Monolithic vs. hierarchical balancing and scheduling of a flexible assembly line

A monolithic and a hierarchical approach are presented for balancing and scheduling of a flexible assembly line (FAL). The system is made up of a set of assembly stations in series, each with limited work space and is capable of simultaneously producing a mix of product types. The objective is to determine an assignment of assembly tasks to stations and an assembly schedule for all products so as to complete the products in minimum time. In the monolithic approach balancing and scheduling decisions are made simultaneously. In the hierarchical approach, however, first the station workloads are balanced, and then detailed assembly schedule is determined for prefixed task assignments and assembly routes by solving a permutation flowshop problem. Mixed integer programming formulations are presented for the two approaches. Numerical examples are included to illustrate and compare the approaches and some computational results are reported.     

A lexicographic approach to bi-objective scheduling of single-period orders in make-to-order manufacturing

This paper presents a lexicographic approach and integer programming formulations for a dual-objective, long-term production scheduling in make-to-order manufacturing environment. The problem objective is to assign single-period customer orders for various product types to planning periods to complete all the orders with minimum number of tardy orders as a primary criterion and to level the aggregate production or the total capacity utilization over a planning horizon as a secondary criterion. Each order must be completed during one planning period. The basic integer programming formulation has been strengthened by the addition of some cutting constraints derived by relating the demand on required capacity to available capacity for each subset of orders with the same due date. The approach has been applied to optimize production schedules in a flexible flowshop made up of several processing stages in series, with identical, parallel machines, and an output buffer of limited capacity for holding completed products before delivery to the customers. Numerical examples modeled after a real-world make-to-order flexible assembly line in the electronics industry are provided and some computational results are reported.     

A note on “A mixed integer programming model for advanced planning and scheduling (APS)”

In a recent paper, Chen and Ji [Chen, K., Ji, P., 2007. A mixed integer programming model for advanced planning and scheduling (APS). European Journal of Operational Research 181, 515–522] develop a mixed integer programming model for advanced planning and scheduling problem that considers capacity constraints and precedence relations between the operations. The orders require processing of several operations on eligible machines. The model presented in the above paper works for the case where each operation can be processed on only one machine. However, machine eligibility means that only a subset of machines are capable of processing a job and this subset may include more than one machine. We provide a general model for advanced planning and scheduling problems with machine eligibility. Our model can be used for problems where there are alternative machines that an operation can be assigned to.     

A Mixed Integer Programming Formulation for the Total Flow Time Single Machine Robust Scheduling Problem with Interval Data

We consider a version of the total flow time single machine scheduling problem where uncertainty about processing times is taken into account. Namely an interval of equally possible processing times is considered for each job, and optimization is carried out according to a robustness criterion. We propose the first mixed integer linear programming formulation for the resulting optimization problem and we explain how some known preprocessing rules can be translated into valid inequalities for this formulation. Computational results are finally presented. Work funded by the Swiss National Science Foundation through project 200020-109854/1.     

含不相关机的动态可重入柔性流水车间问题的混合DABC-GA算法

为了改善生产线的物流平衡和加强阶段间的时间衔接,扩展一般可重入柔性流水车间调度理论,以最小化总加权完工时间为目标,研究了每阶段含不相关并行机的动态可重入柔性流水车间问题,工件在各阶段的加工时间取决于加工它的机器。鉴于所研究问题为NP-hard问题,首先,建立整数规划模型;其次,设计元胞矩阵编码方案,提出融合离散人工蜂群算法和遗传算法的一种混合算法以获得问题的近优解;最后,为了评估混合算法的性能,将所提出算法和一些元启发式算法进行了不同规模问题的对比测试,实验结果说明了所提算法的有效性。     

具有机器适用限制的分布式置换流水车间问题的模型与算法

考虑具有机器适用限制的多个不同置换流水车间的调度问题. 机器适用限制指的是每个工件只能分配到其可加工工厂集合. 所有置换流水车间拥有的机器数相同但是具有不同的加工能力. 首先, 针对该问题建立了基于位置的混合整数线性规划模型; 进而, 对一般情况和三种特殊情况给出了具有较小近似比的多项式时间算法. 其次, 基于NEH方法提出了启发式算法NEHg, 并给出了以NEHg为上界的分支定界算法. 最后, 通过例子说明了NEHg启发式算法和分支定界算法的计算过程, 并进行大量的实验将NEHg与NEH算法结果进行比较, 从而验证了NEHg算法的有效性.     

Dynamic models of production with multiple operations and general processing times

Traditional integer programming model formulations for job-shops and flow-shops do not easily account for characteristics common to high-technology manufacturing such as high-volume semiconductor manufacturing. These characteristics are: (1) products (wafers) are processed by the same machine type more than once during the operation sequence, (2) many lots of similar type are run, and (3) there can be multiple machines of the same type. In this paper, we present two new integer programming formulations which easily account for these characteristics. The approach is based on restricting the allowed domain of events for the start of lot processing. The first model restricts production starts to the beginning of a planning time period. The second model uses a special time grid at each operation with width equal to the processing time, and allows starts to be scheduled at the grid points. In an example problem replicating a high-volume wafer fabrication process, it is shown that it is computationally practical to obtain solutions for the restricted start models where it is not computationally possible for the traditional integer programming model formulations.     

