An integrated approach to dynamic plant location and capacity planning

We consider a dynamic capacitated plant location problem in which capacities of opened plants are determined by acquisition and/or disposal of multiple types of facilities. We determine the opening schedule of plants, allocations of customers' demands and plans for acquisition and/or disposal of plant capacities that minimise the sum of discounted fixed costs for opening plants, delivery costs of products, and acquisition and operation costs of facilities. The dynamic capacitated plant location problem is formulated as a mixed integer linear program and solved by a heuristic algorithm based on Lagrangian relaxation and a cut and branch algorithm which uses Gomory cuts. Several solution properties of the relaxed problem are found and used to develop efficient solution procedures for the relaxed problem. A subgradient optimisation method is employed to obtain better lower bounds. The heuristic algorithm is tested on randomly generated test problems and results show that the algorithm finds good solutions in a reasonable amount of computation time.     

Plant location with minimum inventory

We present an integer programming model for plant location with inventory costs. The linear programming relaxation has been solved by Dantzig-Wolfe decomposition. In this case the subproblems reduce to the minimum cut problem. We have used subgradient optimization to accelerate the convergence of the D-W algorithm. We present our experience with problems arising in the design of a distribution network for computer spare parts. In most cases, from a fractional solution we were able to derive integer solutions within 4% of optimality.     

Part type selection problem in flexible manufacturing systems: tabu search algorithms

Production planning in flexible manufacturing systems is concerned with the organization of production in order to satisfy a given master production schedule. The planning problem typically gives rise to several hierarchical subproblems which are then solved sequentially or simultaneously. In this paper, we address one of the subproblems: the part type selection problem. The problem is to determine a subset of part types having production requirements for immediate and simultaneous processing over the upcoming period of the planning horizon, subject to the tool magazine and processing time limitation. Several versions of tabu search (TS) algorithm are proposed for solving the problem. A systematic computational test is conducted to test the performance of the TS algorithms. The best TS algorithm developed is compared to a simulated annealing algorithm.     

Lagrangian-relaxation-based solution procedures for a multiproduct capacitated facility location problem with choice of facility type

This paper presents exact and heuristic solution procedures for a multiproduct capacitated facility location (MPCFL) problem in which the demand for a number of different product families must be supplied from a set of facility sites, and each site offers a choice of facility types exhibiting different capacities. MPCFL generalizes both the uncapacitated (or simple) facility location (UFL) problem and the pure-integer capacitated facility location problem. We define a branch-and-bound algorithm for MPCFL that utilizes bounds formed by a Lagrangian relaxation of MPCFL which decomposes the problem into UFL subproblems and easily solvable 0-1 knapsack subproblems. The UFL subproblems are solved by the dual-based procedure of Erlenkotter. We also present a subgradient optimization-Lagrangian relaxation-based heuristic for MPCFL. Computational experience with the algorithm and heuristic are reported. The MPCFL heuristic is seen to be extremely effective, generating solutions to the test problems that are on average within 2% of optimality, and the branch-and-bound algorithm is successful in solving all of the test problems to optimality.     

Medium-term hydro-thermal coordination via hydro and thermal subsystem decomposition

Summary This paper addresses the medium-term hydro-thermal coordination problem in an electric energy system. That is, the problem of finding the energy production of every power plant (hydro or thermal) in every subperiod of a given planning period, so that the customer load is supplied at minimum cost. The planning horizon is typically one to two months and the first week of this planning period is modeled in detail. The solution method proposed decomposes the problem in two subproblems corresponding to the hydro and thermal subsystems. These two subproblems are coordinated using a coordinating function for every subperiod. The coordinating function of a given subperiod expresses total production cost in that subperiod as a function of the total hydro production in that subperiod. The decomposition proposed makes it possible to use specialized algorithms to solve the hydro and thermal subproblems. This results in a very efficient computational procedure. From an experimental point of view the coordinating mechanism is robust. A case study is provided. It considers 61 thermal plants, a hydro system including 8 cascaded hydro plants and a 48 subperiods planning period.     

