Flow-shop scheduling with setup and assembly operations

A scheduling model for a production system including machining, setup and assembly operations is considered. Production of a number of single-item products is ordered. Each product is made by assembling a set of several different parts. First, the parts are manufactured in a flow-shop consisting of multiple machines. Then, they are assembled into products on a single assembly stage. Setup operation and setup time are needed when a machine starts processing the parts or it changes items. The operations are partitioned into several blocks. Each block consists of the machining operations, the setup operations, and the assembly operation(s) for one or several products. The parts of the same item in a block are processed successively. The objective function is the mean completion time for all products. We consider a problem to partition the operations into blocks and sequence the parts in each block so as to minimize the objective function. Solution procedures using pseudo-dynamic programming and a branch-and-bound method are proposed. Computational experiments are carried out to evaluate the performance of the solution procedures. It has been found that a good near-optimal schedule is obtained efficiently by the proposed solution procedures.     

A hybrid two-stage transportation and batch scheduling problem

We study the coordinated scheduling problem of hybrid batch production on a single batching machine and two-stage transportation connecting the production, where there is a crane available in the first-stage transportation that transports jobs from the warehouse to the machine and there is a vehicle available in the second-stage transportation to deliver jobs from the machine to the customer. As the job to be carried out is big and heavy in the steel industry, it is reasonable assumed that both the crane and the vehicle have unit capacity. The batching machine processes a batch of jobs simultaneously. Each batch occur a setup cost. The objective is to minimize the sum of the makespan and the total setup cost. We prove that this problem is strongly NP-hard. A polynomial time algorithm is proposed for a case where the job transportation times are identical on the crane or the vehicle. An efficient heuristic algorithm for the general problem is constructed and its tight worst-case bound is analyzed. In order to further verify the performance of the proposed heuristics, we develop a lower bound on the optimal objective function. Computational experiments show that the heuristic algorithm performs well on randomly generated problem instances.     

Balancing Workloads and Minimizing Set-up Costs in the Parallel Processing Shop

This paper presents an optimal scheduling algorithm for minimizing set-up costs in the parallel processing shop while meeting workload balancing restrictions.There are M independent batch type jobs which have sequence dependent set-up costs and N parallel processing machines. Each of the M jobs must be processed on exactly one of the N available machines. It is desirable to minimize total changeover costs with the restriction that each machine workload assignment T _n be within P units of the average machine assignment. The paper describes a static problem in which all jobs are available at time zero. The sequence dependent change over costs are identical for each machine. An extension of the algorithm handles nonidentical processor problems.A combinatorial programming approach to the problem is used. For the special case of identical processors, the problem can be treated as a multi-salesman travelling salesman problem. A general branch and bound algorithm and numerical results are given.     

Multi-family scheduling in a two-machine reentrant flow shop with setups

This paper considers a two-machine multi-family scheduling problem with reentrant production flows. The problem consists of two machines, M₁ and M₂, and each job has the processing route (M₁, M₂, M₁, M₂). There are identical jobs in the same family and the jobs in the same family are processed in succession. Each machine needs a setup time before the first job in a family is processed. The objective is to minimize the maximum completion time. Examples of such a problem occur in the bridge construction, semiconductor industry and job processing on numerical controlled machines, where they usually require that the jobs are reprocessed once and there are identical jobs in the same family. This problem is shown to be NP-hard. A branch-and-bound algorithm is proposed, and computational experiments are provided.     

Simultaneous lotsizing and scheduling on parallel machines

This paper addresses the simultaneous lotsizing and scheduling of several products on non-identical parallel production lines (heterogeneous machines). The limited capacity of the production lines may be further reduced by sequence dependent setup times. Deterministic, dynamic demand of standard products has to be met without back-logging with the objective of minimizing sequence dependent setup, holding and production costs.The problem is heuristically solved by combining the local search metastrategies threshold accepting (TA) and simulated annealing (SA), respectively, with dual reoptimization. Such a solution approach has already proved to be successful for the single machine case. The solution quality and computational performance of the new heuristics are tested by means of real-world problems gathered from industry.     

