Application of the Theory of Constraints (TOC) to Batch Scheduling in Process Industry

Abstract

This paper presents a practical daily batch scheduling problem at one leading global food company for multi-stage, multi-batch scheduling with no-wait. After investigated different approaches of both traditional optimization and simulation technique, the concept of the Theory of Constraint (TOC) was adopted to identify the bottleneck activity first, then the problem was converted from a multi-product batch scheduling to a multi-project critical chain based scheduling, and the scheduling technique of Drum-buffer-rope (DBR) in TOC was specifically adopted to solve the company’s routine scheduling problem. With the help of professional computer software and customized output, it is very efficient and effective for the daily scheduling personnel to operate due to no complicated algorithm or programming involved. This new TOC approach has been implemented in its several plants in headquarter and is expected to expand to other plants.