0 0
C 6 6+4=10 19 19+7=26 0 0
B 10 10+5=15 26 26+8=34 0 0
H 15 15+5=20 34 34+8=42 0 0
F 20 20+8=28 42 42+9=51 0 0
D 28 28+9=37 51 51+4=55 0 0
E 37 37+6=43 55 55+3=58 0 0
G 43 43+7=50 58 58+3=61 61-50=11 0
11 2
Total elapsed time = 61 hours.
Idle time for Machine I = 11 hours; Idle time for Machine II = 2 hours.

3. A machine operator has to perform two operations, turning and threading, on a number of
different jobs. The time required to perform these operations in minutes for each job is given.
Determine the order in which the jobs should be processed in order to minimize the total
time required to turn out all the jobs.
Jobs: 1 2 3 4 5 6
Time for turning (in min.) 3 12 5 2 9 11
Time for threading (in min). 8 10 9 6 3 1
Solution:
The smallest element is 1 in the given matrix and falls under second operation. Hence do the 6
th job last. Next smallest element is 2 for the job 4 and falls under first operation hence do the
fourth job first. Next smallest element is 3 for job 1 falls under first operation hence do the first
job second. Like this go on proceed until all jobs are over. The optimal sequence is:
4 1 3 2 5 6
Total Elapsed Time and Idle Time is given the table:
Turning Threading
Optimal Machine Idle. Job
Operation Operation
Sequence idle
In Out In Out Turning Threading
4 0 0+2=2 2 2+6=8 0 2 0
1 2 2+3=5 8 8+8=16 0 0 3
3 5 5+5=10 16 16+9=25 0 0 6
2 10 10+12=22 25 25+10=35 0 0 3
5 22 22+9=31 35 35+3=38 0 0 4
6 31 31+11=42 42 42+1=42 42-42=0 0 0
0 2

4. A book binder has one printing press, one binding machine and manuscripts of 7 different
books. The times required for performing printing and binding operations for different
books are shown below:
Book 1 2 3 4 5 6 7
Printing time (hours): 20 90 80 20 120 15 65
Binding time (hours): 25 60 75 30 90 35 50
Decide the optimum sequence of processing of books in order to minimize the total
time required to bring out all the books.

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Solution: Examine both printing and binding operations time column wise. The smallest value
is 15 printing hours for book 6. The book 6 is placed first in the sequence and cross off column
6 of the table. Repeat the procedure of finding smallest processing time column wise. Books 1
and 4 are placed in the sequence as shown below:
6 1 4
Cross off columns 1, 4 and 6 of the table. For the remaining columns 2, 3, 5 and 7 the smallest
time is 50 binding hours for book 7, so it should be sequenced in the last as shown below:
6 1 4 7
After this sequence, remaining set of printing and binding times gets reduced as follows:
Book 2 3 5
Printing time (hours): 90 80 120
Binding time (hours): 60 75 90
The smallest time in this reduced data is 60, which corresponds to binding. So book 2 is placed
in the second cell from right. Proceeding in the same manner, the optimal sequence so obtained
is shown below:
6 1 4 5 3 2 7
The total minimum elapsed time for printing and binding is given in Table
Printing Binding
Book Idle Time
Time In Time Out Time In Time Out
6 0 0+15=15 15 15 + 35 = 50 15
1 15 15+20=35 50 50 + 25 = 75 —
4 35 35+20=55 75 75 + 30 = 105 —
5 55 55+120=175 175 175 + 90 = 265 70
3 175 175+80=255 265 265 + 75 = 340 —
2 255 255+90=345 345 345 + 60 = 405 5
7 345 345+65=410 410 410 + 50 = 460 5
The minimum elapsed time, i.e. time from start of printing book 6 to binding the last book 7 is
460 hours. During this time the printing machine remains idle for 460 – 410 = 50 hours.

5. A manufacturing company processes 6 different jobs on two machines A and B. Number of

units of each job and its processing times on A and B are given in the following table. Find
the optimum sequence, the total minimum elapsed time and idle time for each machine.
No of Units on Processing Time (Hours)
Job Number
Each Job Machine A Machine B
1 3 5 8
2 4 16 7
3 2 6 11
4 5 3 5
5 2 9 7.5
6 3 6 14
Solution:
Examine processing time of machines A and B. The smallest value is 3 minutes for job 4 on
machine A. Thus job 4 is scheduled first in the sequence as shown below:
4
Repeating this procedure, the optimal sequence so obtained is shown below.
4 1 3 6 5 2
No of Units on
5 3 2 3 2 4
Each Job

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The total minimum elapsed time and idle time for each machine:
Unit Machine A Machine B Idle Times
Job
Number of Machine
Number Time In Time Out Time In Time Out
of Job (min)
4 1 0 0+3=3 3 3+5=8 3
2 3 3+3=6 8 8+5=13 0
3 6 6+3=9 18 13+5=18 0
4 9 9+3=12 23 18+5=23 0
5 12 12+3=15 28 23+5=28 0
1 1 15 15+5=20 28 28+8=36 0
2 20 20+5=25 36 36+8=44 0
3 25 25+5=30 44 44+8=52 0
3 1 30 30+6=36 52 52+11=63 0
2 36 36+6=42 63 63+11=74 0
6 1 42 42+6=48 74 74+14=88 0
2 48 48+6=54 88 88+14=102 0
3 54 54+6=60 102 102+14=116 0
5 1 60 60+9=69 116 116+7.5=123.5 0
2 69 69+9=78 123.5 123.5+7.5=131 0
2 1 78 78+16=94 131 131+7=138 0
2 94 94+16=110 138 138+7=145 0
3 110 110+16=126 145 145+7=152 0
4 126 126+16=142 152 152+7=159 0
The total elapsed time for all the jobs including the number of units is 159 minutes. However,
machine A remained idle for 17 (= 159 – 142) minutes and machine B remained idle for 3 (3
+ 152 – 152) minutes.