Single machine scheduling problem with multiple due windows assignment in a group technology

We consider group scheduling problem on a single machine with multiple due windows assignment. Jobs are divided into groups in advance according to their processing similarities, and all jobs of the same group are required to be processed contiguously on the machine in order to achieve production efficiency and save time/money resource. A sequence-independent setup time precedes the processing of each group. The goal is to determine the optimal sequence for both groups and jobs, together with an optimal combination of the due windows assignment strategy so as to minimize the total of earliness, tardiness and due windows related costs. We give an \(O(n\log n)\) time algorithm for the problem.     

Heuristic Approaches for a Scheduling Problem in the Plastic Molding Department of an Audio Company

A production scheduling problem for making plastic molds of hi-fi models is considered. The objective is to minimize the total machine makespan in the presence of due dates, variable lot size, multiple machine types, sequence dependent, machine dependent setup times, and inventory limits. Goal programming and load balancing are applied to select the set of machine types and assign mold types to machines, resulting in a set of single-machine scheduling problems. A mixed-integer program (MIP) is formulated for the general problem but could solve only small instances. A single-machine scheduling heuristic is designed to adopt a production sequence from a travelling salesman solution. The start time of every cycle is determined by a simplified MIP. Production cycles are defined to equalize the stockout times of mold types. A post-processing step reduces the number of setups in the last cycle. Results using real-life data are promising. Characteristics giving rise to high machine utilization are discussed.     

Two-machine flow shop scheduling problem with an outsourcing option

We consider a two-machine flow shop problem in which each job is processed through an in-house system or outsourced to a subcontractor. A schedule is established for the in-house jobs, and performance is measured by the makespan. Jobs processed by subcontractors require paying an outsourcing cost. The objective is to minimize the sum of the makespan and total outsourcing costs. We show that the problem is NP-hard in the ordinary sense. We consider a special case in which each job has a processing requirement, and each machine a characteristic value. In this case, the time a job occupies a machine is equal to the job’s processing requirement plus a setup time equal to the characteristic value of that machine. We introduce some optimality conditions and present a polynomial-time algorithm to solve the special case.     

The wafer probing scheduling problem (WPSP)

The wafer probing scheduling problem (WPSP) is a variation of the parallel-machine scheduling problem, which has many real-world applications, particularly, in the integrated circuit (IC) manufacturing industry. In the wafer probing factories, the jobs are clustered by their product types, which must be processed on groups of identical parallel machines and be completed before the due dates. Further, the job processing time depends on the product type, and the machine setup time is sequence dependent on the orders of jobs processed. Since the wafer probing scheduling problem involves constraints on job clusters, job-cluster dependent processing time, due dates, machine capacity, and sequence dependent setup time, it is more difficult to solve than the classical parallel-machine scheduling problem. In this paper, we formulate the WPSP as an integer programming problem. We also transform the WPSP into the vehicle routing problem with time windows (VRPTW), a well-known network routing problem which has been investigated extensively. An illustrative example is given to demonstrate the proposed transformation. Based on the provided transformation, we present three efficient algorithms to solve the WPSP near-optimally.     

Unrelated parallel machine scheduling with past-sequence-dependent setup time and learning effects

In this article, we study an unrelated parallel machine scheduling problem with setup time and learning effects simultaneously. The setup time is proportional to the length of the already processed jobs. That is, the setup time of each job is past-sequence-dependent. The objective is to minimize the total completion time. We show that there exists a polynomial time solution for the proposed problem. We also discuss two special cases of the problem and show that they can be optimally solved by lower order algorithms.     

