A robust optimization model for production planning of perishable products

In this study, a robust optimization model is developed to solve production planning problems for perishable products in an uncertain environment in which the setup costs, production costs, labour costs, inventory costs, and workforce changing costs are minimized. Using the concept of postponement, the production process for perishable products is differentiated into two phases to better utilize the resources. By adjusting penalty parameters, decision-makers can determine an optimal production loading plan and better utilize resources while considering different economic growth scenarios. A case from a Hong Kong plush toy company is studied and the characteristics of perishable products are discussed. Numerical results demonstrate the robustness and effectiveness of the proposed model. An analysis of the trade-off between solution robustness and model robustness is also presented.     

A robust optimization model for agile and build-to-order supply chain planning under uncertainties

Supply chain planning as one of the most important processes within the supply chain management concept, has a great impact on firms’ success or failure. This paper considers a supply chain planning problem of an agile manufacturing company operating in a build-to-order environment under various kinds of uncertainty. An integrated optimization approach of procurement, production and distribution costs associated with the supply chain members has been taken into account. A robust optimization scenario-based approach is used to absorb the influence of uncertain parameters and variables. The formulation is a robust optimization model with the objective of minimizing the expected total supply chain cost while maintaining customer service level. The developed multi-product, multi-period, multi-echelon robust mixed-integer linear programming model is then solved using the CPLEX optimization studio and guidance related to future areas of research is given.     

A robust optimization model for multi-site production planning problem in an uncertain environment

This paper addresses the multi-site production planning problem for a multinational lingerie company in Hong Kong subject to production import/export quotas imposed by regulatory requirements of different nations, the use of manufacturing factories/locations with regard to customers’ preferences, as well as production capacity, workforce level, storage space and resource conditions at the factories. In this paper, a robust optimization model is developed to solve multi-site production planning problem with uncertainty data, in which the total costs consisting of production cost, labor cost, inventory cost, and workforce changing cost are minimized. By adjusting penalty parameters, production management can determine an optimal medium-term production strategy including the production loading plan and workforce level while considering different economic growth scenarios. The robustness and effectiveness of the developed model are demonstrated by numerical results. The trade-off between solution robustness and model robustness is also analyzed.     

Robust production planning in a manufacturing environment with random yield: A case in sawmill production planning

This paper addresses a multi-period, multi-product sawmill production planning problem where the yields of processes are random variables due to non-homogeneous quality of raw materials (logs). In order to determine the production plans with robust customer service level, robust optimization approach is applied. Two robust optimization models with different variability measures are proposed, which can be selected based on the tradeoff between the expected backorder/inventory cost and the decision maker risk aversion level about the variability of customer service level. The implementation results of the proposed approach for a realistic-scale sawmill example highlights the significance of using robust optimization in generating more robust production plans in the uncertain environments compared with stochastic programming.     

Ranking robustness and its application to evacuation planning

We present a new approach to handle uncertain combinatorial optimization problems that uses solution ranking procedures to determine the degree of robustness of a solution. Unlike classic concepts for robust optimization, our approach is not purely based on absolute quantitative performance, but also includes qualitative aspects that are of major importance for the decision maker.We discuss the two variants, solution ranking and objective ranking robustness, in more detail, presenting problem complexities and solution approaches. Using an uncertain shortest path problem as a computational example, the potential of our approach is demonstrated in the context of evacuation planning due to river flooding.     

Formulating and solving production planning problems

Production planning problems frequently involve the assignment of jobs or operations to machines. The simplest model of this problem is the well known assignment problem (AP). However, due to simplifying assumptions this model does not provide implementable solutions for many actual production planning problems. Extensions of the simple assignment model known as the generalized assignment problem (GAP) and the multi-resource generalized assignment problem (MRGAP) have been developed to overcome this difficulty. This paper presents an extension of the (MRGAP) to allow splitting individual batches across multiple machines, while considering the effect of setup times and setup costs. The extension is important for many actual production planning problems, including ones in the injection molding industry and in the metal cutting industry. We formulate models which are logical extensions of previous models which ignored batch splitting for the problem we address. We then give different formulations and suggest adaptations of a genetic algorithm (GA) and simulated annealing (SA). A systematic evaluation of these algorithms, as well as a Lagrangian relaxation (LR) approach, is presented.     