6. There are seven jobs, each of which has to go through the machines A and B in the order
AB. Processing times in hours are as follows:
Job 1 2 3 4 5 6 7
Machine A 3 12 15 6 10 11 9
Machine B 8 10 10 6 12 1 3
Determine a sequence of these jobs that will minimize the total elapsed time T. Also
find T and idle time for machines A and B.
Solution:
The smallest processing time is 1 hour for job 6 on machine B. Thus job 6 will be processed
last on machine A as shown below:
6
The reduced set of processing times becomes
Job 1 2 3 4 5 7
Machine A 3 12 15 6 10 9
Machine B 8 10 10 6 12 3
There are two equal minimal values: processing time of 3 hours for job 1 on machine A and
processing time of 3 hours for job 7 on machine B. According to Johnson’s rules, job 1 is
scheduled first and job 7 next to 6 as shown below:
1 7 6
The reduced set of processing times becomes
Job 2 3 4 5
Machine A 12 15 6 10
Machine B 10 10 6 12

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Again there are two equal minimal values: processing time of 6 hours for job 4 on machine A
as well as on machine B. We may choose arbitrarily to process (schedule) job 4 next to job 1
or next to job 7 as shown below:
1 4 7 6
or
1 4 7 6
The reduced set of processing times becomes
Job 2 3 5
Machine A 12 15 10
Machine B 10 10 12
There are three equal minimal values: processing time of 10 hours for job 5 on machine A and
for jobs 2 and 3 on machine B. According to rules: job 5 is scheduled next to job 4 in the first
schedule or next to job 1 in the second schedule. Job 2 then is scheduled next to job 7 in the
first schedule or next to job 4 in the second schedule. The optimal sequences are shown below:
1 4 5 3 2 7 6
or
1 5 3 2 4 7 6

The calculations for total elapsed time and idle times for machines A and B are shown in Table
Machine A Machine B Idle Time for
Job
Time In Time Out Time In Time Out Machine B
1 0 0+3=3 3 3+8=11 3
4 3 3+6=9 11 11+6=17 0
5 9 9+10=19 19 19+12=31 2
3 19 19+15=34 34 34+10=44 3
2 34 34+12=46 46 46+10=56 2
7 46 46+9=55 56 56+3=59 0
6 55 55+11=66 66 66+1=67 7
17
The minimum elapsed time is 67 hours. Idle time for machine A is 1 hours (66th–67th hour)
and for Machine B is 17 hours.

Practice Problems:
1. We have five jobs, each of which must be processed on the two machines A and B, in the
order AB. Processing times in hours are given in the table below:
Job 1 2 3 4 5
Machine A 5 1 9 3 10
Machine B 2 6 7 8 4
Determine a sequence for the five jobs that will minimize the elapsed time T.
(Ans: Optimal sequence: 2 – 4 – 3 – 5 – 1; Elapsed time = 30 hours. Idle time for
machine A = 2 hours, and for machine B = 3 hours.)
2. Find the sequence that minimizes the total elapsed time to complete the following jobs. Each
job is processed in the order (i) AB (ii)BA
Job 1 2 3 4 5 6 7
Machine A (min) 12 6 5 11 5 7 6
Machine B (min) 7 8 9 4 7 8 3
Determine the sequence for the jobs so as to minimize the process time. Also find total
elapsed time.
(Ans. (i) 3 – 5 – 2 – 6 – 1 – 1 – 7; 51 min; 3 min (ii) 7 – 4 – 1 – 6 – 2 – 5 – 3; 55 min; 9
min)

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3. A book binder has one printing press, one binding machine, and manuscripts of a number
of books. The time required to perform the printing and binding operations on each book
are shown below. The binder wishes to determine the order in which the books should be
processed, so that the total time required to process all books is minimized.
Book 1 2 3 4 5 6
Printing Time (hrs) 30 120 50 20 90 110
Binding Time (hrs) 80 100 90 60 30 10
(Ans: Optimal sequence: 4 – 1 – 3 – 2 – 5 – 6; Elapsed time = 430 hours. Idle time for
printing machine = 10 hours, and for binding machine = 40 hours.)
4. A readymade garment manufacturer has to process 7 items through two stages of production,
viz. cutting and sewing. The time taken for each of these items at the different stages is
given below in appropriate units.
Item 1 2 3 4 5 6 7
Cutting Time 5 7 3 4 6 7 12
Sewing Time 2 6 7 5 9 5 8
Find the order in which these items are to be processed through these stages so as to
minimize the total processing time.
(Ans: 3 – 4 – 5 – 7 – 2 6 – 1)
5. Five jobs are performed, first on machine X and then on machine Y. The time taken, in
hours by each job on each machine is given below:
Job A B C D E
Time on machine X 12 4 20 14 22
Time on machine Y 3 14 16 18 10
Determine the optimum sequence of jobs that minimizes the total elapsed time to complete
the jobs. Also compute the minimum time.
(Ans: Optimal sequence: B – D – C – E – A; Elapsed time = 48 hours. Idle time is 12
hours for machines X and Y each.)
6. The following table shows the machine time (in hours) for 5 jobs to be processed on two
different machines:
Job 1 2 3 4 5
Machine A (min) 3 7 4 5 7
Machine B (min) 6 2 7 3 4
Passing is not allowed. Find the optimal sequence in which jobs should be processed.
(Ans: Optimal sequence: 1 – 3 – 5 – 4 – 2; Elapsed time = 28 hours. Idle time for
machine A = 2 hours, and for machine B = 3 hours.)
7. Six jobs go over machine I first and then over II. The order of the completion of jobs has no
significance. The following table gives the machine times in hours for six jobs and the two
machines.
Job 1 2 3 4 5 6
Machine I 5 9 4 7 8 6
Machine B II 7 4 8 3 9 5
Find the sequence of the jobs that minimizes the total elapsed time for completing the jobs.
Find the minimum time by using Gantt Chart or by any other method.
(Ans: Optimal sequence: 3 – 1 – 5 – 6 – 2 – 4; Elapsed time = 35 hours.)
8. We have five jobs, each of which must go through two machines in the order AB. Their
processing times are given below:
Job 1 2 3 4 5
Machine A 10 2 18 6 20
Machine B 4 12 14 16 18
(Ans: Optimal sequence: 2 – 4 – 3 – 5 –1; Elapsed time = 60 hours.)

