Pricing,relaxing and fixing under lot sizing and scheduling

We present a novel mathematical model and a mathematical programming based approach to deliver superior quality solutions for the single machine capacitated lot sizing and scheduling problem with sequence-dependent setup times and costs. The formulation explores the idea of scheduling products based on the selection of known production sequences. The model is the basis of a matheuristic, which embeds pricing principles within construction and improvement MIP-based heuristics. A partial exploration of distinct neighborhood structures avoids local entrapment and is conducted on a rule-based neighbor selection principle. We compare the performance of this approach to other heuristics proposed in the literature. The computational study carried out on different sets of benchmark instances shows the ability of the matheuristic to cope with several model extensions while maintaining a very effective search. Although the techniques described were developed in the context of the problem studied, the method is applicable to other lot sizing problems or even to problems outside this domain.     

Capacitated Lot Sizing for Injection Moulding: A Case Study

This paper considers the medium-term production smoothing problem for the injection moulding department of a Belgian firm. The problem is formulated as a series of one machine capacitated dynamic lot sizing problems, which are then solved by heuristic procedures. Computational results for real-life data are presented. It follows that the capacitated lot sizing approach succeeds in smoothing production such that subcontracting, which was often necessary with the E.O.Q. approach used by the firm, could be avoided in the future. Moreover, total set-up and inventory costs are reduced by about 20%.     

Capacitated dynamic lot sizing problems in closed-loop supply chain

In this paper, we address the capacitated dynamic lot sizing problem arising in closed-loop supply chain where returned products are collected from customers. These returned products can either be disposed or be remanufactured to be sold as new ones again; hence the market demands can be satisfied by either newly produced products or remanufactured ones. The capacities of production, disposal and remanufacturing are limited, and backlogging is not allowed. A general model of this problem is formulated, and several useful properties of the problem are characterized when cost functions are concave. Moreover, this problem is analyzed and solved to optimality using dynamic programming algorithms under different scenarios. It is shown that the problem with only disposal or remanufacturing can be converted into a traditional capacitated lot sizing problem and be solved by a polynomial algorithm if the capacities are constant. A pseudo-polynomial algorithm is proposed for the problem with both capacitated disposal and remanufacturing. The problem with capacitated production and remanufacturing and the problem with uncapacitated production and capacitated remanufacturing are also analyzed and solved. Through numerical experiments we show that the proposed algorithms perform well when solving problems of practical sizes. From the experimental results also indicates that it is worthwhile to expand the remanufacturing capacity only when returned products exist in a relatively long planning horizon, and production capacities have little effect on the remanufacturing plan when the demand is mainly satisfied by the production.     

Capacitated lot sizing and scheduling with parallel machines and shared buffers: A case study in a packaging company

The aim of this work is to propose a solution approach for a capacitated lot sizing and scheduling real problem with parallel machines and shared buffers, arising in a packaging company producing yoghurt. The problem has been formulated as a hybrid Continuous Set-up and Capacitated Lot Sizing Problem (CSLP–CLSP). A new effective two stage optimisation heuristic based on the decomposition of the problem into a lot sizing problem and a scheduling problem has been developed. An assignment of mixture to buffers is made in the first stage, and therefore the corresponding orders are scheduled on the production lines by performing a local search. Computational tests have been performed on the real data provided by the company. The heuristic exhibits near-optimal solutions, all obtained in a very short computational time.     