Computationally Efficient Solution of a Multiproduct,Two-Stage Distribution—Location Problem

A two-stage distribution planning problem, in which customers are to be served with different commodities from a number of plants, through a number of intermediate warehouses is addressed. The possible locations for the warehouses are given. For each location, there is an associated fixed cost for opening the warehouse concerned, as well as an operating cost and a maximum capacity. The demand of each customer for each commodity is known, as are the shipping costs from a plant to a possible warehouse and thereafter to a customer. It is required to choose the locations for opening warehouses and to find the shipping schedule such that the total cost is minimized. The problem is modelled as a mixed-integer programming problem and solved by branch and bound. The lower bounds are calculated through solving a minimum-cost, multicommodity network flow problem with capacity constraints. Results of extensive computational experiments are given.     

A multiperiod model for production planning and design in a multiproduct batch environment

A general multiperiod model to optimize simultaneously production planning and design decisions applied to multiproduct batch plants is proposed. This model includes deterministic seasonal variations of costs, prices, demands and supplies. The overall problem is formulated as a mixed-integer linear programming model by applying appropriate linearizations of non-linear terms. The performance criterion is to maximize the net present value of the profit, which comprises sales, investment, inventories, waste disposal and resources costs, and a penalty term accounting for late deliveries. A noteworthy feature of this approach is the selection of unit dimensions from the available discrete sizes, following the usual procurement policy in this area. The model simultaneously calculates the plant structure (parallel units in every stage, and allocation of intermediate storage tanks), and unit sizes, as well as the production planning decisions in each period (stocks of both product and raw materials, production plans, policies of sales and procurement, etc.).     

A search tree algorithm for plant location problems

This paper deals with the classical plant location problem, by introducing a new algorithm based on a ranking procedure of all the possible combinations of plant locations. The ranking is obtained by introducing a properly defined search tree and by exploiting its structural properties, so that the algorithm suitably combines a search procedure on the tree with a ranking method. The number of subproblems to be examined is greatly reduced by the use of a stopping rule and a lower bound. The lower bound is given by the value of the objective function of a dual feasible solution for the transportation problem associated to each combination. Computational results for a set of real size problems with different data structures are finally discussed.     

An efficient solution method for Weber problems with barriers based on genetic algorithms

In this paper we consider the problem of locating one new facility with respect to a given set of existing facilities in the plane and in the presence of convex polyhedral barriers. It is assumed that a barrier is a region where neither facility location nor travelling are permitted. The resulting non-convex optimization problem can be reduced to a finite series of convex subproblems, which can be solved by the Weiszfeld algorithm in case of the Weber objective function and Euclidean distances. A solution method is presented that, by iteratively executing a genetic algorithm for the selection of subproblems, quickly finds a solution of the global problem. Visibility arguments are used to reduce the number of subproblems that need to be considered, and numerical examples are presented.     

Optimal and heuristic algorithms for multiproduct uncapacitated facility location

We consider a generalization of the classic uncapacitated facility location problem (UFLP) in which customers require multiple products. We call this the multiproduct uncapacitated facility location problem (MUFLP). In MUFLP, in addition to a fixed cost for opening a facility, a fixed cost is incurred for each product that a facility is equipped to handle. Also, an assignment cost is incurred for satisfying a customer's requirement for a particular product at a chosen facility. We describe a branch-and-bound algorithm for MUFLP. Lower bounds are obtained by solving a UFLP subproblem for each product using a dual ascent routine. We also describe a heuristic branch-and-bound procedure in which the solutions to the subproblems at a given node might not generate a true lower bound. To generate a feasible solution, a ‘superposition’ heuristic based on solving UFLP subproblems for each product, as well as a ‘drop’ heuristic that eliminates facilities and equipment from the solution in a step-by-step manner, are given. Computational results are reported.     

Single machine earliness and tardiness scheduling

We examine the problem of scheduling a given set of jobs on a single machine to minimize total early and tardy costs without considering machine idle time. We decompose the problem into two subproblems with a simpler structure. Then the lower bound of the problem is the sum of the lower bounds of two subproblems. A lower bound of each subproblem is obtained by Lagrangian relaxation. Rather than using the well-known subgradient optimization approach, we develop two efficient multiplier adjustment procedures with complexity O(nlog n) to solve two Lagrangian dual subproblems. A branch-and-bound algorithm based on the two efficient procedures is presented, and is used to solve problems with up to 50 jobs, hence doubling the size of problems that can be solved by existing branch-and-bound algorithms. We also propose a heuristic procedure based on the neighborhood search approach. The computational results for problems with up to 3 000 jobs show that the heuristic procedure performs much better than known heuristics for this problem in terms of both solution efficiency and quality. In addition, the results establish the effectiveness of the heuristic procedure in solving realistic problems to optimality or near optimality.     

