Capacity planning in manufacturing and computer networks

This paper addresses capacity planning in manufacturing and computer networks. More specifically, given a manufacturing or computer system modeled as a network of queues, we consider the minimum cost selection of capacity levels from a discrete set of choices such that a single system performance constraint is satisfied. We focus on settings where the cost of obtaining capacity is a concave function, allowing fixed charges and economies of scale to be handled. To solve this class of capacity planning problems, we present a branch and bound algorithm that globally minimizes a concave cost function over a single convex nonlinear performance constraint and lower and upper bounds on the discrete capacity variables. We also present reoptimization procedures that allow the subproblems to be solved more efficiently. Computational results with the algorithm are reported.     

Expert systems for planning and scheduling manufacturing systems

In this paper, research and applications of expert systems in production planning and scheduling are reviewed. Components of expert systems are briefly discussed. Relationship between expert system and operations research approaches are presented. Integration of operations research and expert system techniques is explored.     

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.     

Capacity planning in manufacturing networks with discrete options

We consider multiproduct manufacturing systems modeled by open networks of queues with general distributions for arrival patterns and service times. Since exact solutions are not available for measuring mean number of jobs in these systems, we rely on approximate analyses based on the decomposition approach developed, among others, by Reiser and Kobayashi [16], Kuehn [14], Shanthikumar and Buzacott [19], Whitt [29], and extensions by Bitran and Tirupati [2]. The targeting problem (TP) presented in this paper addresses capacity planning issues in multiproduct manufacturing systems. Since TP is a nonlinear integer program that is not easy to solve, we present a heuristic to obtain an approximate solution. We also provide bounds on the performance of this heuristic and illustrate our approach by means of a numerical example.     

Capacity planning in networks of queues with manufacturing applications

This paper addresses capacity planning in systems that can be modeled as a network of queues. More specifically, we present an optimization model and solution methods for the minimum cost selection of capacity at each node in the network such that a set of system performance constraints is satisfied. Capacity is controlled through the mean service rate at each node. To illustrate the approach and how queueing theory can be used to measure system performance, we discuss a manufacturing model that includes upper limits on product throughput times and work-in-process in the system. Methods for solving capacity planning problems with continuous and discrete capacity options are discussed. We focus primarily on the discrete case with a concave cost function, allowing fixed charges and costs exhibiting economies of scale with respect to capacity to be handled.     

Design,planning, scheduling,and control problems of flexible manufacturing systems

The design and use of flexible manufacturing systems (FMSs) involve some intricate operations research problems.FMS design problems include, for example, determining the appropriate number of machine tools of each type, the capacity of the material handling system, and the size of buffers.FMS planning problems include the determination of which parts should be simultaneously machined, the optimal partition of machine tools into groups, allocations of pallets and fixtures to part types, and the assignment of operations and associated cutting tools among the limited-capacity tool magazines of the machine tools.FMS scheduling problems include determining the optimal input sequence of parts and an optimal sequence at each machine tool given the current part mix.FMS control problems are those concerned with, for example, monitoring the system to be sure that requirements and due dates are being met and that unreliability problems are taken care of. This paper defines and describes these FMS problems in detail for OR/MS researchers to work on.     

Planning and scheduling of multistage multiproduct batch plants operating under production campaigns

When plants are operated under stable conditions during reasonable time periods, operation with campaigns is particularly appropriate. The regular operation of the facilities simplifies the production control, the inventory management, the plant operability, etc. A?campaign includes several batches of different products that are going to be manufactured and the same one is cyclically repeated over the time horizon. In this work, a mixed integer linear programming formulation is proposed for the planning and scheduling of given multiproduct batch plants operating with campaigns. The number and size of batches for each product, the campaign composition, the assignment of batches to units and their sequencing, and the number of times that the campaign is repeated over the time horizon must be determined. Taking into account this scenario, an appropriate performance measure is the minimization of the cycle time. An asynchronous slot-based continuous-time representation for modeling the assignment of batches to units and their sequencing is employed, and a novel rule for determining the maximum number of slots postulated for each unit is proposed.     

Preemptive scheduling of interval orders is polynomial

In 1979, Papadimitriou and Yannakakis gave a polynomial time algorithm for the scheduling of jobs requiring unit completion times when the precedence constraints form an interval order. The authors solve here the corresponding problem, for preemptive scheduling (a job can be interrupted to work on more important tasks, and completed at a later time, subject to the usual scheduling constraints.) The m-machine preemptive scheduling problem is shown to have a polynomial algorithm, for both unit time and variable execution times as well, when the precedence constraints are given by an interval order.     

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.).     

Log-weight scheduling in switched networks

We consider switched queueing networks in which there are constraints on which queues may be served simultaneously. The scheduling policy for such a network specifies which queues to serve at any point in time. We introduce and study a variant of the popular maximum weight or backpressure policy which chooses the collection of queues to serve that has maximum weight. Unlike the maximum weight policies studied in the literature, the weight of a queue depends on logarithm of its queue-size in this paper. For any multihop switched network operating under such maximum log-weighted policy, we establish that the network Markov process is positive recurrent as long as it is underloaded. As the main result of this paper, a meaningful fluid model is established as the formal functional law of large numbers approximation. The fluid model is shown to be work-conserving. That is, work (or total queue-size) is nonincreasing as long as the network is underloaded or critically loaded. We identify invariant states or fixed points of the fluid model. When underloaded, null state is the unique invariant state. For a critically loaded fluid model, the space of invariant states is characterized as the solution space of an optimization problem whose objective is lexicographic ordering of total queue-size and the negative entropy of the queue state. An important contribution of this work is in overcoming the challenge presented by the log-weight function in establishing meaningful fluid model. Specifically, the known approaches in the literature primarily relied on the “scale invariance” property of the weight function that log-function does not possess.     