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Processing n Jobs Through Three Machines:

Consider n jobs (1, 2 ... n) processing on three machines M1, M2 and M3. The list of jobs with
their processing times on three machines M1, M2 and M3 is given below. An optimal solution
to this problem can be obtained if either or both of the following conditions hold good:
Processing Time Job Number
on Machine 1 2 3 … n
M1 t11 t12 t13 … t1n
M2 t21 t21 t21 … t2n
M3 t31 t31 t31 … t3n
1. The minimum processing time on machine M1 is at least as great as the maximum
processing time on machine M2, that is, min t1j ≥ max t2j, for j = 1, 2, . . ., n
2. The minimum processing time on machine M3 is at least as great as the maximum
processing time on machine M2, that is, min t3j ≥ max t2j, for j = 1, 2, . . ., n

If either or both the above conditions hold good, then the steps of the algorithm can be
summarized in the following steps:
Procedure:
Step 1: Examine the processing times of the given jobs on all three machines and if either one
or both the above conditions hold, then go to Step 2, otherwise the algorithm fails.
Step 2: Introduce two fictitious machines, say G and H with corresponding processing times
given by:
i. tGj = t1j + t2j, j = 1, 2, . . ., n
that is, the processing time on machine G is the sum of the processing times on
machines M1 and M2, and
ii. tHj = t2j + t3j, j = 1, 2, . . ., n
that is, processing time on machine H is the sum of the processing times on machines
M2 and M3.
Step 3: Determine the optimal sequence of jobs for this n – job, two machine equivalent
sequencing problem with the prescribed ordering GH in the same way as discussed
earlier.

Problems:
1. Find the sequence that minimizes the total time required in performing the following jobs
on three machines in the order ABC. Processing times (in hours) are given in the following
table:
Job 1 2 3 4 5
Machine A 8 10 6 7 11
Machine B 5 6 2 3 4
Machine C 4 9 8 6 5
Solution:
From data of the problem, we know that min (tAj) = 6; min (tCj) = 4; max (tBj) = 6. Since min
(tAj) ≥ (tBj) for all j is satisfied, the given problem can be converted into a problem of 5 jobs
and two machines. The processing time on two dummy machines G and H can be determined
by the following relationships:
tGj = tAj + tBj ; and tHj = tBj + tCj ; j = 1, 2, . . ., n
The processing times for the new problem are given below:
Job 1 2 3 4 5
Machine G 8 + 5 = 13 10 + 6 = 16 6 + 2 = 8 7 + 3 = 10 11 + 4 = 15
Machine H 5 + 4=9 6 + 9 = 15 2 + 8 = 10 3 + 6 = 9 4+5=9
When the procedure described for n jobs on two machines is applied to this problem, the
optimal sequence, so obtained, is given by:

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3 2 5 1 4
The total minimum elapsed time is given in Table
Job Machine A Machine B Machine C
Sequence Time In Time Out Time In Time Out Time In Time Out
3 0 0+6=6 6 6+2=8 8 8+8=16
2 6 6+10=16 16 16+6=22 22 22+9=31
5 16 16+11=27 27 27+4=31 31 31+5=36
1 27 27+8=35 35 35+5=40 40 40+4=44
4 35 35+7=42 42 42+3=45 45 45+6=51
Table indicates that the minimum total elapsed time is 51 hours. The idle time for machines A,
B and C is 9 (= 51 – 42) hours, 6 (= 51 – 45) hours and 9 {= (8 – 0) + (45 – 44)} hours,
respectively.

2. A machine operator has to perform three operations, turning, threading and knurling, on a
number of different jobs. The time required to perform these operations (in minutes) on each
job is known. Determine the order in which the jobs should be processed in order to
minimize the total time required to turn out all the jobs. Also find the minimum elapsed
time.
Job 1 2 3 4 5 6
Turning 3 12 5 2 9 11
Threading 8 6 4 6 3 1
Knurling 13 14 9 12 8 13
Solution:
Let us consider the three machines as A, B and C.
A = Turning; B = Threading; C = Knurling
i. Min (Ai Ci) = (2, 8)
Max (Bi) = 8
ii. Min Ai = 2 Not greater than Max Bi = 8
Min Ci = 8 ≥ Max Bi is satisfied.
Define two machines G and H
Such that, Gi = Ai + Bi
Hi = Bi + Ci
Job 1 2 3 4 5 6
Machine G 3 + 8 = 11 12 + 6 = 18 5 + 4 = 9 2+6=8 9 + 3 = 12 11 + 1 = 12
Machine H 8 + 13 =21 6 + 14 = 20 4 + 9 = 13 6 + 12 = 18 3 + 8 = 11 1 + 13 = 14
We adopt Johnson’s algorithm steps to get the optimum sequence.
4 3 1 6 2 5
To find the min. total elapsed time and idle time for machines A, B and C
Job Machine A Machine B Machine C
Sequence Time In Time Out Time In Time Out Time In Time Out
4 0 0+2=2 2 2+6=8 8 8+12=20
3 2 2+5=7 8 8+4=12 20 20+9=29
1 7 7+3=10 12 12+8=20 29 29+13=42
6 10 10+11=21 21 21+1=22 42 42+13=55
2 21 21+12=33 33 33+6=39 55 55+14=69
5 33 33+9=42 42 42+3=45 69 69+8=77
Table indicates that the minimum total elapsed time is 77 hours. The idle time for machines A,
B and C is 35 (= 77 – 42) hours, 47 {= (21 – 20) + (33 – 22) + (42 – 39) + (77 – 45)} hours
and 8 {= (8 – 0) + (69 – 69)} hours, respectively.

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 ADVANCED DECISION MODELLING

3. A readymade garments manufacturer has to process 7 items through two stages of

production, viz., cutting and sewing. The time taken for each of these items at the different
stages are given below in appropriate units:
Item 1 2 3 4 5 6 7
Cutting Process Time 5 7 3 4 6 7 12
Sewing Process Time 2 6 7 5 9 5 8
i. Find an order in which these items are to be processed through these stages so as to
minimize the total processing time.
ii. Suppose a third stage of production is added, viz. pressing and packing, with processing
time for these items as follows:
Item 1 2 3 4 5 6 7
Printing and Packing Process Time 10 12 11 13 12 10 11
Find an order in which these seven items are to be processed so as to minimize the time taken
to process all the items through all the three stages.

