Hybrid heuristics for the capacitated lot sizing and loading problem with setup times and overtime decisions

The capacitated lot sizing and loading problem (CLSLP) deals with the issue of determining the lot sizes of product families/end items and loading them on parallel facilities to satisfy dynamic demand over a given planning horizon. The capacity restrictions in the CLSLP are imposed by constraints specific to the production environment considered. When a lot size is positive in a specific period, it is loaded on a facility without exceeding the sum of the regular and overtime capacity limits. Each family may have a different process time on each facility and furthermore, it may be technologically feasible to load a family only on a subset of existing facilities. So, in the most general case, the loading problem may involve unrelated parallel facilities of different classes. Once loaded on a facility, a family may consume capacity during setup time. Inventory holding and overtime costs are minimized in the objective function. Setup costs can be included if setups incur costs other than lost production capacity. The CLSLP is relevant in many industrial applications and may be generalized to multi-stage production planning and loading models. The CLSLP is a synthesis of three different planning and loading problems, i.e., the capacitated lot sizing problem (CLSP) with overtime decisions and setup times, minimizing total tardiness on unrelated parallel processors, and, the class scheduling problem, each of which is NP in the feasibility and optimality problems. Consequently, we develop hybrid heuristics involving powerful search techniques such as simulated annealing (SA), tabu search (TS) and genetic algorithms (GA) to deal with the CLSLP. Results are compared with optimal solutions for 108 randomly generated small test problems. The procedures developed here are also compared against each other in 36 larger size problems.     

Multi-item lot size determination and scheduling under capacity constraints

This paper deals with the planning of a production group, which has to produce several products. For each product there is a delivery plan covering several periods. Moreover, there are capacity constraints. Such a situation requires integrated optimization of lot sizes and lot scheduling. Since exact solution of the problem is in general not feasible, we will present a non exact approach which gives quite good results in some practical cases and might be a good starting point in other cases.     

Minimizing the completion time of a project under resource constraints and feeding precedence relations: a Lagrangian relaxation based lower bound

In this paper we study the Resource Constrained Project Scheduling Problem (RCPSP) with “Feeding Precedence” (FP) constraints and minimum makespan objective. This problem typically arises in production planning environment, like make-to-order manufacturing, where the effort associated with the execution of an activity is not univocally related to its duration percentage and the traditional finish-to-start precedence constraints or the generalized precedence relations cannot completely represent the overlapping among activities. In this context, we need to introduce in the RCPSP the FP constraints. For this problem we propose a new mathematical formulation and define a lower bound based on the Lagrangian relaxation of the resource constraints. A computational experimentation on randomly generated instances of sizes of up to 100 activities shows a better performance of this lower bound when compared to other lower bounds. Moreover, for the optimally solved instances, its value is very close to the optimal one. Furthermore, in order to show the effectiveness of the proposed lower bound on large instances for which the optimal solution is known, we adapted our approach to solve the benchmarks of the basic RCPSP from the PSLIB with 120 activities.     

An Augmented Arborescence Formulation for the Two-Level Network Design Problem

In this paper we discuss formulations for the Two Level Network Design (TLND) problem. In particular, we present an arborescence based formulation with extra constraints guaranteeing that the set of primary nodes is spanned by primary edges. This characterization suggests an arborescence based Lagrangian relaxation where the extra constraints are dualized. Although the Linear Programming (LP) value of the new formulation is proved to be theoretically weaker than the LP bound given by the flow based formulation presented by Balakrishnan, Magnanti and Mirchandani, our computational results show that for certain classes of instances the two LP bounds are quite close. Our results also show that the Lagrangian relaxation based method is quite efficient, providing a reasonable alternative to handle the problem.     

Lower bounds for nonlinear assignment problems using many body interactions

This paper concerns lower bounding techniques for the general α-adic assignment problem. The nonlinear objective function is linearized by the introduction of additional variables and constraints, thus yielding a mixed integer linear programming formulation of the problem. The concept of many body interactions is introduced to strengthen this formulation and incorporated in a modified formulation obtained by lifting the original representation to a higher dimensional space. This process involves two steps — (i) addition of new variables and constraints and (ii) incorporation of the new variables in the objective function. If this lifting process is repeated β times on an α-adic assignment problem along with the incorporation of higher order interactions, it results in the mixed-integer formulation of an equivalent (α + β)-adic assignment problem. The incorporation of many body interactions in the higher dimensional formulation improves its degeneracy properties and is also critical to the derivation of decomposition methods for the solution of these large scale mathematical programs in the higher dimensional space. It is shown that a lower bound to the optimal solution of the corresponding linear programming relaxation can be obtained by dualizing a subset of constraints in this formulation and solving O(N^2(α+β−1)) linear assignment problems, whose coefficients depend on the dual values. Moreover, it is proved that the optimal solution to the LP relaxation is obtained if we use the optimal duals for the solution of the linear assignment problems. This concept of many body interactions could be applied in designing algorithms for the solution of formulations obtained by lifting general MILP's. We illustrate all these concepts on the quadratic assignment problems With these decomposition bounds, we have found the provably optimal solutions of two unsolved QAP's of size 32 and have also improved upon existing lower bounds for other QAP's.     

