Intelligent Manufacturing Planning System Using Dispatch Rules: A Case Study in Roofing Manufacturing Industry

Abstract

This paper aims to investigate the optimal sorting of orders reflecting on the material changing lead time over the machines in the roofing manufacturing industry. Specifically, a number of jobs were sorted together based on the material used and then consolidated for subsequent processes, i.e., assigned to the corresponding machines. To achieve the optimal sorting for the received orders, a combinatorial dispatch rule was proposed, which were Earliest Due Date (EDD), First In First Out (FIFO), and Shortest Processing Time (SPT). The sequence of orders organized by the scheduling algorithm was able to minimize the changing material lead time and also maximize the number of orders to be scheduled in the production. Consequently, on-time delivery could be achieved. Tests based on real data have been set up to evaluate the performance of the proposed algorithm in sorting the received orders. As a result, the proposed algorithm has successfully reduced the material changing lead time by 47.3% and 40% in the first and second tests, respectively.

Keywords

• manufacturing industry
• dispatch rule
• Earliest Due Date (EDD)
• First In First Out (FIFO)
• Shortest Processing Time (SPT)
• Make-To-Order (MTO)