Solution:
Using Johnson’s optimal sequencing procedure, the optimal sequence so obtained is shown
below. The calculations for total elapsed time is shown in Table
3 4 5 7 2 6 1

Total elapsed time and idle time is shown in the table below:
Cutting Sewing Idle time
Item
Time In Time Out Time In Time Out for Sewing
3 0 0+3=3 3 3+7=10 3
4 3 3+4=7 10 10+5=15 0
5 7 7+6=13 15 15+9=24 0
7 13 13+12=25 25 25+8=33 1
6 25 25+7=32 33 33+5=38 0
1 32 32+5=37 38 38+2=40 0
The total elapsed time is 46 hours. Idle item on cutting machine is 2 (= 46 – 44) hours and on
sewing machine 4 hours.
ii. When the third stage of production (viz., pressing and packing) is added, the problem
is that of seven jobs on three machines with processing time (in hours) given below:
Item 1 2 3 4 5 6 7
Cutting, Ci 5 7 3 4 6 7 12
Sewing, Si 2 6 7 5 9 5 8
Pressing, Pi 10 12 11 13 12 10 11
Given that min (Ci) = 3, min (Pi) = 10 and max (Si) = 9. Since the condition min (Pi) ≥ max
(Si) for all i is satisfied, the problem can be converted into that of 7 jobs and 2 machines. If G
and H are two fictitious machines such that Gi = Ci + Si and Hi = Si + Pi for all i, then the
given problem can be re-written as the problem of two machines and 7 items with their
processing times given below:
Item 1 2 3 4 5 6 7
Gi 5+2=7 7 + 6 = 13 3 + 7 = 11 4+5=9 6 + 9 = 15 7 + 5 = 12 12 + 8 = 20
Hi 2 + 10 =12 6 + 12 = 18 7 + 11 = 18 5 + 13 = 18 9 + 12 = 21 5 + 10 = 15 8 + 11 = 19
Using the optimal sequence algorithm, the optimal sequence so obtained is as follows:
1 4 3 6 2 5 7
The total elapsed time for three processes is given in Table
Cutting Sewing Printing and Packing
Item
Time In Time Out Time In Time Out Time In Time Out
1 0 0+5=5 5 5+2=7 7 7+10=17
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 ADVANCED DECISION MODELLING

4 5 5+4=9 9 9+5=14 17 17+13=30

3 9 9+3=12 14 14+7=21 30 30+11=41
6 12 12+7=21 21 21+5=26 41 41+10=51
2 21 21+7=27 28 28+6=34 51 51+12=63
5 27 27+6=33 34 34+9=43 63 63+12=75
7 33 33+12=45 45 45+8=53 75 75+11=86
The minimum total elapsed time is 86 hours with idle time of 42 hours for cutting, 44 hours for
sewing and 7 hours for pressing and packing.

4. We have five jobs, each of which must go through the machines A, B and C in the order
ABC. Determine the sequence that will minimize the total elapsed time.
Job No 1 2 3 4 5
Machine A 5 7 6 9 5
Machine B 2 1 4 5 3
Machine C 3 7 5 6 7
Solution:
The optimum sequence can be obtained by converting the problem into that of two-machines,
by using the following steps.
Step 1 Find Min (Ai Ci) i = 1, 2 ... 5
= (5, 3).
Step 2 Max (Bi) = 5
Min Ai = 5 = Max Bi = 5
∴ Min Ai ≥ Max Bi is satisfied.
We convert the problem into a two-machine problem by defining two machines G and H, such
that the processing time on G and H are given by,
Gi = Ai + Bi
Hi = Bi + Ci
Job 1 2 3 4 5
G 7 8 10 14 8
H 5 8 9 11 10
We obtain the optimum sequence by using the steps in Johnson’s algorithm.
5 2 4 3 1
To find the total elapsed time and idle time on three machines.
Machine A Machine B Machine C Idle Time
Job
Time In Time Out Time In Time Out Time In Time Out A B C
5 0 0+5=5 5 5+3=8 8 8+7=15 0 5 8
2 5 5+7=12 12 12+1=13 15 15+7=22 0 4 0
4 12 12+9=21 21 21+5=26 26 26+6=32 0 8 4
3 21 21+6=27 27 27+4=31 32 32+5=37 0 1 0
1 27 27+5=32 32 32+2=34 37 37+3=40 0 1 0
Total elapsed time = 40 hours.
Idle time for machine A = 8 (40 – 32 = 8) hours;
Idle time for machine B = 25 (40 – 34 + 8+4+8+1+1 = 25) hours;
Idle time for machine C = 12 hours.

Practice Problems:
1. A machine operator has to perform three operations, turning, threading and knurling on a
number of different jobs. The time required to perform these operations (in minutes) for
each job is known and is give below:
Time (min)
Job
Turning Threading Knurling
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1 3 8 13
2 12 6 14
3 5 4 9
4 2 6 12
5 9 3 8
6 11 1 13
Determine the order in which the jobs should be processed in order to minimize the total
time required to turn out all the jobs.
(Ans: Optimal sequences: (i) 4 – 3 – 1 – 6 – 2 – 5; Elapsed time = 77 minutes; Idle time
is 35 minutes for turning operation; 49 minutes for threading operation and 8 minutes
for knurling operation.)
2. A foreman wants to process four different jobs on three machines: a shaping machine, a
drilling machine and a tapping machine, the sequence of operations being shaping – drilling
– tapping. Decide the optimal sequence for the four jobs to minimize the time elapsed from
the start of first job to the end of last job if the process times are
Job Shaping Drilling Tapping
1 13 3 18
2 18 8 4
3 8 6 13
4 23 6 8
(Ans: 3 – 1 – 4 – 2; Elapsed time = 74 minutes; Idle time is 12, 51 and 31 minutes
respectively)
3. Determine the optimal sequence of jobs that minimize the total elapsed time, based on the
following information. Processing time on machines is given in hours and passing is not
allowed.
Job No A B C D E F G
Machine M1 3 8 7 4 9 8 7
Machine M2 4 3 2 5 1 4 3
Machine M3 6 7 5 11 5 6 12
(Ans: Optimal sequences: D – G – F – B – C – E; Elapsed time = 59 hours. Idle time is
13 hours for machine M1; 37 hours for machine M2 and 7 hours for machine M3.)
4. Find the sequence, for the following eight jobs, that will minimize the total elapsed time for
the completion of all the jobs. Each job is processed in the same order CAB. Entries give
the time in hours on the machines.
Job No 1 2 3 4 5 6 7 8
A 4 6 7 4 5 3 6 2
Times on
B 8 10 7 8 11 8 9 13
machines
C 5 6 2 3 4 9 15 11
(Ans: 4 – 1 – 3 – 5 – 2 – 8 – 7 - 6; Tmin = 81 hours.)
5. We have six jobs, each of which must go through machines A, B and C in the order ABC.
Processing time (in hours) are given in the following table:
Job No 1 2 3 4 5 6
Machine A 8 3 7 2 5 1
Machine B 3 4 5 2 1 6
Machine C 8 7 6 9 10 9
Determine a sequence for the five jobs that will minimize the elapsed time t.
(Ans: Optimal sequences: (i) 4 – 5 – 2 – 6 – 1 – 3, (ii) 4 – 5 – 2 – 6 – 1 – 3; Elapsed
time = 53 hours. Idle time is 27 hours for machine A; 32 hours for machine B and 4
hours for machine C.)