A stochastic programming approach for multi-site aggregate production planning

Production planning problems play a vital role in the supply chain management area, by which decision makers can determine the production loading plan—consisting of the quantity of production and the workforce level at each production plant—to fulfil market demand. This paper addresses the production planning problem with additional constraints, such as production plant preference selection. To deal with the uncertain demand data, a stochastic programming approach is proposed to determine optimal medium-term production loading plans under an uncertain environment. A set of data from a multinational lingerie company in Hong Kong is used to demonstrate the robustness and effectiveness of the proposed model. An analysis of the probability distribution of economic demand assumptions is performed. The impact of unit shortage costs on the total cost is also analysed.     

Service level robustness in stochastic production planning under random machine breakdowns

In this paper, we consider a multi-period, multi-product production planning problem where the production rate and the customer service level are random variables due to machine breakdowns. In order to determine robust production plans, constraints are introduced in the stochastic capacitated lot-sizing problem to ensure that a pre-specified customer service level is met with high probability. The probability of meeting a service level is evaluated by using the first passage time theory of a Wiener process to a boundary. A two-step optimization approach is proposed to solve the developed model. In the first step, the mean-value deterministic model is solved. Then, a method is proposed in the second step to improve the probability of meeting service level. The resulting approach has the advantage of not being a scenario-based one. It is shown that substantial improvements in service level robustness are often possible with minimal increases in expected cost.     

Integrated production scheduling and distribution planning in dairy supply chain by hybrid modelling

In this paper we address the production scheduling and distribution planning problem in a yoghurt production line of the multi-product dairy plants. A mixed integer linear programming model is developed for the considered problem. The objective function aims to maximize the benefit by considering the shelf life dependent pricing component and costs such as processing, setup, storage, overtime, backlogging, and transportation costs. Key features of the model include sequence dependent setup times, minimum and maximum lot sizes, overtime, shelf life requirements, machine speeds, dedicated production lines, typically arising in the dairy industry. The model obtains the optimal production plan for each product type, on each production line, in each period together with the delivery plan. The hybrid modelling approach is adopted to explore the dynamic behavior of the real world system. In the hybrid approach, operation time is considered as a dynamic factor and it is adjusted by the results of the simulation and optimization model iteratively. Thus, more realistic solutions are obtained for the scheduling problem in yoghurt industry by using the iterative hybrid optimization-simulation procedure. The efficiency and applicability of the proposed model and approach are demonstrated in a case study for a leading dairy manufacturing company in Turkey.     

Decision support for strategic energy planning: A robust optimization framework

Optimization models for long-term energy planning often feature many uncertain inputs, which can be handled using robust optimization. However, uncertainty is seldom accounted for in the energy planning practice, and robust optimization applications in this field normally consider only a few uncertain parameters. A reason for this gap between energy practice and stochastic modeling is that large-scale energy models often present features—such as multiplied uncertain parameters in the objective and many uncertainties in the constraints—which make it difficult to develop generalized and tractable robust formulations. In this paper, we address these limiting features to provide a complete robust optimization framework allowing the consideration of all uncertain parameters in energy models. We also introduce an original approach to make use of the obtained robust formulations for decision support and provide a case study of a national energy system for validation.     