Lower Bounds for Fixed Spectrum Frequency Assignment

Determining lower bounds for the sum of weighted constraint violations in fixed spectrum frequency assignment problems is important in order to evaluate the performance of heuristic algorithms. It is well known that, when adopting a binary constraints model, clique and near-clique subproblems have a dominant role in the theory of lower bounds for minimum span problems. In this paper we highlight their importance for fixed spectrum problems. We present a method based on the linear relaxation of an integer programming formulation of the problem, reinforced with constraints derived from clique-like subproblems. The results obtained are encouraging both in terms of quality and in terms of computation time.     

Reformulation and a Lagrangian heuristic for lot sizing problem on parallel machines

We consider the capacitated lot sizing problem with multiple items, setup time and unrelated parallel machines. The aim of the article is to develop a Lagrangian heuristic to obtain good solutions to this problem and good lower bounds to certify the quality of solutions. Based on a strong reformulation of the problem as a shortest path problem, the Lagrangian relaxation is applied to the demand constraints (flow constraint) and the relaxed problem is decomposed per period and per machine. The subgradient optimization method is used to update the Lagrangian multipliers. A primal heuristic, based on transfers of production, is designed to generate feasible solutions (upper bounds). Computational results using data from the literature are presented and show that our method is efficient, produces lower bounds of good quality and competitive upper bounds, when compared with the bounds produced by another method from the literature and by high-performance MIP software.     

New lower bounds for the three-dimensional finite bin packing problem

The three-dimensional finite bin packing problem (3BP) consists of determining the minimum number of large identical three-dimensional rectangular boxes, bins, that are required for allocating without overlapping a given set of three-dimensional rectangular items. The items are allocated into a bin with their edges always parallel or orthogonal to the bin edges. The problem is strongly NP-hard and finds many practical applications. We propose new lower bounds for the problem where the items have a fixed orientation and then we extend these bounds to the more general problem where for each item the subset of rotations by 90° allowed is specified. The proposed lower bounds have been evaluated on different test problems derived from the literature. Computational results show the effectiveness of the new lower bounds.     

A two-dimensional strip cutting problem with sequencing constraint

We study a strip cutting problem that arises in the production of corrugated cardboard. In this context, rectangular items of different sizes are obtained by machines, called corrugators, that cut strips of large dimensions according to particular schemes containing at most two types of items. Because of buffer restrictions, these schemes have to be sequenced in such a way that, at any moment, at most two types of items are in production and not completed yet (sequencing constraint). We show that the problem of finding a set of schemes of minimum trim loss that satisfies an assigned demand for each item size is strongly NP-hard, even if the sequencing constraint is relaxed. Then, we present two heuristics for the problem with the sequencing constraint, both based on a graph characterization of the feasible solutions. The first heuristic is a two-phase procedure based on a mixed integer linear programming model. The second heuristic follows a completely combinatorial approach and consists of solving a suitable sequence of minimum cost matching problems. For both procedures, an upper bound on the number of schemes (setups) is found. Finally, a computational study comparing the quality of the heuristic solutions with respect to an LP lower bound is reported.     

A branch and bound algorithm for disassembly scheduling with assembly product structure

This paper considers a production planning problem in disassembly systems, which is the problem of determining the quantity and timing of disassembling end-of-use/life products in order to satisfy the demand of their parts or components over a planning horizon. The case of single product type without parts commonality is considered for the objective of minimizing the sum of setup and inventory holding costs. To show the complexity of the problem, we prove that the problem is NP-hard. Then, after deriving the properties of optimal solutions, a branch and bound algorithm is suggested that incorporates the Lagrangean relaxation-based upper and lower bounds. Computational experiments are performed on a number of randomly generated problems and the test results indicate that the branch and bound algorithm can give optimal solutions up to moderate-sized problems in a reasonable computation time. A Lagrangean heuristic for a viable alternative for large-sized problems is also suggested and compared with the existing heuristics to show its effectiveness.     

Economic lot sizing problem with inventory bounds

This paper studies a economic lot sizing (ELS) problem with both upper and lower inventory bounds. Bounded ELS models address inventory control problems with time-varying inventory capacity and safety stock constraints. An O(n²) algorithm is found by using net cumulative demand (NCD) to measure the amount of replenishment requested to fulfill the cumulative demand till the end of the planning horizon. An O(n) algorithm is found for the special case, the bounded ELS problem with non-increasing marginal production cost.     

A o(n logn) algorithm for LP knapsacks with GUB constraints

A specialization of the dual simplex method is developed for solving the linear programming (LP) knapsack problem subject to generalized upper bound (GUB) constraints. The LP/GUB knapsack problem is of interest both for solving more general LP problems by the dual simplex method, and for applying surrogate constraint strategies to the solution of 0–1 Multiple Choice integer programming problems. We provide computational bounds for our method of o(n logn), wheren is the total number of problem variables. These bounds reduce the previous best estimate of the order of complexity of the LP/GUB knapsack problem (due to Witzgall) and provide connections to computational bounds for the ordinary knapsack problem.We further provide a variant of our method which has only slightly inferior worst case bounds, yet which is ideally suited to solving integer multiple choice problems due to its ability to post-optimize while retaining variables otherwise weeded out by convex dominance criteria.     