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Processing n Jobs Through m Machines:

Let there be n jobs, each of which is to be processed through m machines, say M1, M2, . . .,Mm
in the order M1 M2 . . . Mm. The optimal solution to this problem can be obtained if either or
both of the following conditions hold good.
i. Min {t1j} ≥ Max {tij}; j = 2, 3, . . ., m – 1 and/or
ii. Min {tmj} ≥ Max {tij}; j = 2, 3, . . ., m – 1
that is, the minimum processing time on machines M1 and Mm is as great as the maximum
processing time on any of the remaining (m – 1) machines.
If either or both these conditions hold good, then the steps of the algorithm can be summarized
in the following steps:
Step 1: Find, Min {t1j}, Min {tmj} and Max {tij} and verify the above conditions. If either or
both the conditions mentioned above hold, then go to Step 2. Otherwise the algorithm
fails.
Step 2: Convert m-machine problem into 2-machine problem by introducing two fictitious
machines, say G and H with corresponding processing times given by:
i. tGj = t1j + t2j + . . . + tm – 1j; j = 1, 2, . . ., n
i.e. processing time of n-jobs on machine G is the sum of the processing times on machines
M1, M2, . . .,Mm–1, j
ii. tHj = t2j + t3j + . . . + tmj; j = 1, 2, . . ., n
i.e. processing time of n-jobs on machine H is the sum of the processing times on machines
M2, M3, . . ., Mm.
Step 3: The new processing times, so obtained, can now be used for solving n-job, two-machine
equivalent sequencing problem with the prescribed ordering HG in the same way as
discussed earlier.

Remarks
1. In addition to the conditions given in Step 2, if:
t2j + t3j + . . . + tm – 1, j = k (constant)
for all j = 1, 2, . . ., m – 1, then the optimal sequence can be obtained for n-jobs and two
machines M1 and Mm in the order M1Mm as usual.
2. If t1j = tmj and tGj = tHj, for all j = 1, 2, . . ., n, then the total number of optimal sequences
will be n and total minimum elapsed time in these cases would also be the same.
3. The method described above for solving n-jobs and m-machines sequencing problem
is not a general method. It is applicable only to certain problems where the minimum
cost (or time) of processing the jobs through first and/or last machine is more than or
equal to the cost (or time) of processing the jobs through the remaining machines.

Problems:
1. Four jobs 1, 2, 3 and 4 are to be processed on each of the five machines A, B, C, D and E
in the order A B C D E. Find the total minimum elapsed time if no passing of jobs is
permitted. Also find the idle time for each machine.
Jobs
Machines
1 2 3 4
A 7 6 5 8
B 5 6 4 3
C 2 4 5 3
D 3 5 6 2
E 9 10 8 6
Solution:
Since the problem is to be sequenced on five machines, we convert the problem into a two –
machine problem by adopting the following steps.
Step 1: Find Min (Ai, Ei) = (5, 6) i = 1, 2, 3, 4
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Max (Bi, Ci, Di) = (6, 5, 6)

Step 2: The inequality
Min Ei = 6 ≥ Max (Bi, Ci, Di ) is satisfied.
Therefore, we can convert the problem into a two-machine problem.
Step 3: Since Bi + Ci + Di ≠ C, where C is a fixed constant, we define two machines G and H
such that,
Gi = Ai + Bi + Ci + Di
Hi = Bi + Ci + Di + Ei i = 1, 2, 3, 4.
Job 1 2 3 4
G 17 21 20 16
H 19 25 23 24
We obtain the optimum sequence by using the steps in Johnson’s algorithm.
1 3 2 4
Total elapsed time and idle time on five machines.
Machine Machine Machine Machine Machine
Idle Time
Job A B C D E
In Out In Out In Out In Out In Out A B C D E
1 0 7 7 12 12 14 14 17 17 26 0 7 12 14 17
3 7 12 12 16 14 19 19 25 26 34 0 0 0 2 0
2 12 18 18 24 24 28 28 33 44 44 0 2 5 3 0
4 18 26 26 29 29 32 33 35 44 50 0 2 1 0 0
Total elapsed time = 50 hours.
Idle time for machine A = 24 hours; (50 – 26)
Idle time for machine B = 32 hours; (50 – 29) + 11
Idle time for machine C = 36 hours; (50 – 32) + 18
Idle time for machine D = 34 hours; (50 – 35) + 19
Idle time for machine E = 17 hours.