Activity network for planning and scheduling

A procedure for constructing a planning and scheduling network is given, where each activity to be scheduled is represented uniquely by a line. No events need be defined manually. Input is the set of activities with a list of preceding (but not necessarily immediately preceding) activities for each of them. Some comparisons with events network of Pert type are made.     

MIP-based decomposition strategies for large-scale scheduling problems in multiproduct multistage batch plants: A benchmark scheduling problem of the pharmaceutical industry

An efficient systematic iterative solution strategy for solving real-world scheduling problems in multiproduct multistage batch plants is presented. Since the proposed method has its core a mathematical model, two alternative MIP scheduling formulations are suggested. The MIP-based solution strategy consists of a constructive step, wherein a feasible and initial solution is rapidly generated by following an iterative insertion procedure, and an improvement step, wherein the initial solution is systematically enhanced by implementing iteratively several rescheduling techniques, based on the mathematical model. A salient feature of our approach is that the scheduler can maintain the number of decisions at a reasonable level thus reducing appropriately the search space. A fact that usually results in manageable model sizes that often guarantees a more stable and predictable optimization model behavior. The proposed strategy performance is tested on several complicated problem instances of a multiproduct multistage pharmaceuticals scheduling problem. On average, high quality solutions are reported with relatively low computational effort. Authors encourage other researchers to adopt the large-scale pharmaceutical scheduling problem to test on it their solution techniques, and use it as a challenging comparison reference.     

Integration of equipment planning and project scheduling

It is common to schedule project activities first, then the utilization of equipment and its operating crew is planned based on such schedule. Real world experiences indicate that activity scheduling can be heavily impacted by the resources needed. In particular, if a project requires highly specialized and expensive equipment type, then one needs to take into account the schedule and cost of such resources in developing the project schedule.     

Production capacity planning and control in multi-stage manufacturing

This paper develops a mathematical model for determining the optimum lot-sizes for a set of products and the capacity required to produce them in a multi-stage production system. The purpose of the modelling is to support capacity planning at the production function level and the basic criterion considered for the optimisation is the minimisation of the total system cost (TSC) per unit time. The TSC consists of (i) set-up cost, (ii) cost due to the quenching of batches, and (iii) hiring cost of the machines. An example is presented to explain the model.     

MILP-based approaches for medium-term planning of single-stage continuous multiproduct plants with parallel units

In this paper, we address the problem of medium-term planning of single-stage continuous multiproduct plants with multiple processing units in parallel. Sequence-dependent changeover times and costs occur when switching from one type of product to another. A traveling salesman problem (TSP)-based mixed-integer linear programming (MILP) model is proposed based on a hybrid discrete/continuous time representation. We develop additional constraints and variables to ensure that subtours do not occur in the solution. The model is successfully applied to an example of a polymer processing plant to illustrate its applicability. In order to solve larger model instances and planning horizons, a rolling horizon approach is developed to reduce the computational expense. Finally, the proposed model is compared to a recently published approach through literature examples, and the results show that the computational performance of the proposed model is superior.     

Fuzzy scheduling of job orders in a two-stage flowshop with batch-processing machines

In this paper, we present a mixed-integer fuzzy programming model and a genetic algorithm (GA) based solution approach to a scheduling problem of customer orders in a mass customizing furniture industry. Independent job orders are grouped into multiple classes based on similarity in style so that the required number of setups is minimized. The family of jobs can be partitioned into batches, where each batch consists of a set of consecutively processed jobs from the same class. If a batch is assigned to one of available parallel machines, a setup is required at the beginning of the first job in that batch. A schedule defines the way how the batches are created from the independent jobs and specifies the processing order of the batches and that of the jobs within the batches. A machine can only process one job at a time, and cannot perform any processing while undergoing a setup. The proposed formulation minimizes the total weighted flowtime while fulfilling due date requirements. The imprecision associated with estimation of setup and processing times are represented by fuzzy sets.     

Online time-constrained scheduling in linear and ring networks

We consider the problem of scheduling a sequence of packets over a linear network, where every packet has a source and a target, as well as a release time and a deadline by which it must arrive at its target. The model we consider is bufferless, where packets are not allowed to be buffered in nodes along their paths other than at their source. This model applies to optical networks where opto-electronic conversion is costly, and packets mostly travel through bufferless hops. The offline version of this problem was previously studied in M. Adler et al. (2002) [3]. In this paper we study the online version of the problem, where we are required to schedule the packets without knowledge of future packet arrivals. We use competitive analysis to evaluate the performance of our algorithms. We present the first online algorithms for several versions of the problem. For the problem of throughput maximization, where all packets have uniform weights, we give an algorithm with a logarithmic competitive ratio, and present some lower bounds. For other weight functions, we show algorithms that achieve optimal competitive ratios.     

Experimental investigation of real-time scheduling in flexible manufacturing systems

This paper presents a new two-phase (TP) approximate method for real-time scheduling in a flexible manufacturing system (FMS). This method combines a reduced enumeration schedule generation algorithm with a 0–1 optimization algorithm. In order to make the combined algorithm practicable, heuristic rules are introduced for the selection of jobs to be scheduled. The relative performance of the TP method vis-a-vis conventional heuristic dispatching rules such as SPT, LPT, FCFS, MWKR, and LWKR is investigated using combined process-interaction/discrete-event simulation models. An efficient experimental procedure is designed and implemented using these models, and the statistical analysis of the results is presented. For the particular case investigated, the conclusions are very encouraging. In terms of mean flow time, the TP method performs significantly better than any other tested heuristic dispatching rules. Also, the experimental results show that using global information significantly improves the FMS performance.