Planning and coordination of production and distribution facilities for multiple commodities

We study an integrated logistics model for locating production and distribution facilities in a multi-echelon environment. Designing such logistics systems requires two essential decisions, one strategic (e.g., where to locate plants and warehouses) and the other operational (distribution strategy from plants to customer outlets through warehouses). The distribution strategy is influenced by the product mix at each plant, the shipments of raw material from vendors to manufacturing plants and the distribution of finished products from the plants to the different customer zones through a set of warehouses. First we provide a mixed integer programming formulation to the integrated model. Then, we present an efficient heuristic solution procedure that utilizes the solution generated from a Lagrangian relaxation of the problem. We use this heuristic procedure to evaluate the performance of the model with respect to solution quality and algorithm performance. Results of extensive tests on the solution procedure indicate that the solution method is both efficient and effective. Finally a `real-world' example is solved to explore the implications of the model.     

Two-stage fuzzy production planning expected value model and its approximation method

This work develops a novel two-stage fuzzy optimization method for solving the multi-product multi-period (MPMP) production planning problem, in which the market demands and some of the inventory costs are assumed to be uncertainty and characterized by fuzzy variables with known possibility distributions. Some basic properties about the MPMP production planning problem are discussed. Since the fuzzy market demands and inventory costs usually have infinite supports, the proposed two-stage fuzzy MPMP production planning problem is an infinite-dimensional optimization problem that cannot be solved directly by conventional numerical solution methods. To overcome this difficulty, this paper adopts an approximation method (AM) to turn the original two-stage fuzzy MPMP production planning problem into a finite-dimensional optimization problem. The convergence about the AM is discussed to ensure the solution quality. After that, we design a heuristic algorithm, which combines the AM and simulated annealing (SA) algorithm, to solve the proposed two-stage fuzzy MPMP production planning problem. Finally, one real case study about a furniture manufacturing company is presented to illustrate the effectiveness and feasibility of the proposed modeling idea and designed algorithm.     

A heuristic lagrangean algorithm for the capacitated plant location problem

Lagrangean techniques have been widely applied to the uncapacitated plant location problem, and in some cases they have proven to be successfull even when capacitated problems with additional constraints are taken into account. In our paper we study the application of these techniques to the capacitated plant location problem when the model considered is a pure integer one. Several lagrangean decompositions are considered and for some of them heuristic algorithms have been designed to solve the resulting lagrangean subproblems, the heuristics consisting of a two phase procedure. The first (location phase) defines a set of multipliers from the analysis of the dual LP relaxation, and makes a choice of the plants considering the resulting subproblems as a particular case of the general assignment problems. Several heuristics have been studied for this second phase, based either on a decomposition of knapsack type subproblems through a definition of a set of penalties, or of looking into the duality gap and trying to reduce it. Computational experience is reported.     

Neighborhood search approaches to beam orientation optimization in intensity modulated radiation therapy treatment planning

The intensity modulated radiation therapy (IMRT) treatment planning problem consists of several subproblems which are typically solved sequentially. We seek to combine two of the subproblems: the beam orientation optimization (BOO) problem and the fluence map optimization (FMO) problem. The BOO problem is the problem of selecting the beam orientations to deliver radiation to the patient. The FMO problem is the problem of determining the amount of radiation intensity, or fluence, of each beamlet in each beam. The solution to the FMO problem measures the quality of a beam set, but the majority of previous BOO studies rely on heuristics and approximations to gauge the quality of the beam set. In contrast with these studies, we use an exact measure of the treatment plan quality attainable using a given beam set, which ensures convergence to a global optimum in the case of our simulated annealing algorithm and a local optimum in the case of our local search algorithm. We have also developed a new neighborhood structure that allows for faster convergence using our simulated annealing and local search algorithms, thus reducing the amount of time required to obtain a good solution. Finally, we show empirically that we can generate clinically acceptable treatment plans that require fewer beams than in current practice. This may reduce the length of treatment time, which is an important clinical consideration in IMRT.     

