Despatching and Dynamic Machine Loading in a Wire Rope Factory: A Case Study

Scheduling of production in a wire rope factory is complicated by several features: (a) the simultaneous requirement for two types of limited resource, machines and bobbins; (b) multi‐stage production with normally two or three stranding and one or two closing operations; (c)queuing at the closing machines; the typical job splits into sub‐batches when passing from the stranding to the closing operation; these sub‐batches usually queue at the closing operations which, being faster than stranding operations, generally receive work from several queues;(d) alternative choices in the selection of machines and bobbin sizes for any given stranding or closing operation; (e) the presence of random elements in the timing of machine breakdowns and repairs. In this case study factory in a developing country, the existing control of production flows was ad hoc rather than according to a specified method. The management needed to know whether a scientific scheduling approach could significantly improve the low utilisation of machines. As a first attempt a strategy was synthesised based on well‐known concepts from the theory of scheduling in static and dynamic environments, taking into consideration certain effects of the complicating factors mentioned above. Simulation revealed that a significant improvement was possible.