2. Find an optimal sequence for the following sequencing problems of four jobs and five
machines, when passing is not allowed. Its processing time (in hours) is given below:
Machines
Job
M1 M2 M3 M4 M5
A 7 5 2 3 9
B 6 6 4 5 10
C 5 4 5 6 8
D 8 3 3 2 6
Also find the total elapsed time.
Solution:
Here, Min (tM1 , j ) = 5 = tM1 ,C ; Min (tM5 , j ) = 6 = tM5 ,D
and Max {tM2 , j , tM3 , j , tM4 , j}= {6, 5, 6} respectively.
Since the condition of Min (tM5 , j ) ≥ Max otM2 , j , tM3 , j , tM4 , jt is satisfied, therefore
the given problem can be converted into a four jobs and two machines problem as G and H.
The processing times of four jobs denoted by tGj and tHj on G and H, respectively are as
follows:
Job A B C D
Machine G 17 21 20 16
Machine H 19 25 23 14

Now, using the optimal sequence algorithm, the following optimal sequence can be obtained
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A C B D
The total elapsed time, corresponding to the optimal sequence can be calculated as shown in
Table, using the individual processing times given in the original problem.
Machines
Job Sequence
M1 M2 M3 M4 M5
A 0–7 7 – 12 12 – 14 14 – 17 12 – 26
C 7 – 12 12 – 16 16 – 21 21 – 27 27 – 35
B 12 – 18 18 – 24 24 – 28 28 – 33 35 – 45
D 18 – 26 26 – 29 29 – 32 33 – 35 45 – 51
Table shows that the minimum total elapsed time is 51 hours.
The idle time for machines M1, M2, M3, M4 and M5 is 25, 33, 37 and 18 hrs, respectively.

3. Solve the following sequencing problem, giving an optimal solution when passing is not
allowed.
Job
Machine
A B C D E
M1 11 13 9 16 17
M2 6 7 5 8 4
M3 6 7 5 8 4
M4 15 8 13 9 11
Solution:
From the data of the problem it is observed that

and
Since both the conditions

are satisfied, therefore the given problem can be converted into a 5-jobs and 2-machine
problem as G and H. Further, it may be noted that, tM2,j + tM3.j = 10 (a fixed constant) for all
j ( j = 1, 2, . . ., 5). Thus, the given problem is reduced to a problem of solving 5 – jobs
through 2 – machines M1 and M4 in the order M1M4. This means machines M2 and M4 will
have no effect on the optimality of the sequences.
The processing times of 5 jobs on machine M1 and M4 is as follows:
Job A B C D E
Machine M1 11 13 9 16 17
Machine M4 15 8 13 9 11
Now, using the algorithm described earlier, the optimal sequence so obtained is as follows:
C A E D B
The total elapsed time corresponding to the optimal sequence is 83 hours as shown in Table,
using the individual processing times given in the original problem:
Machines
Job Sequence
M1 M2 M3 M4
C 0–9 9 – 14 14 – 19 19 – 32
A 9 – 20 20 – 24 24 – 30 32 – 45
E 29 – 36 36 – 42 42 – 46 46 – 57
D 36 – 52 52 – 54 54 – 62 62 – 71
B 52 – 65 65 – 68 68 – 75 75 – 83

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4. Four jobs 1, 2, 3 and 4 are to be processed on each of the five machines A, B, C, D and E in
the order ABCDE. Find the total minimum elapsed time if no passing of jobs is permitted.
Also determine idle time for each machine.
Machines
Job
A B C D E
1 7 5 2 3 9
2 6 6 4 5 10
3 5 4 5 6 8
4 8 3 3 2 6
Solution:
Here min Ai = 8, min Ei = 6 and max (Bi, Ci, Di) = (6, 5 6). Since min Ei = max (Bi, Di),
the equivalent problem involving 4 jobs 2 machines G and H becomes
Job Machine G Machine H
1 17 19
2 21 25
3 20 23
4 16 14
Examining the columns, we find that the optimal sequence is
1 3 2 4
Now calculate the total elapsed time corresponding to the optimal sequence , using the
individual processing times.
Machines
Job Sequence
A B C D E
1 0–7 7 – 12 12 – 14 14 – 17 17 – 26
3 7 – 12 12 – 16 16 – 21 21 – 27 27 – 35
2 12 – 18 18 – 24 24 – 28 28 – 33 35 – 45
4 18 – 26 26 – 29 29 – 32 33 – 35 45 – 51
Thus the minimized elapsed time is 51 time units. Idle time on machine
A = 51 – 26 = 25 time units
B = 7 + 2 + 2 + (51 – 29) = 33 time units
C = 12 + 2 + 3 + 1 + (51 – 32) = 37 time units
D = 14 + 1 + + (51 – 35) = 35 time units
And E = 17 + 1 = 18 time units

5. Determine an optimal sequence for the folowingnsequencing problem:

Job M1 M2 M3 M4
A 20 10 9 20
B 17 7 15 17
C 21 8 10 21
D 25 5 9 25
Solution:
Here min Mi1 = 17, min Mi4 = 17 and max Mi2 = 10, Mi3 = 15. Since min (Mi1, Mi4) > max (M2,
Mi3), thus Gi and Hi are two machines such that
MiG = Mi1 + Mi2 + Mi3
MiH = Mi2 + Mi3 + Mi4
Job Machine Gi Machine Hi
A 39 39
B 39 39
C 39 39
D 39 39

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Here, Since Gi = Hi, i = 1, 2, 3, 4 and Mi1 = Mi4, there will be 4! = 24 schedules each giving
us an optimal sequence. They are
ABCD ABDC ACBD ACDB ADBC ADCB
BACD BADC BCAD BCDA BDAC BDCA
CABD CADB CBAD CBDA CDAB CSBA
DABC DACB DBAC DBCA DCAB DCBA
Each of the above optimal sequence yields the same total elapsed time and given by table
`Machines
Job
M1 M2 M3 M4
A 0 – 20 20 – 30 30 – 39 39 – 59
B 20 – 37 37 – 44 44 – 59 59 – 76
C 37 – 58 58 – 66 66 – 76 76 – 97
D 58 – 83 83 – 88 88 – 97 97 – 122
Thus the total minimum elapsed time for each of the above 24 sequences is 122 hours.