The use of state space relaxation for the dynamic facility location problem

Dynamic facility location is concerned with developing a location decision plan over a given planning horizon during which changes in the market and in costs are expected to occur. The objective is to select from a list of predetermined possible facility sites the locations of the facilities to use in each period of the planning horizon to minimise the total costs of operating the system. The costs considered here include not only transport and operation/maintenance charges but also relocation costs arising from the opening and closing of facilities as required by the plan.The problem is formulated in terms of dynamic programming but for simplicity with restrictions on the numbers of facilities that can be opened in a given period. The problem was solved using both dynamic programming and a branch and bound approach using state space relaxation. These two approaches are contrasted with different data and with different assumptions to compare the influence of alternative factors on the computational efficiency of both solution methods.     

Robust supply chain network design with multi-products for a company in the food sector

The paper aims to solve a problem faced by a company competing in the snacks market in Turkey. In line with the growth in this market, the company needs to make important decisions over the next few years about the timing and location of a new plant, its initial capacity, the timing and amount of additional capacity to be installed at the new and existing plants, the assignment of demand points to plants and the amount of raw materials to be shipped from suppliers to the plants in each period. The objective is to minimize the total cost of various components. The problem is formulated as a multi-period supply chain network design model with multi products. The resulting mixed-integer linear programming model is solved by the commercial solver CPLEX. This model enables us to carry out all analyses requested by the company in an efficient way. After this deterministic model is solved on the basis of a 9% annual increase in demand, it is extended to a minimax regret model to deal with uncertainty in demand quantities. The results suggest that opening the new plant in the city of İzmir is indeed a robust solution that is unaffected in different scenarios that are based on three distinct demand increase rates. Even though the location of the new plant remains unchanged with respect to scenarios, the optimal robust solution differs from the optimal solution of each scenario in terms of the capacity expansion decisions. After all obtained results had been communicated to the company managers and executives, the new plant construction was started in 2016 very close to the city that the mathematical model had determined. The new plant is expected to start operating in 2018.     

Dynamic lot-sizing with price changes and price-dependent holding costs

This paper proposes a new formulation of the dynamic lot-sizing problem with price changes which considers the unit inventory holding costs in a period as a function of the procurement decisions made in previous periods. In Section 1, the problem is defined and some of its fundamental properties are identified. A dynamic programming approach is developed to solve it when solutions are restricted to sequential extreme flows, and results from location theory are used to derive an O(T²) algorithm which provides a provably optimal solution of an integer linear programming formulation of the general problem. In Section 2, a heuristic is developed for the case where the inventory carrying rates and the order costs are constant, and where the item price can change once during the planning horizon. Permanent price increases, permanent price decreases and temporary price reductions are considered. In Section 3, extensive testing of the various optimal and heuristic algorithms is reported. Our results show that, in this context, the two following intuitive actions usually lead to near optimal solutions: accumulate stock at the lower price just prior to price increase and cut short on orders when a price decrease is imminent.     

A branch-and-price algorithm for the capacitated facility location problem

The capacitated facility location problem (CFLP) is a well-known combinatorial optimization problem with applications in distribution and production planning. It consists in selecting plant sites from a finite set of potential sites and in allocating customer demands in such a way as to minimize operating and transportation costs. A number of solution approaches based on Lagrangean relaxation and subgradient optimization has been proposed for this problem. Subgradient optimization does not provide a primal (fractional) optimal solution to the corresponding master problem. However, in order to compute optimal solutions to large or difficult problem instances by means of a branch-and-bound procedure information about such a primal fractional solution can be advantageous. In this paper, a (stabilized) column generation method is, therefore, employed in order to solve a corresponding master problem exactly. The column generation procedure is then employed within a branch-and-price algorithm for computing optimal solutions to the CFLP. Computational results are reported for a set of larger and difficult problem instances.     

A mathematical programming model for integrating production and procurement transport decisions

In this paper, we propose a new mathematical programming model for integrating production and procurement transport planning decisions in manufacturing systems in a unique optimization model. This problem was introduced conceptually and dubbed as MRP IV by Díaz-Madroñero et al. (2012) to extend the current MRP (material requirement planning) systems. This proposal simultaneously considers material, production resources capacities and procurement transport planning decisions with different shipping modes (such as full-truckload, less-than-truckload and milk-run) in the supply chain to avoid suboptimal results, which are usually generated due to sequential and independent plans. We considered an industrial automobile company to validate the proposed model using real world data. The results obtained by the MRP IV proposed model, in terms of total planning costs and transport efficiency indicators, are better than those obtained in the current heuristic procedures followed in the company under study.