Online scheduling of ordered flow shops

We consider online as well as offline scheduling of ordered flow shops with the makespan as objective. In an online flow shop scheduling problem, jobs are revealed to a decisionmaker one by one going down a list. When a job is revealed to the decision maker, its operations have to be scheduled irrevocably without having any information regarding jobs that will be revealed afterwards. We consider for the online setting the so-called Greedy Algorithm which generates permutation schedules in which the jobs on the machines are at all times processed without any unnecessary delays. We focus on ordered flow shops, in particular proportionate flow shops with different speeds and proportionate flow shops with different setup times. We analyze the competitive ratio of the Greedy Algorithm for such flow shops in the online setting. For several cases, we derive lower bounds on the competitive ratios.     

Genetic algorithm-based subproblem solution procedures for a modified shifting bottleneck heuristic for complex job shops

In this paper, we consider a modified shifting bottleneck heuristic for complex job shops. The considered job shop environment contains parallel batching machines, machines with sequence-dependent setup times and reentrant process flows. Semiconductor wafer fabrication facilities (Wafer Fabs) are typical examples for manufacturing systems with these characteristics. Our primary performance measure is total weighted tardiness (TWT). The shifting bottleneck heuristic uses a disjunctive graph to decompose the overall scheduling into scheduling problems for single tool groups. The scheduling algorithms for these scheduling problems are called subproblem solution procedures (SSPs). In previous research, only subproblem solution procedures based on dispatching rules have been considered. In this paper, we are interested in how much we can gain in terms of TWT if we apply more sophisticated subproblem solution procedures like genetic algorithms for parallel machine scheduling. We conduct simulation experiments in a dynamic job shop environment in order to assess the performance of the suggested subproblem solution procedures. It turns out that using near to optimal subproblem solution procedures leads in many situations to improved results compared to dispatching-based subproblem solution procedures.     

Single-machine scheduling with deteriorating jobs and past-sequence-dependent setup times

In many realistic scheduling settings a job processed later consumes more time than the same job processed earlier – this is known as scheduling with deteriorating jobs. Most research on scheduling with deteriorating jobs assumes that the actual processing time of a job is an increasing function of its starting time. Thus a job processed late may incur an excessively long processing time. On the other hand, setup times occur in manufacturing situations where jobs are processed in batches whereby each batch incurs a setup time. This paper considers scheduling with deteriorating jobs in which the actual processing time of a job is a function of the logarithm of the total processing time of the jobs processed before it (to avoid the unrealistic situation where the jobs scheduled late will incur excessively long processing times) and the setup times are proportional to the actual processing times of the already scheduled jobs. Under the proposed model, we provide optimal solutions for some single-machine problems.     

Modeling job shop scheduling with batches and setup times by timed Petri nets

Batch and setup times are two important factors in practical job shop scheduling. This paper proposes a method to model job shop scheduling problems including batches and anticipatory sequence-dependent setup times by timed Petri nets. The general modeling method is formally presented. The free choice property of the model is proved. A case study extracted from practical scheduling is given to show the feasibility of the modeling method. Comparison with some previous work shows that our model is more compact and effective in finding the best solution.     

Scheduling in bicriteria single machine systems with past-sequence-dependent setup times and learning effects

Scheduling with setup times and learning plays a crucial role in today's manufacturing and service environments where scheduling decisions are made with respect to multiple performance criteria rather than a single criterion. In this paper, we address a bicriteria single machine scheduling problem with job-dependent past-sequence-dependent setup times and job-dependent position-based learning effects. The setup time and actual processing time of a job are respectively unique functions of the actual processing times of the already processed jobs and the position of the job in a schedule. The objective is to derive the schedule that minimizes a linear composite function of a pair of performance criteria consisting of the makespan, the total completion time, the total lateness, the total absolute differences in completion times, and the sum of earliness, tardiness, and common due date penalty. We show that the resulting problems cannot be solved in polynomial time; thus, branch-and-bound (B&B) methods are proposed to obtain the optimal schedules. Our computational results demonstrate that the B&B can solve instances of various size problems with attractive times.     

Admission policies for the customized stochastic lot scheduling problem with strict due-dates

This papers considers admission control and scheduling of customer orders in a production system that produces different items on a single machine. Customer orders drive the production and belong to product families, and have family dependent due-date, size, and reward. When production changes from one family to another a setup time is incurred. Moreover, if an order cannot be accepted, it is considered lost upon arrival. The problem is to find a policy that accepts/rejects and schedules orders such that long run profit is maximized. This problem finds its motivation in batch industries in which suppliers have to realize high machine utilization while delivery times should be short and reliable and the production environment is subject to long setup times.We model the joint admission control/scheduling problem as a Markov decision process (MDP) to gain insight into the optimal control of the production system and use the MDP to benchmark the performance of a simple heuristic acceptance/scheduling policy. Numerical results show that the heuristic performs very well compared with the optimal policy for a wide range of parameter settings, including product family asymmetries in arrival rate, order size, and order reward.     

