An effective heuristic algorithm to minimise stack shuffles in selecting steel slabs from the slab yard for heating and rolling

Steel production is a multi-stage process. A slab yard serves as a buffer between the continuous casting stage and the steel rolling stage. Steel slabs are stored in stacks in the yard. Shuffling is needed when picking up a slab for heating and rolling, if it is not in the top position of a stack. This paper studies the problem of selecting appropriate slabs in the yard for a given rolling schedule so as to minimise the total shuffling cost. The study uses the hot strip rolling mill in Shanghai Baoshan Iron and Steel Complex as an application background. We propose a new heuristic algorithm to solve the problem. This is a two-phase algorithm that first generates an initial feasible solution and then improves it using local search. The new algorithm is compared with the algorithm in use on randomly generated test problems and on real data. Experimental results show that the proposed algorithm yields significant better solutions. The average improvement over the old algorithm is 15%.