Multiple machine continuous setup lotsizing with sequence-dependent setups

We address the short-term production planning and scheduling problem coming from the glass container industry. A furnace melts the glass that is distributed to a set of parallel molding machines. Both furnace and machine idleness are not allowed. The resulting multi-machine multi-item continuous setup lotsizing problem with a common resource has sequence-dependent setup times and costs. Production losses are penalized in the objective function since we deal with a capital intensive industry. We present two mixed integer programming formulations for this problem, which are reduced to a network flow type problem. The two formulations are improved by adding valid inequalities that lead to good lower bounds. We rely on a Lagrangian decomposition based heuristic for generating good feasible solutions. We report computational experiments for randomly generated instances and for real-life data on the aforementioned problem, as well as on a discrete lotsizing and scheduling version.     

Exploiting process plan flexibility in production scheduling: A multi-objective approach

When solving a product/process design problem, we must exploit the available degrees of freedom to cope with a variety of issues. Alternative process plans can be generated for a given product, and choosing one of them has implications on manufacturing functions downstream, including planning/scheduling. Flexible process plans can be exploited in real time to react to machine failures, but they are also relevant for off-line scheduling. On the one hand, we should select a process plan in order to avoid creating bottleneck machines, which would deteriorate the schedule quality; on the other one we should aim at minimizing costs. Assessing the tradeoff between these possibly conflicting objectives is difficult; actually, it is a multi-objective problem, for which available scheduling packages offer little support. Since coping with a multi-objective scheduling problem with flexible process plans by an exact optimization algorithm is out of the question, we propose a hierarchical approach, based on a decomposition into a machine loading and a scheduling sub-problem. The aim of machine loading is to generate a set of efficient (non-dominated) solutions with respect to the load balancing and cost objectives, leaving to the user the task of selecting a compromise solution. Solving the machine loading sub-problem essentially amounts to selecting a process plan for each job and to routing jobs to the machines; then a schedule must be determined. In this paper we deal only with the machine loading sub-problem, as many scheduling methods are already available for the problem with fixed process plans. The machine loading problem is formulated as a bicriterion integer programming model, and two different heuristics are proposed, one based on surrogate duality theory and one based on a genetic descent algorithm. The heuristics are tested on a set of benchmark problems.     

On discrete lot-sizing and scheduling on identical parallel machines

We consider the multi-item discrete lot-sizing and scheduling problem on identical parallel machines. Based on the fact that the machines are identical, we introduce aggregate integer variables instead of individual variables for each machine. For the problem with start-up costs, we show that the inequalities based on a unit flow formulation for each machine can be replaced by a single integer flow formulation without any change in the resulting LP bound. For the resulting integer lot-sizing with start-ups subproblem, we show how inequalities for the unit demand case can be generalized and how an approximate version of the extended formulation of Eppen and Martin can be constructed. The results of some computational experiments carried out to compare the effectiveness of the various mixed-integer programming formulations are presented.     

A Mixed Integer Linear Programming model for simultaneous design and scheduling of flowshop plants

Models representing batch plants, especially flowshop facilities where all the products require the same processing sequence, have received much attention in the last decades. In particular, plant design and production scheduling have been addressed as disconnected problems due to the tremendous combinatory complexity associated to their simultaneous optimization. This paper develops a model for both design and scheduling of flowshop batch plants considering mixed product campaign and parallel unit duplication. Thus, a realistic formulation is attained, where industrial and commercial aspects are jointly taken into account. The proposed approach is formulated as a Mixed Integer Linear Programming model that determines the number of units per stages, unit and batch sizes and batch sequencing in each unit in order to fulfill the demand requirements at minimum investment cost. A set of novel constraints is proposed where the number of batches of each product in the campaign is an optimization variable. The approach performance is evaluated through several numerical examples.     

A solution for cyclic scheduling of multi-hoists without overlapping

In this paper, we study the cyclic scheduling problem for electroplating lines where products are loaded into the system at one end and unloaded at the other end. The electroplating jobs must be processed within a given time window in each tank. There is no buffer between tanks. Two hoists sharing a common track are used to move products between the tanks in the production line. The objective is to minimize the production cycle time through scheduling hoist moves. A solution procedure is proposed in this study. The production line is first divided into two non-overlapping zones with a hoist assigned to each zone. Then a mixed integer linear programming model is developed for scheduling hoist moves. Computational results on a benchmark example problem are given in the paper to demonstrate the application of the proposed method.     