Hybrid heuristics for the capacitated lot sizing and loading problem with setup times and overtime decisions

The capacitated lot sizing and loading problem (CLSLP) deals with the issue of determining the lot sizes of product families/end items and loading them on parallel facilities to satisfy dynamic demand over a given planning horizon. The capacity restrictions in the CLSLP are imposed by constraints specific to the production environment considered. When a lot size is positive in a specific period, it is loaded on a facility without exceeding the sum of the regular and overtime capacity limits. Each family may have a different process time on each facility and furthermore, it may be technologically feasible to load a family only on a subset of existing facilities. So, in the most general case, the loading problem may involve unrelated parallel facilities of different classes. Once loaded on a facility, a family may consume capacity during setup time. Inventory holding and overtime costs are minimized in the objective function. Setup costs can be included if setups incur costs other than lost production capacity. The CLSLP is relevant in many industrial applications and may be generalized to multi-stage production planning and loading models. The CLSLP is a synthesis of three different planning and loading problems, i.e., the capacitated lot sizing problem (CLSP) with overtime decisions and setup times, minimizing total tardiness on unrelated parallel processors, and, the class scheduling problem, each of which is NP in the feasibility and optimality problems. Consequently, we develop hybrid heuristics involving powerful search techniques such as simulated annealing (SA), tabu search (TS) and genetic algorithms (GA) to deal with the CLSLP. Results are compared with optimal solutions for 108 randomly generated small test problems. The procedures developed here are also compared against each other in 36 larger size problems.     

On the equivalence of strong formulations for capacitated multi-level lot sizing problems with setup times

Several mixed integer programming formulations have been proposed for modeling capacitated multi-level lot sizing problems with setup times. These formulations include the so-called facility location formulation, the shortest route formulation, and the inventory and lot sizing formulation with (?, S) inequalities. In this paper, we demonstrate the equivalence of these formulations when the integrality requirement is relaxed for any subset of binary setup decision variables. This equivalence has significant implications for decomposition-based methods since same optimal solution values are obtained no matter which formulation is used. In particular, we discuss the relax-and-fix method, a decomposition-based heuristic used for the efficient solution of hard lot sizing problems. Computational tests allow us to compare the effectiveness of different formulations using benchmark problems. The choice of formulation directly affects the required computational effort, and our results therefore provide guidelines on choosing an effective formulation during the development of heuristic-based solution procedures.     

Heuristics for the multi-level capacitated minimum spanning tree problem

The capacitated minimum spanning tree (CMST) problem is fundamental to the design of centralized communication networks. In this paper we consider the multi-level capacitated minimum spanning tree problem, a generalization of the well-known CMST problem. Based on work previously done in the field, three heuristics are presented, addressing unit and non-unit demand cases. The proposed heuristics have been also integrated into a mixed integer programming solver. Evaluation results are presented, for an extensive set of experiments, indicating the improvements that the heuristics bring to the particular problem.     

On alternative mixed integer programming formulations and LP-based heuristics for lot-sizing with setup times

We address the multi-item, capacitated lot-sizing problem (CLSP) encountered in environments where demand is dynamic and to be met on time. Items compete for a limited capacity resource, which requires a setup for each lot of items to be produced causing unproductive time but no direct costs. The problem belongs to a class of problems that are difficult to solve. Even the feasibility problem becomes combinatorial when setup times are considered. This difficulty in reaching optimality and the practical relevance of CLSP make it important to design and analyse heuristics to find good solutions that can be implemented in practice. We consider certain mixed integer programming formulations of the problem and develop heuristics including a curtailed branch and bound, for rounding the setup variables in the LP solution of the tighter formulations. We report our computational results for a class of instances taken from literature.     

A multi-class multi-level capacitated lot sizing model

When demand loading is higher than available capacity, it takes a great deal of effort for a traditional MRP system to obtain a capacity-feasible production plan. Also, the separation of lot sizing decisions and capacity requirement planning makes the setup decisions more difficult. In a practical application, a production planning system should prioritize demands when allocating manufacturing resources. This study proposes a planning model that integrates all MRP computation modules. The model not only includes multi-level capacitated lot sizing problems but also considers multiple demand classes. Each demand class corresponds to a mixed integer programming (MIP) problem. By sequentially solving the MIP problems according to their demand class priorities, this proposed approach allocates finite manufacturing resources and generates feasible production plans. In this paper we experiment with three heuristic search algorithms: (1) tabu search; (2) simulated annealing, and (3) genetic algorithm, to solve the MIP problems. Experimental designs and statistical methods are used to evaluate and analyse the performance of these three algorithms. The results show that tabu search and simulated annealing perform best in the confirmed order demand class and forecast demand class, respectively.     