Integer linear programming formulation of the material requirements planning problem

Lot sizing procedures for discrete and dynamic demand form a distinct class of inventory control problems, usually referred to asmaterial requirements planning. A general integer programming formulation is presented, covering an extensive range of problems: single-item, multi-item, and multi-level optimization; conditions on lot sizes and time phasing; conditions on storage and production capacities; and changes in production and storage costs per unit. The formulation serves as a uniform framework for presenting a problem and a starting point for developing and evaluating heuristic and tailor-made optimum-seeking techniques.     

Lagrangean relaxation based heuristics for lot sizing with setup times

We consider a lot sizing problem with setup times where the objective is to minimize the total inventory carrying cost only. The demand is dynamic over time and there is a single resource of limited capacity. We show that the approaches implemented in the literature for more general versions of the problem do not perform well in this case. We examine the Lagrangean relaxation (LR) of demand constraints in a strong reformulation of the problem. We then design a primal heuristic to generate upper bounds and combine it with the LR problem within a subgradient optimization procedure. We also develop a simple branch and bound heuristic to solve the problem. Computational results on test problems taken from the literature show that our relaxation procedure produces consistently better solutions than the previously developed heuristics in the literature.     

Phasing out Capital Equipment

A new formulation is proposed for the problem of the optimal phasing out over some time period of a group of similar items of capital equipment. The possibility of hiring items from an external source is explicitly considered, as are policy constraints which restrict the minimum number of items which may be held at any time. Initially formulated as an integer program, the problem is transformed to the familiar transportation form of linear programming.     

An LP-based heuristic for two-stage capacitated facility location problems

In this paper, a linear programming based heuristic is considered for a two-stage capacitated facility location problem with single source constraints. The problem is to find the optimal locations of depots from a set of possible depot sites in order to serve customers with a given demand, the optimal assignments of customers to depots and the optimal product flow from plants to depots. Good lower and upper bounds can be obtained for this problem in short computation times by adopting a linear programming approach. To this end, the LP formulation is iteratively refined using valid inequalities and facets which have been described in the literature for various relaxations of the problem. After each reoptimisation step, that is the recalculation of the LP solution after the addition of valid inequalities, feasible solutions are obtained from the current LP solution by applying simple heuristics. The results of extensive computational experiments are given.     

Dynamic graph generation for the shortest path problem in time expanded networks

In discrete optimization problems the progress of objects over time is frequently modeled by shortest path problems in time expanded networks, but longer time spans or finer time discretizations quickly lead to problem sizes that are intractable in practice. In convex relaxations the arising shortest paths often lie in a narrow corridor inside these networks. Motivated by this observation, we develop a general dynamic graph generation framework in order to control the networks’ sizes even for infinite time horizons. It can be applied whenever objects need to be routed through a traffic or production network with coupling capacity constraints and with a preference for early paths. Without sacrificing any information compared to the full model, it includes a few additional time steps on top of the latest arcs currently in use. This “frontier” of the graphs can be extended automatically as required by solution processes such as column generation or Lagrangian relaxation. The corresponding algorithm is efficiently implementable and linear in the arcs of the non-time-expanded network with a factor depending on the basic time offsets of these arcs. We give some bounds on the required additional size in important special cases and illustrate the benefits of this technique on real world instances of a large scale train timetabling problem.     

A mathematical programming system for preference and compatibility maximized menu planning and scheduling

In this paper, the analytical representation of food preference is used in a separable non-linear program to yield the serving frequencies of menu items for a finite time horizon. The frequencies obtained in this way insure cost and nutritional control. Subsequently, the scheduling problem dealing with item assignments to meals and days is formulated as an integer program consisting of several transportation problems linked by weekly nutritional constraints. This problem is solved using a branch and bound algorithm which employs Lagrangian relaxation to obtain bounds and to decide on branching strategy.     

Efficient algorithms for solving multiconstraint zero-one knapsack problems to optimality

The multiconstraint 0–1 knapsack problem is encountered when one has to decide how to use a knapsack with multiple resource constraints. Even though the single constraint version of this problem has received a lot of attention, the multiconstraint knapsack problem has been seldom addressed. This paper deals with developing an effective solution procedure for the multiconstraint knapsack problem. Various relaxation of the problem are suggested and theoretical relations between these relaxations are pointed out. Detailed computational experiments are carried out to compare bounds produced by these relaxations. New algorithms for obtaining surrogate bounds are developed and tested. Rules for reducing problem size are suggested and shown to be effective through computational tests. Different separation, branching and bounding rules are compared using an experimental branch and bound code. An efficient branch and bound procedure is developed, tested and compared with two previously developed optimal algorithms. Solution times with the new procedure are found to be considerably lower. This procedure can also be used as a heuristic for large problems by early termination of the search tree. This scheme was tested and found to be very effective.