Practice Problems:
1. There are four jobs each of which has to be processed on machines A, B, C, D, E and F in
the order ABCDEF. Processing time in hours is given in the table below. Find the optimal
sequencing of jobs, mimimum time required to process these jobs and the idle time for each
of the machines.
Job A B C D E F
1 15 8 6 14 6 36
2 17 7 9 10 15 22
3 21 7 12 9 11 19
4 18 6 11 12 14 17
(Ans: 1 – 2 – 4 – 3; Tmin = 133 hrs; Idle times: 62, 105, 95, 88, 87 and 49 hrs
respectively)
2. Find an optimal sequence for the following sequencing problem of four jobs and five
machines (when passing is not allowed) of which processing time (in hrs) is as follows.
Job 1 2 3 4
Machine M1 6 5 4 7
Machine M2 4 5 3 2
Machine M3 1 3 4 2
Machine M4 2 4 5 1
Machine M5 8 9 7 5
Also find the total elapsed time.
(Ans: Optimal sequence: 1 – 3 – 2 – 4; Minimum total elapsed time = 43 hours.)
3. Solve the following sequencing problem giving an optimal solution when no passing is
allowede:
Job
1 2 3 4 5
A 14 7 12 8 10
B 5 6 4 7 3
Machine
C 3 2 4 1 5
D 10 12 8 15 16
(Ans: 2 – 4 – 5 – 1 – 3; Tmin = 76 time units; Idle times: 25, 51, 61, 15 time units
respectively)
4. There are 4 jobs each of which has to go through the machines M1, M2, M3, M4, M5 and M6
in the order M1M2M3M4M5M6. Processing times in minutes are given. Determine the
sequence of these four jobs which minimizes the total elapsed time T.

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Machines
M1 M2 M3 M4 M5 M6
A 20 10 9 4 12 27
B 19 8 11 8 10 21
Jobs
C 13 7 10 7 9 17
D 22 6 5 6 10 14
(Ans: C – A – B – D; Tmin = 130 min)

Problems with 2 jobs through M Machines:

Consider two jobs, each of which is to be processed on M machines M1, M2 ……….... Mm in
two different orders. The ordering of each of the two jobs through K machines is known in
advance. Such ordering may not be the same for both the jobs. The exact or expected processing
times on all the given machines are known.
Each machine can perform only one job at a time. The objective is to determine the optimal
sequence of processing the jobs so as to minimize the total elapsed time.
The optimal sequence in this case can be obtained by making use of the graph. The procedure
is given in the following steps.
Step 1 First draw a set of axes, where the horizontal axis represents processing time on job 1
and the vertical axis represents processing time on job 2.
Step 2 Mark the processing time for job 1 and job 2 on the horizontal and vertical lines
respectively, according to the given order of machines.
Step 3 Construct various blocks starting from the origin (starting point), by pairing the same
machines until the end point.
Step 4 Draw the line starting from the origin to the end point by moving horizontally, vertically
and diagonally along a line which makes an angle of 45º with the horizontal line (base).
The horizontal segment of this line indicates that the first job is under process while
second job is idle. Similarly, the vertical line indicates that the second job is under
process while first job is idle. The diagonal segment of the line shows that the jobs are
under process simultaneously.
Step 5 An optimum path is the one that minimizes the idle time for both the jobs. Thus, we
must choose the path on which diagonal movement is maximum.
Step 6 The total elapsed time is obtained by adding the idle time for either job to the processing
time for that job.

Problems:
1. Use the graphical method to minimize the time needed to process the following jobs on the
machines shown, i.e. for each machine find the job that should be done first. Also, calculate
the total elapsed time to complete both jobs.
Machine
Sequence: A B C D E
Job 1
Time (hrs): 3 4 2 6 2
Machine
Sequence: B C A D E
Job 2
Time (hrs): 5 4 3 2 6
Solution:
The solution procedure for solving the above problem can be summarized in the following
steps:
1. Draw a set of axes at right angle to each other where x-axis represents the processing
time of job 1 on different machines while job 2 remains idle and y-axis represents
processing time of job 2 while job 1 remains idle.

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2. Mark the processing times for jobs 1 and 2 on x-axis and y-axis, respectively, according
to the given order of machines as shown in Fig

Machine A takes 3 hours for job 1 and 3 hours for job 2. Construct the rectangle for machine
A, as shown in above Fig. Similarly, construct other rectangles for machines B, C, D and E.
3. Construct various blocks starting from the origin by pairing the same machines until a
point marked ‘finished’ is obtained.
4. Draw a line starting from the origin to the point marked ‘finish’ by moving horizontally,
vertically and diagonally along a line that makes an angle of 45º with the horizontal
axis. Moving horizontally along this line indicates that the first job is under process
while the second job is idle. Similarly, moving vertically along this line indicates that
the second job is under process while the first job is idle. The diagonal movement along
this line shows that both the jobs are simultaneously under process.
Since simultaneous processing of both jobs on a machine is not possible,
therefore, a diagonal movement is not allowed. In other words, diagonal movement
through rectangle areas is not allowed.
5. An optimal path is one that minimizes the idle time for both the jobs. Thus, we must
choose the path on which diagonal movement is maximum as shown in Fig
6. Total elapsed time is obtained by adding the idle time for either job to the processing
time for that job. In this example, the idle time for the chosen path is found to be 5 hrs
and 2 hrs for jobs 1 and 2, respectively. The total elapsed time is calculated as follows:
Elapsed time, Job 1 = Processing time of job 1 + Idle time for job 1
= 17 + (2 + 3) = 22 hours
Elapsed time, Job 2 = Processing time of job 2 + Idle time for job 2
= 20 + (17 – 15) = 20 hours.

2. Use graphical method to minimize the time needed to process the following jobs on the
machines shown below, i.e., for each machine find the job that should be done first. Also
calculate the total time needed to complete both the jobs.
Sequence of Machine: A B C D E
Job 1
Time (hrs): 2 3 4 6 2
Sequence of Machine: C A D E B
Job 2
Time (hrs): 4 5 3 2 6
Solution:
The given information is shown in the figure. The shaded blocks represent the overlaps that are
to be avoided.

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An optimal path is one that minimizes the idle time for job 1 (horizontal movement). Similarly,
an optimal path is one that minimizes the idle time for job 2 (vertical movement).
For the elapsed time, we add the idle time for either of the job to the processing time for that
job.
In this problem, the idle time for the chosen path is seen to be 3 hours for job 1 and zero for
job 2.
Thus, the total elapsed time = 17 + 3 = 20 hours.