An artificial bee colony algorithm for the capacitated vehicle routing problem

This paper introduces an artificial bee colony heuristic for solving the capacitated vehicle routing problem. The artificial bee colony heuristic is a swarm-based heuristic, which mimics the foraging behavior of a honey bee swarm. An enhanced version of the artificial bee colony heuristic is also proposed to improve the solution quality of the original version. The performance of the enhanced heuristic is evaluated on two sets of standard benchmark instances, and compared with the original artificial bee colony heuristic. The computational results show that the enhanced heuristic outperforms the original one, and can produce good solutions when compared with the existing heuristics. These results seem to indicate that the enhanced heuristic is an alternative to solve the capacitated vehicle routing problem.     

Improved lower bounds for the capacitated lot sizing problem with setup times

We present new lower bounds for the capacitated lot sizing problem, applying decomposition to the network reformulation. The demand constraints are the linking constraints and the problem decomposes into subproblems per period containing the capacity and setup constraints. Computational results and a comparison to other lower bounds are presented.     

Meta-heuristics for dynamic lot sizing: A review and comparison of solution approaches

Proofs from complexity theory as well as computational experiments indicate that most lot sizing problems are hard to solve. Because these problems are so difficult, various solution techniques have been proposed to solve them. In the past decade, meta-heuristics such as tabu search, genetic algorithms and simulated annealing, have become popular and efficient tools for solving hard combinatorial optimization problems. We review the various meta-heuristics that have been specifically developed to solve lot sizing problems, discussing their main components such as representation, evaluation, neighborhood definition and genetic operators. Further, we briefly review other solution approaches, such as dynamic programming, cutting planes, Dantzig–Wolfe decomposition, Lagrange relaxation and dedicated heuristics. This allows us to compare these techniques. Understanding their respective advantages and disadvantages gives insight into how we can integrate elements from several solution approaches into more powerful hybrid algorithms. Finally, we discuss general guidelines for computational experiments and illustrate these with several examples.     

Hybrid simulated annealing and MIP-based heuristics for stochastic lot-sizing and scheduling problem in capacitated multi-stage production system

This paper addresses lot sizing and scheduling problem of a flow shop system with capacity constraints, sequence-dependent setups, uncertain processing times and uncertain multi-product and multi-period demand. The evolution of the uncertain parameters is modeled by means of probability distributions and chance-constrained programming (CCP) theory. A new mixed-integer programming (MIP) model with big bucket time approach is proposed to formulate the problem. Due to the complexity of problem, two MIP-based heuristics with rolling horizon framework named non-permutation heuristic (NPH) and permutation heuristic (PH) have been performed to solve this model. Also, a hybrid meta-heuristic based on a combination of simulated annealing, firefly algorithm and proposed heuristic for scheduling is developed to solve the problem. Additionally, Taguchi method is conducted to calibrate the parameters of the meta-heuristic and select the optimal levels of the algorithm’s performance influential factors. Computational results on a set of randomly generated instances show the efficiency of the hybrid meta-heuristic against exact solution algorithm and heuristics.     

Dynamic uncapacitated lot sizing with random demand under a fillrate constraint

This paper deals with the single-item dynamic uncapacitated lot sizing problem with random demand. We propose a model based on the “static uncertainty” strategy of Bookbinder and Tan (1988). In contrast to these authors, we use exact expressions for the inventory costs and we apply a fillrate constraint. We present an exact solution method and modify several well-known dynamic lot sizing heuristics such that they can be applied for the case of dynamic stochastic demands. A numerical experiment shows that there are significant differences in the performance of the heuristics whereat the ranking of the heuristics is different from that reported for the case of deterministic demand.     