Scheduling orders for multiple product types to minimize total weighted completion time

We consider the problem of scheduling orders for multiple different product types in an environment with m dedicated machines in parallel. The objective is to minimize the total weighted completion time. Each product type is produced by one and only one of the m dedicated machines; that is, each machine is dedicated to a specific product type. Each order has a weight and may also have a release date. Each order asks for certain amounts of various different product types. The different products for an order can be produced concurrently. Preemptions are not allowed. Even when all orders are available at time 0, the problem has been shown to be strongly NP-hard for any fixed number (?2) of machines. This paper focuses on the design and analysis of efficient heuristics for the case without release dates. Occasionally, however, we extend our results to the case with release dates. The heuristics considered include some that have already been proposed in the literature as well as several new ones. They include various static and dynamic priority rules as well as two more sophisticated LP-based algorithms. We analyze the performance bounds of the priority rules and of the algorithms and present also an in-depth comparative analysis of the various rules and algorithms. The conclusions from this empirical analysis provide insights into the trade-offs with regard to solution quality, speed, and memory space.     

带两个服务等级的三台机最优在线算法

研究了带服务等级约束的三台平行机在线排序问题.每台机器和每个工件的服务等级为1或者2,工件只能在等级不高于它的机器上加工,即等级为1的工件只能在等级为1的机器上加工,等级为2的工件可在所有机器上加工.每个工件的加工时间为一个单位,目标是极小化所有工件的总完工时间.考虑两种情形:当一台机器等级为1,两台机器等级为2时,给出了竞争比为17/14的最优在线算法;当两台机器等级为1,一台机器等级为2时,给出了竞争比为43/36的最优在线算法.     

Algorithms for the wafer probing scheduling problem with sequence-dependent set-up time and due date restrictions

In this paper, we consider the wafer probing scheduling problem (WPSP) to sequence families of jobs on identical parallel machines with due date restrictions. The machine set-up time is sequentially dependent on the product types of the jobs processed on the machine. The objective is to minimize the total machine workload without violating the machine capacity and job due date restrictions. The WPSP is a variation of the classical parallel-machine scheduling problem, that can be transformed into the vehicle-routing problem with time windows (VRPTW). One can therefore solve the WPSP efficiently using existing VRPTW algorithms. We apply four existing savings algorithms presented in the literature including sequential, parallel, generalized, and matching based savings, and develop three modifications called the modified sequential, the compound matching based, and the modified compound matching-based savings algorithms, to solve the WPSP. Based on the characteristics of the wafer probing process, a set of test problems is generated for testing purposes. Computational results show that the three proposed modified algorithms perform remarkably well.     

Scheduling orders on either dedicated or flexible machines in parallel to minimize total weighted completion time

We are interested in the problem of scheduling orders for different product types in a facility with a number of machines in parallel. Each order asks for certain amounts of various different product types which can be produced concurrently. Each product type can be produced on a subset of the machines. Two extreme cases of machine environments are of interest. In the first case, each product type can be produced on one and only one machine which is dedicated to that product type. In the second case, all machines are identical and flexible; each product type can be produced by any one of the machines. Moreover, when a machine in this case switches over from one product type to another, no setup is required. Each order has a release date and a weight. Preemptions are not allowed. The objective is minimizing the total weighted completion time of the orders. Even when all orders are available at time 0, both types of machine environments have been shown to be NP-hard for any fixed number (≥2) of machines. This paper focuses on the design and analysis of approximation algorithms for these two machine environments. We also present empirical comparisons of the various algorithms. The conclusions from the empirical analyses provide insights into the trade-offs with regard to solution quality, speed, and memory space. Electronic Supplementary Material The online version of this article () contains supplementary material, which is available to authorized users. This research is supported by the National Science Foundation through grants DMI-0300156 and DMI-0245603.     

A linear time approximation algorithm for movement minimization in conveyor flow shop processing

We consider the movement minimization problem in a conveyor flow shop processing controlled by one worker for all machines. A machine can only execute tasks if the worker is present. Each machine can serve as a buffer. The worker has to cover a certain distance to move from one machine to the other. The distance between two machines P_p and P_q is |p−q|. The objective is to minimize the total distance the worker has to cover for the processing of all jobs. We introduce a linear time approximation algorithm for the conveyor flow shop problem with performance 3. Such minimization problems usually appear in conveyor controlled manufacturing systems.     