A production scheduling heuristic for an electronics manufacturer with sequence-dependent setup costs

In this paper, we develop a three-step heuristic to address a production scheduling problem at a high volume assemble-to-order electronics manufacturer. The heuristic provides a solution for scheduling multiple product families on parallel, identical production lines so as to minimize setup costs. The heuristic involves assignment, sequencing, and time scheduling steps, with an optimization approach developed for each step. For the most complex step, the sequencing step, we develop a greedy randomized adaptive search procedure (GRASP). We compare the setup costs resulting from the use of our scheduling heuristic against a heuristic previously developed and implemented at the electronics manufacturer that assumes approximately equal, sequence-independent, setup costs. By explicitly considering the sequence-dependent setup costs and applying GRASP, our empirical results show a reduction in setups costs for an entire factory of 14–21% with a range of single production line reductions from 0% to 49%.     

Robust optimal dynamic production/pricing policies in a closed-loop system

Hybrid manufacturing/remanufacturing systems play a key role in implementing closed-loop production systems which have been considered due to increasingly environmental concerns and latent profit of used products. Manufacturing and remanufacturing rates, selling price of new products, and acquisition price of used products are the most critical variables to optimize in such hybrid systems. In this paper, we develop a dynamic production/pricing problem, in which decisions should be made in each period confronting with uncertain demand and return. The manufacturer is able to control the demand and return by adjusting selling price and acquisition price respectively, also she can stock inventories of used and new products to deal with uncertainties. Modeling a nominal profit maximization problem, we go through robust optimization approach to reformulate it for the uncertain case. Final robust optimization model is obtained as a quadratic programming model over discrete periods which can be solved by optimization packages of QP. A numerical example is defined and sensitivity analysis is performed on both basic parameters and parameters associated with uncertainty to create managerial views.     

联合订货下基于ø-散度的多产品库存鲁棒优化模型

针对多产品联合库存决策问题,在市场需求不确定条件下,建立了考虑联合订货成本的多产品库存鲁棒优化模型。针对不确定市场需求,采用一系列未知概率的离散情景进行描述,给出了基于最小最大准则的鲁棒对应模型,并证明了(s,S)库存策略的最优性。进一步,在仅知多产品市场需求历史数据基础上,采用基于ø-散度的数据驱动方法构建了满足一定置信度要求的关于未知需求概率分布的不确定集。在此基础上,为获得(s,S)库存策略的相关参数,运用拉格朗日对偶方法将所建模型等价转化为易于求解的数学规划问题。最后,通过数值计算分析了Kullback-Leibler散度和Cressie-Read散度以及不同的置信水平下的多产品库存绩效,并将其与真实分布下应用鲁棒库存策略得到的库存绩效进行对比。结果表明,需求分布信息的缺失虽然会导致一定的库存绩效损失,但损失值很小,表明基于文中方法得到的库存策略能够有效抑制需求不确定性扰动,具有良好的鲁棒性。     

Robust Optimization for Power Systems Capacity Expansion under Uncertainty

We develop a robust optimization model for planning power system capacity expansion in the face of uncertain power demand. The model generates capacity expansion plans that are both solution and model robust. That is, the optimal solution from the model is ‘almost’ optimal for any realization of the demand scenarios (i.e. solution robustness). Furthermore, the optimal solution has reduced excess capacity for any realization of the scenarios (i.e. model robustness). Experience with a characteristic test problem illustrates not only the unavoidable trade-offs between solution and model robustness, but also the effectiveness of the model in controlling the sensitivity of its solution to the uncertain input data. The experiments also illustrate the differences of robust optimization from the classical stochastic programming formulation.     

一种求解柔性资源约束前摄性项目调度问题的启发式算法

在不确定环境中,一个具有较高鲁棒性的进度计划可以保证项目的稳定实施。考虑到现实中资源可能具有多种技能,会对制定鲁棒性较高进度计划的过程产生影响,因此本文研究了柔性资源约束下前摄性项目调度优化问题。首先界定研究问题;然后从鲁棒性最大化的视角出发,构建了研究问题的优化模型,在对模型进行分析的基础上将其分解为经典鲁棒优化和资源技能分配两个子模型;随后设计了求解问题的基于削峰算法的启发式算法;最后用一个实际案例验证了算法有效性,并分析了关键参数对进度计划鲁棒性的影响,得到如下结论:项目进度计划鲁棒性随着项目工期的延长、资源可用量的增加或资源柔性的提高而增大。     