3. A workshop has six machines A. B, C, D, E and F. two jobs have to be processed through
each pf these machines. The processing time on each machine and technological sequence
of jobs is given below:
Job 1: A – C – D – B – E – F
Job 2: A – C – B – D – F – E
Time in hours on machine
A B C D E F
Job 1 20 30 10 10 25 15
Job 2 10 15 30 10 20 15
In which order should the jobs be done on each of the machines to minimize the total time
required to process the jobs? Also find the minimum elapsed time.
Solution:
Mark the processing times for job 1 and 2 on the horizontal and vertical axes according to the
given technological ordering of the machines.
Construct the rectangular blocks by pairing the sane machine as shown in the fig. Now mark a
path from the origin O to the point finish moving as much possible along 450 line.
Idle time for job 1 is 15 + 5 = 20 hours and for job 2 is 20 + 10 = 30 hours.

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Total elapsed time = 110 + 20 = 130 hours (considering job1)

= 100 + 30 = 130 hours (considering job2)

4. Two major parts P1 and P2 for a product require processing through machine centres. The
technological sequence of the parts on six machines and manufacturing times on each
machine are
Machine sequence: C A E F D B
Part P1
Time (hrs): 2 3 4 5 6 1
Machine sequence: B A E F C D
Part P2
Time (hrs): 3 2 5 3 2 3
What would be the optimal scheduling to minimize the total processing time for these two
parts? Find also the total elapsed time. For each machine specify the part that should be
processed first.
Solution:
Mark the processing times for parts P1 and P2 on the horizontal and vertical axes according to
the given technological ordering of the machines.
Construct the rectangular blocks by pairing the sane machine as shown in the fig. Now mark a
path from the origin O to the point finish moving as much possible along 450 line.

Idle time for part P1 is 2 hours and for part P2 is 2 + 2 + 1 = 5 hours.

Total elapsed time = 21 + 2 = 23 hours (considering part P1)
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= 18 + 5 = 23 hours (considering part P2)

Part that should be processed first:
Machine A: Part P1 precedes part P2
Machine B: Part P2 precedes part P1
Machine C: Part P1 precedes part P2
Machine D: Part P1 precedes part P2
Machine E: Part P1 precedes part P2
Machine F: Part P1 precedes part P2

5. Using the graphical method, calculate the minimum time needed to process jobs 1 and 2 on
five machines A, B, C, D and E, i.e. for each machine find the job that should be done first.
Also, calculate the total time needed to complete both jobs.
Machine
Sequence: A B C D E
Job 1
Time (hrs): 6 8 4 12 4
Sequence: B C A D E
Job 2
Time (hrs): 10 8 6 4 12
Solution:
Draw two axes at right angle to each other where x-axis represents the processing time of job
1 on different machines while job 2 remains idle and y-axis represents the processing time of
job 2 on different machines while job 1 remains idle.
Mark the processing times for both the jobs 1 and 2 on x-axis and y-axis, respectively according
to the given order of machines, as shown in Fig. For example, machine A takes 6 hours for job
1 as well as for job 2. Construct the rectangle for machine A as shown in Fig. 20.2. Similarly,
construct other rectangles for machines B, C, D and E.
Draw a line starting from the origin to the point marked ‘finished’ by moving horizontally,
vertically and diagonally along a line which makes an angle of 45º with the horizontal axis. A
horizontal move represents processing of job 1 while job 2 remains idle; a vertical move
represents processing of job 2 while job 1 remains idle. The diagonal movement (i.e. a 45º line)
shows that both the jobs are under process simultaneously. Since simultaneous processing of
both the jobs on a machine is not possible, therefore, diagonal movement is not allowed.
An optimal path is one that minimizes idle time for both jobs 1 and 2. This means that this path
should coincide with 45º line to the maximum extent. Thus, we must choose the path on which
diagonal movement is maximum, as shown in Fig. 20.2. The total elapsed time is obtained by
adding idle time for either job to the processing time for that job.

The idle time for the chosen path is found to be 10 (= 4 + 6) hours for job 1 and 4 hours for job
2.
The total elapsed time is calculated as follows:

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 ADVANCED DECISION MODELLING

Elapsed time, Job 1 = Processing time + Idle time = 34 + (4 + 6) = 44 hours.

Elapsed time, Job 2 = Processing time + Idle time = 40 + (32 – 28) = 44 hours.

Practice Problems:
1. Two jobs are to be processed on four machines A, B, C and D. The technological order for
these jobs on machines is as follows:
Job 1 A B C D
Job 2 D B A C
Processing times are given in the following table
Machines
A B C D
Job 1 4 6 7 3
Job 2 4 7 5 8
Find the optimal sequence of jobs on each of the machines.
(Ans: Idle time is 4 hours for job 1 and zero hour for job 2; Elapsed time for job 1 is 20
+ 4 = 24.)
2. Use graphical method to minimize the time needed to process the following jobs on
machines A, B, C, D and E. Find the total elapsed time to complete both jobs. Also find for
each job, the machine on which it should be processed first.
Machine
Sequence: A B C D E
Job 1
Time (hrs): 2 3 5 2 1
Sequence: D C A B E
Job 2
Time (hrs): 6 2 3 1 3
(Ans: Tmin = 16 hrs; A(1), B(1), C(1), D(2), E(1 or 2))
3. A machine shop has four machines, A, B, C and D. Two jobs must be processed through
each of these machines. The time (in hrs) taken on each of the machines and the necessary
sequence of jobs through the shop are given below:
Sequence: A B C D E
Job 1
Time (hrs): 2 4 5 1 2
Sequence: D E A C B
Job 2
Time (hrs): 6 4 2 3 6
Use the graphic method to obtain the total minimum elapsed time.
(Ans: Total elapsed time is 15 hours.)
4. There are two jobs to be processed through five machines A, B, C, D and E. The prescribed
technological order is
Job 1 A B C D E
Job 2 B C A D E
The process times in hours are given in table below
Job 1 Job 2
Sequence Sequence
Time Time
of Machine of Machine
A 3 B 5
B 4 C 4
C 2 A 3
D 6 D 2
E 2 E 6
Find out the optimal sequencing of the jobs on machines and minimum time required to
process these jobs.
(Ans: Tmin = 22 hrs; A(1), B(2), C(2), D(1), E(2))

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