An interactive approach to bicriterion loading of a flexible assembly system

This paper presents integer programming formulations and an interactive solution procedure for a bicriterion loading problem in a flexible assembly system. The system is made up of a set of assembly stations linked with an automated material handling system. In the system, several different product types can be assembled simultaneously. The problem objective is to assign assembly tasks and products to stations with limited working space, so as to balance the station workloads and to minimize station-to-station product transfer time, subject to precedence relations among the tasks for a mix of product types. The solution procedure proposed is based on the weighting method and the interactive search for a set of weights which would produce the most preferred nondominated solution. Numerical examples are included to illustrate possible applications of the interactive approach for various problem formulations proposed.     

Realistic two-stage flowshop batch scheduling problems with transportation capacity and times

This paper investigates single-batch and batch-single flow shop scheduling problem taking transportation among machines into account. Both transportation capacity and transportation times are explicitly considered. While the single processing machine processes one job at a time, the batch processing machine processes a batch of jobs simultaneously. The batch processing time is the longest processing times of jobs assigned to that batch.Each problem is formulated as a mixed integer programming model to find optimal makespan. Lower bounds and heuristic algorithms are proposed and computational experiments are carried out to verify their effectiveness.     

混合整数规划求解多联票据印刷过程中的生产调度问题

多联票据的印刷过程包括排版、单联印刷和多联配页与装订三个过程。该过程是柔性的流水生产线与装配混合的生产系统。本文研究了该系统中的票据印刷生产调度问题,目标是最小化所有产品的最大完成时间（Makespan）。该问题到目前为止还没有人研究,本文首先建立了该问题的混合整数规划模型,然后提出了该模型的求解方法,并给出了该问题的下界。最后的量化示例和算例试验表明本文的模型是有效的。     

Optimal solutions for a dock assignment problem with trailer transportation

This paper presents a model for a dock assignment problem, where trailers need to be assigned to gates for a given period of time for loading or unloading activities. The parking lot is used as a buffer zone. Transportation between the parking lot and the gates is performed by additional resources called terminal tractors. The problem is modeled as a three-stage flexible flow shop, where the first and the third stage share the same identical parallel machines and the second stage consists of a different set of identical parallel machines. We examine multiple integer-programming formulations for the parallel-machine model in stage two and for the three-stage flow shop and we provide extensive computational results. Our goal is to explore the limits of the instance sizes that can be solved to guaranteed optimality within acceptable running times using integer programming.     

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.     

无重叠区的双抓钩周期性排序问题的求解

在当今的自动化制造系统中，计算机控制的抓钩的排序直接影响系统的生产率。本文研究了产品在系统的一边装载、而在另一边卸载的电镀线周期性排序问题。工件在每个工作站的处理时间在给定时间范围内，工作站之间没有缓冲槽，相同轨道上的两个抓钩用于工作站之间工件的运送，目标是对运送进行排序以极小化生产周期。为了求解这个问题，本文提出一个求解方法，所提出的方法首先将生产线分为两个无重叠的区域，并且为每个区域分配一个抓钩，然后，提出了一个给定抓钩分配下的混合整数线性规划模型。通过求解不同抓钩分配下模型的最优解，并且选择这些解中最好的一个，以便得到最优解，一个标杆示例被运行，以表明该方法的应用。另外，给出有多重处理槽工序问题的模型和求解方法。     

A dynamic programming algorithm for scheduling jobs in a two-machine open shop with an availability constraint

This paper studies a two-machine open shop scheduling problem with an availability constraint, ie we assume that a machine is not always available and that the processing of the interrupted job can be resumed when the machine becomes available again. We consider the makespan minimization as criterion. This problem is NP-hard. We develop a pseudo-polynomial time dynamic programming algorithm to solve the problem optimally when the machine is not available at time s>0. Then, we propose a mixed integer linear programming formulation, that allows to solve instances with up to 500 jobs optimally in less than 5?min with CPLEX solver. Finally, we show that any heuristic algorithm has a worst-case error bound of 1.     

Scheduling a single machine with multiple job processing ability to minimize makespan

This paper investigates a new problem, called single machine scheduling with multiple job processing ability, which is derived from the production of the continuous walking beaming reheating furnace in iron and steel industry. In this problem, there is no batch and the jobs enter and leave the machine one by one and continuously, which is different from general single machine batch scheduling problem where the jobs in a batch share the same start and departure time. Therefore, the start time and the departure time of a job depend on not only the job sequence but also the machine capacity. This problem is also different from the single semi-continuous batching machine scheduling recently studied in the literature, where the jobs are processed in batch mode and a new batch cannot be started for processing until the processing of the previous batch is completed though jobs in the same batch enter and leave the machine one by one. The objective of this problem is to minimize the makespan. We formulate this problem as a mixed integer linear programming model and propose a particle swarm optimization (PSO) algorithm for this problem. Computational results on randomly generated instances show that the proposed PSO algorithm is effective.