求解一类逆鲁棒优化问题的牛顿型扰动方法

逆优化问题是指通过调整目标函数和约束中的某些参数使得已知的一个解成为参数调整后的优化问题的最优解.本文考虑求解一类逆鲁棒优化问题.首先,我们将该问题转化为带有一个线性等式约束,一个二阶锥互补约束和一个线性互补约束的极小化问题;其次,通过一类扰动方法来对转化后的极小化问题进行求解,然后利用带Armijo线搜索的非精确牛顿法求解每一个扰动问题.最后,通过数值实验验证该方法行之有效.     

New models for the robust shortest path problem: complexity, resolution and generalization

In optimization, it is common to deal with uncertain and inaccurate factors which make it difficult to assign a single value to each parameter in the model. It may be more suitable to assign a set of values to each uncertain parameter. A scenario is defined as a realization of the uncertain parameters. In this context, a robust solution has to be as good as possible on a majority of scenarios and never be too bad. Such characterization admits numerous possible interpretations and therefore gives rise to various approaches of robustness. These approaches differ from each other depending on models used to represent uncertain factors, on methodology used to measure robustness, and finally on analysis and design of solution methods. In this paper, we focus on the application of a recent criterion for the shortest path problem with uncertain arc lengths. We first present two usual uncertainty models: the interval model and the discrete scenario set model. For each model, we then apply a criterion, called bw-robustness (originally proposed by B. Roy) which defines a new measure of robustness. According to each uncertainty model, we propose a formulation in terms of large scale integer linear program. Furthermore, we analyze the theoretical complexity of the resulting problems. Our computational experiments perform on a set of large scale graphs. By observing the results, we can conclude that the approved solvers, e.g. Cplex, are able to solve the mathematical models proposed which are promising for robustness analysis. In the end, we show that our formulations can be applied to the general linear program in which the objective function includes uncertain coefficients.     

A robust optimization model for dynamic market with uncertain production cost

This article presents a robust optimization formulation for dealing with production cost uncertainty in an oligopolistic market scenario. It is not uncommon that players in the market face an equilibrium selling price but uncertain production costs. We show that, based on a nominal problem, the robust optimization formulation can be derived as a variational inequality with control and state variables. This convenient approach may be applied for computing optimal solutions efficiently, which help manufacturers dramatically and rapidly reform production and distribution schedules such that they can compete in the market successfully.     

Robust economic order quantity models

In this paper, we study the classical economic order quantity (EOQ) model under significant. In particular, the problem under consideration is the economic order quantity model with the input data of the demand rate, the order cost, and the holding cost rate being uncertain. A robustness approach based on scenario characterization of the input data is adopted to describe the uncertainties. The aim of the approach is to find an inventory policy that performs well under all realizable input data scenarios. An efficient linear time algorithm is devised to find the robust decisions. Analytical results are obtained for the case where input data are defined in continuous intervals. Comparisons on performances between the robust decisions and the stochastic optimization decisions are conducted. The results demonstrate the advantages of robustness approach.     

到达不确定呼叫中心人员配置的鲁棒优化模型

针对呼叫中心实际运营中顾客到达不确定的特点,采用鲁棒离散优化方法,建立呼叫中心人员配置的鲁棒模型。利用对偶原理将鲁棒模型转换易于求解的线性鲁棒对等式,通过调节模型中的鲁棒参数来权衡鲁棒解的保守性与最优性之间的关系,计算模型中约束违背概率上限来表示鲁棒解的可靠性。通过现实呼叫中心数据算例,验证了模型的有效性,分析了不同鲁棒水平下各时间段服务人员配置规律,以及系统最小成本与违背概率之间的权衡关系。最后,对到达扰动系数进行了敏感性分析。