An approximation algorithm for parallel machine scheduling with a common server

In this paper we study the scheduling of a given set of jobs on several identical parallel machines tended by a common server. Each job must be processed on one of the machines. Prior to processing, the server has to set up the relevant machine. The objective is to schedule the jobs so as to minimize the total weighted job completion times. We provide an approximation algorithm to tackle this intractable problem and analyze the worst-case performance of the algorithm for the general, as well as a special, case of the problem.     

Clustered flow shop models

This paper deals with flow-shop models where n items are grouped in fixed sequences, called clusters. The clusters are to be processed on m machines in the same technological order. Each machine handles the clusters in the same order. Each completed item is available for processing on the next machine. The question is how to arrange the clusters to minimize the completion time. Models that include setup times for clusters with identical items are also examined. Approximate solutions along with new lower bounds are presented. Those solutions are optimal for the two machine case.     

A bicriteria parallel machine scheduling with a learning effect of setup and removal times

In studies on scheduling problems, generally setup times and removal times of jobs have been neglected or by including those into processing times. However, in some production systems, setup times and removal times are very important such that they should be considered independent from processing times. Since, in general jobs are done according to automatic machine processes in production systems processing times do not differ according to process sequence. But, since human factor becomes influential when setup times and removal times are taken into consideration, setup times will be decreasing by repeating setup processes frequently. This fact is defined with learning effect in scheduling literature. In this study, a bicriteria m-identical parallel machines scheduling problem with a learning effect of setup times and removal times is considered. The objective function of the problem is minimization of the weighted sum of total completion time and total tardiness. A mathematical programming model is developed for the problem which belongs to NP-hard class. Results of computational tests show that the proposed model is effective in solving problems with up to 15 jobs and five machines. We also proposed three heuristic approaches for solving large jobs problems. According to the best of our knowledge, no work exists on the minimization of the weighted sum of total completion time and total tardiness with a learning effect of setup times and removal times.     

Single Machine Batch Scheduling Problem with Resource Dependent Setup and Processing Time in the Presence of Fuzzy Due Date

We consider a batch scheduling problem on a single machine which processes jobs with resource dependent setup and processing time in the presence of fuzzy due-dates given as follows:1. There are n independent non-preemptive and simultaneously available jobs processed on a single machine in batches. Each job j has a processing time and a due-date.2. All jobs in a batch are completed together upon the completion of the last job in the batch. The batch processing time is equal to the sum of the processing times of its jobs. A common machine setup time is required before the processing of each batch.3. Both the job processing times and the setup time can be compressed through allocation of a continuously divisible resource. Each job uses the same amount of the resource. Each setup also uses the same amount of the resource.4. The due-date of each job is flexible. That is, a membership function describing non-decreasing satisfaction degree about completion time of each job is defined.5. Under above setting, we find an optimal batch sequence and resource values such that the total weighted resource consumption is minimized subject to meeting the job due-dates, and minimal satisfaction degree about each due-date of each job is maximized. But usually we cannot optimize two objectives at a time. So we seek non-dominated pairs i.e. the batch sequence and resource value, after defining dominance between solutions.A polynomial algorithm is constructed based on linear programming formulations of the corresponding problems.     

Learning and forgetting effects on a group scheduling problem

This paper proposes to investigate learning and forgetting effects on the problem of scheduling families of jobs on a single machine to minimize total completion time of jobs. A setup time is incurred whenever the single machine transfers job processing from a family to another family. To analyze the impact of learning and forgetting on this group scheduling problem, we structure three basic models and make some comparisons through computational experiments. The three models, including no forgetting, total forgetting and partial forgetting, assume that the processing time of a job is dependent on its position in a schedule. Some scheduling rules and a lower bound are derived in order to constitute our branch-and-bound algorithm for searching an optimal sequence. In addition, an efficient and simply-structured heuristic is also built to find a near-optimal schedule.