A hybrid adaptive large neighborhood search heuristic for lot-sizing with setup times

This paper presents a hybrid of a general heuristic framework and a general purpose mixed-integer programming (MIP) solver. The framework is based on local search and an adaptive procedure which chooses between a set of large neighborhoods to be searched. A mixed integer programming solver and its built-in feasibility heuristics is used to search a neighborhood for improving solutions. The general reoptimization approach used for repairing solutions is specifically suited for combinatorial problems where it may be hard to otherwise design suitable repair neighborhoods. The hybrid heuristic framework is applied to the multi-item capacitated lot sizing problem with setup times, where experiments have been conducted on a series of instances from the literature and a newly generated extension of these. On average the presented heuristic outperforms the best heuristics from the literature, and the upper bounds found by the commercial MIP solver ILOG CPLEX using state-of-the-art MIP formulations. Furthermore, we improve the best known solutions on 60 out of 100 and improve the lower bound on all 100 instances from the literature.     

A tabu search heuristic for solving the CLSP with backlogging and set-up carry-over

In this paper, the multi-item, single-level, capacitated, dynamic lot sizing problem with set-up carry-over and backlogging, abbreviated to CLSP⁺, is considered. The problem is formulated as a mixed integer programming problem. A heuristic method consisting of four elements: (1) a demand shifting rule, (2) lot size determination rules, (3) checking feasibility conditions and (4) set-up carry-over determination, provides us with an initial feasible solution. The resulting feasible solution is improved by adopting the corresponding set-up and set-up carry-over schedule and re-optimizing it by solving a minimum-cost network flow problem. Then the improved solution is used as a starting solution for a tabu search procedure, with the value of moves assessed using the same minimum-cost network problem. Computational results on randomly generated problems show that the algorithm, which is coded in C++, is able to provide optimal solutions or solutions extremely close to optimal. The computational efficiency makes it possible to solve reasonably large problem instances routinely on a personal computer.     

A polynomial time algorithm to solve the single-item capacitated lot sizing problem with minimum order quantities and concave costs

This paper deals with the single-item capacitated lot sizing problem with concave production and storage costs, and minimum order quantity (CLSP-MOQ). In this problem, a demand must be satisfied at each period t over a planning horizon of T periods. This demand can be satisfied from the stock or by a production at the same period. When a production is made at period t, the produced quantity must be greater to than a minimum order quantity (L) and lesser than the production capacity (U). To solve this problem optimally, a polynomial time algorithm in O(T⁵) is proposed and it is computationally tested on various instances.     

Heuristics for solving a capacitated multiple allocation hub location problem with application in German wagonload traffic

In this paper, we present a capacitated multiple allocation hub location problem, which arose from a network design problem in German wagonload traffic. We develop heuristic solution approaches based on local improvements. We solve the problem with the heuristics and CPLEX on test data sets provided by our partner Deutsche Bahn AG. The computational results are presented and compared.     

A Bionomic Approach to the Capacitated p-Median Problem

This paper advocates the use of the bionomic algorithm, a recently proposed metaheuristic technique, as an effective method to solve capacitated p-median problems (CPMP). Bionomic algorithms already proved to be an effective framework for finding good solutions to combinatorial optimization problems, when good local optimization algorithms are available. The paper also presents an effective local search technique for the CPMP. Computational results show the effectiveness of the proposed approach, when compared to the best performing heuristics so far presented in the literature.     

Scheduling multiple orders per job in a single machine to minimize total completion time

This paper deals with a single-machine scheduling problem with multiple orders per job (MOJ) considerations. Both lot processing machines and item processing machines are also examined. There are two primary decisions that must be made in the proposed problem: (1) how to group the orders together, and (2) how to schedule the jobs once they are formed. In order to obtain the optimal solution to a scheduling problem, these two decisions should be made simultaneously. The performance measure is the total completion time of all orders. Two mixed binary integer programming models are developed to optimally solve this problem. Also, two efficient heuristics are proposed for solving large-sized problems. Computational results are provided to demonstrate the efficiency of the models and the effectiveness of the heuristics.