Generalization of Johnson's and Talwar's scheduling rules in two-machine stochastic flow shops

The paper deals with the classical problem of minimizing the makespan in a two-machine flow shop. When the job processing times are deterministic, the optimal job sequence can be determined by applying Johnson's rule. When they are independent and exponential random variables, Talwar's rule yields a job sequence that minimizes the makespan stochastically. Assuming that the random job processing times are independent and Gompertz distributed, we propose a new scheduling rule that is a generalization of both Johnson's and Talwar's rules. We prove that our rule yields a job sequence that minimizes the makespan stochastically. Extensions to m-machine proportionate stochastic flow shops, two-machine stochastic job shops, and stochastic assembly systems are indicated.     

Family sequencing and cooperation

This paper analyzes a single-machine scheduling problem with family setup times both from an optimization and a cost allocation perspective. In a family sequencing situation jobs are processed on a single machine, there is an initial processing order on the jobs, and every job within a family has an identical cost function that depends linearly on its completion time. Moreover, a job does not require a setup when preceded by another job from the same family while a family specific setup time is required when a job follows a member of some other family.     

Textile Production Systems: a Succession of Non-identical Parallel Processor Shops

The different problems of sequencing production operations in parallel processor shops of a textile company are considered in this paper. The complexity of these problems depends on: (1) the machine changeover times which occur when the changeovers cannot be realized in parallel during processing times, and (2) the operation due dates which have to be at best respected when the workshops do not constitute stocks. The objective is to minimize mean completion time or mean tardiness. This paper models these different scheduling problems. It presents some tools to solve these problems, and it explains the choice of algorithms issued from the graph theory and employed in industrial studies. Some results are shown.     

Lot Streaming in a Two-stage Flow Shop with Set-up,Processing and Removal Times Separated

This paper considers the job (lot) scheduling problem for two-stage flow shops in which the movement of transfer batches (sublots) from the first stage to the next are allowed. Set-up, processing and removal times are considered as separable and independent of the order in which jobs are processed at any of two stages. An optimal transfer batch sizing and scheduling algorithm which has an objective of minimizing the maximum flow time (makespan) is developed and demonstrated by a numerical example.     

Audit scheduling with overlapping activities and sequence-dependent setup costs

Audit firms are faced with the complex job of scheduling auditors to audit tasks. The scheduling becomes more complex as the firm needs to consider real life issues in determining an optimal schedule. Among these issues are the setup times and costs emanating from changing the assignments of the auditors and the lead and lag relationships between the audit tasks.Audit scheduling with overlapping activities and sequence-dependent setup cost has not been treated in literature. This paper presents a formulation and a solution approach for this audit scheduling problem. First, the problem is represented by an activity network with lead/lag relationships. Then the network is analyzed to determine the early and late finish times of activities. An integer linear program (ILP), which uses the early and late finish times of activities to reduce the number of decision variables, is formulated. A four-auditor two-engagement example is used to illustrate the ILP model and its solution. The results indicate that incorporating the setup cost and the overlapping of activities yields lower cost schedules leading to sizable savings in the cost of audits. The proposed treatment is of merit in providing realistic schedules that can be easily implemented     

Optimization of setup times in the furniture industry

The aim of this paper is to develop a scheduling policy oriented towards minimizing setup times in the made-to-order furniture industry. The task is treated as a dynamic job shop scheduling problem, with the exception that customers?? orders collected over a?specified period of time are combined into a?production plan and released together. A?simulation of a production flow based on technological routes of real subassemblies was performed. The proposed method of calculating a setup time eliminates the need to determine machine setup time matrices. Among the tested priority rules the best performance was observed in the case of the hierarchical rule that combines similar setup, the earliest due date and the shortest processing time. This rule allowed the setup time per operation to be reduced by 58?% compared to a combination of the earliest due date with the shortest setup and processing time rule and by over 70?% compared to the single shortest processing time rule.     

Single machine group scheduling with resource dependent setup and processing times

A single machine scheduling problem is studied. There is a partition of the set of n jobs into g groups on the basis of group technology. Jobs of the same group are processed contiguously. A sequence independent setup time precedes the processing of each group. Two external renewable resources can be used to linearly compress setup and job processing times. The setup times are jointly compressible by one resource, the job processing times are jointly compressible by another resource and the level of the resource is the same for all setups and all jobs. Polynomial time algorithms are presented to find an optimal job sequence and resource values such that the total weighted resource consumption is minimum, subject to meeting job deadlines. The algorithms are based on solving linear programming problems with two variables by geometric techniques.     

Complexity of the job insertion problem in multi-stage scheduling

The job insertion problem in multi-stage scheduling is: given a schedule for n jobs and an additional job, find a feasible insertion of the additional job into the schedule that minimizes the resulting makespan. We prove that finding the optimal job insertion is NP-hard for flow shops and open shops.     

Single-machine scheduling against due dates with past-sequence-dependent setup times

Recently Koulamas and Kyparisis [Koulamas, C., Kyparisis, G.J., in press. Single-machine scheduling with past-sequence-dependent setup times. European Journal of Operational Research] introduced past-sequence-dependent setup times to scheduling problems. This means that the setup time of a job is proportionate to the sum of processing times of the jobs already scheduled. Koulamas and Kyparisis [Koulamas, C., Kyparisis, G.J., in press. Single-machine scheduling with past-sequence-dependent setup times. European Journal of Operational Research] were able to show for a number of single-machine scheduling problems with completion time goals that they remain polynomially solvable. In this paper we extend the analysis to problems with due dates. We demonstrated that some problems remain polynomially solvable. However, for some other problems well-known polynomially solution approaches do not guarantee optimality any longer. Consequently we concentrated on finding polynomially solvable special cases.     

Batch scheduling with controllable setup and processing times to minimize total completion time

We study a problem of scheduling n jobs on a single machine in batches. A batch is a set of jobs processed contiguously and completed together when the processing of all jobs in the batch is finished. Processing of a batch requires a machine setup time dependent on the position of this batch in the batch sequence. Setup times and job processing times are continuously controllable, that is, they are real-valued variables within their lower and upper bounds. A deviation of a setup time or job processing time from its upper bound is called a compression. The problem is to find a job sequence, its partition into batches, and the values for setup times and job processing times such that (a) total job completion time is minimized, subject to an upper bound on total weighted setup time and job processing time compression, or (b) a linear combination of total job completion time, total setup time compression, and total job processing time compression is minimized. Properties of optimal solutions are established. If the lower and upper bounds on job processing times can be similarly ordered or the job sequence is fixed, then O(n³ log n) and O(n⁵) time algorithms are developed to solve cases (a) and (b), respectively. If all job processing times are fixed or all setup times are fixed, then more efficient algorithms can be devised to solve the problems.     

需要安装时间的平行多功能机排序问题的启发式算法

考虑需要安装时间的平行多功能机排序问题。在该模型中,每个工件对应机器集合的一个子集,其只能在这个子集中的任一台机器上加工,称这个子集为该工件的加工集合;工件分组,同组工件具有相同的加工时间和加工集合,不同组中的工件在同一台机器上连续加工需要安装时间,目标函数为极小化最大完工时间。对该问题NP-难的一般情况设计启发式算法:首先按照特定的规则将所有工件组都整组地安排到各台机器上,然后通过在各机器间转移工件不断改进当前最大完工时间。通过与下界的比较检验算法的性能,大量的计算实验表明,算法是实用而有效的。     

基于启发式Q学习的汽车涂装车间作业排序优化

针对汽车涂装车间中的作业优化排序问题,提出一种基于启发式Q学习的优化算法。首先,建立包括满足总装车间生产顺序和最小化喷枪颜色切换次数的多目标整数规划模型。将涂装作业优化排序问题抽象为马尔可夫过程,建立基于启发式Q算法的求解方法。通过具体案例,对比分析了启发式Q学习、Q学习、遗传算法三种方案的优劣。结果表明：在大规模问题域中,启发式Q学习算法具有寻优效率更高、效果更好的优势。本研究为机器学习算法在汽车涂装作业优化排序问题的应用提出了新思路。     

Group Scheduling with Controllable Setup and Processing Times: Minimizing Total Weighted Completion Time

The following single machine scheduling problem is studied. A partition of a set of n jobs into g groups on the basis of group technology is given. The machine processes jobs of the same group contiguously, with a sequence independent setup time preceding the processing of each group. The setup times and the job processing times are controllable through the allocation of a continuously divisible or discrete resource to them. Each job uses the same amount of the resource. Each setup also uses the same amount of resource, which may be different from that for the jobs. Polynomial-time algorithms are constructed for variants of the problem of finding an optimal job sequence and resource values so as to minimize the total weighted job completion time, subject to given restrictions on resource consumption. The algorithms are based on a polynomial enumeration of the candidates for an optimal job sequence and solving the problem with a fixed job sequence by linear programming. This research was supported in part by The Hong Kong Polytechnic University under grant number G-T246 and the Research Grants Council of Hong Kong under grant number PolyU 5191/01E. In addition, the research of M.Y. Kovalyov was supported by INTAS under grant number 00-217.     

A survey of scheduling problems with setup times or costs

The first comprehensive survey paper on scheduling problems with separate setup times or costs was conducted by [Allahverdi, A., Gupta, J.N.D., Aldowaisan, T., 1999. A review of scheduling research involving setup considerations. OMEGA The International Journal of Management Sciences 27, 219–239], who reviewed the literature since the mid-1960s. Since the appearance of that survey paper, there has been an increasing interest in scheduling problems with setup times (costs) with an average of more than 40 papers per year being added to the literature. The objective of this paper is to provide an extensive review of the scheduling literature on models with setup times (costs) from then to date covering more than 300 papers. Given that so many papers have appeared in a short time, there are cases where different researchers addressed the same problem independently, and sometimes by using even the same technique, e.g., genetic algorithm. Throughout the paper we identify such areas where independently developed techniques need to be compared. The paper classifies scheduling problems into those with batching and non-batching considerations, and with sequence-independent and sequence-dependent setup times. It further categorizes the literature according to shop environments, including single-machine, parallel machines, flow shop, no-wait flow shop, flexible flow shop, job shop, open shop, and others.