Set-Up Coordination between Two Stages of a Supply Chain

In the material flow of a plant, parts are processed in batches, each having two distinct attributes, say shape and color. In one department, a set-up occurs every time the shape of the new batch is different from the previous one. In a downstream department, there is a set-up when the color of the new batch is different from the previous one. Since a unique sequence of batches must be established, the problem consists in finding such a common sequence optimizing an overall utility index. Here we consider two indices, namely the total number of set-ups and the maximum number of set-ups between the two departments. Both problems are shown to be NP-hard. An efficient heuristic approach is presented for the first index which allows to solve a set of real-life instances and performs satisfactorily on a large sample of experimental data.     

Approximation algorithms for two-machine flow shop scheduling with batch setup times

In many practical situations, batching of similar jobs to avoid setups is performed while constructing a schedule. This paper addresses the problem of non-preemptively scheduling independent jobs in a two-machine flow shop with the objective of minimizing the makespan. Jobs are grouped into batches. A sequence independent batch setup time on each machine is required before the first job is processed, and when a machine switches from processing a job in some batch to a job of another batch. Besides its practical interest, this problem is a direct generalization of the classical two-machine flow shop problem with no grouping of jobs, which can be solved optimally by Johnson's well-known algorithm. The problem under investigation is known to be NP-hard. We propose two O(n logn) time heuristic algorithms. The first heuristic, which creates a schedule with minimum total setup time by forcing all jobs in the same batch to be sequenced in adjacent positions, has a worst-case performance ratio of 3/2. By allowing each batch to be split into at most two sub-batches, a second heuristic is developed which has an improved worst-case performance ratio of 4/3. © 1998 The Mathematical Programming Society, Inc. Published by Elsevier Science B.V.     

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.     

Scheduling with batch setup times and earliness-tardiness penalties

We consider a scheduling model in which several batches of jobs need to be processed by a single machine. During processing, a setup time is incurred whenever there is a switch from processing a job in one batch to a job in another batch. All the jobs in the same batch have a common due date that is either externally given as an input data or internally determined as a decision variable. Two problems are investigated. One problem is to minimize the total earliness and tardiness penalties provided that each due date is externally given. We show that this problem is NP-hard even when there are only two batches of jobs and the two due dates are unrestrictively large. The other problem is to minimize the total earliness and tardiness penalties plus the total due date penalty provided that each due date is a decision variable. We give some optimality properties for this problem with the general case and propose a polynomial dynamic programming algorithm for solving this problem with two batches of jobs. We also consider a special case for both of the problems when the common due dates for different batches are all equal. Under this special case, we give a dynamic programming algorithm for solving the first problem with an unrestrictively large due date and for solving the second problem. This algorithm has a running time polynomial in the number of jobs but exponential in the number of batches.     

Two-Machine Flowshop Batching and Scheduling

We consider in this paper a two-machine flowshop scheduling problem in which the first machine processes jobs individually while the second machine processes jobs in batches. The forming of each batch on the second machine incurs a constant setup time. The objective is to minimize the makespan. This problem was previously shown to be NP-hard in the ordinary sense. In this paper, we first present a strong NP-hardness result of the problem. We also identify a polynomially solvable case with either anticipatory or non-anticipatory setups. We then establish a property that an optimal solution for the special case is a lower bound for the general problem. To obtain near-optimal solutions for the general problem, we devise some heuristics. The lower bound is used to evaluate the quality of the heuristic solutions. Results of computational experiments reveal that the heuristics produce solutions with small error ratios. They also suggest that the lower bound is close to the optimal solution.     

An iterative approach for the serial batching problem with parallel machines and job families

In this paper, we consider a parallel machine scheduling problem to minimize the total completion time. Each job belongs to a certain family. All jobs of one family have identical processing times. Major setups occur between jobs of different families, and we include sequence dependencies. Batches of jobs belonging to the same family can be formed to avoid these setups. Furthermore, we assume serial batching and batch availability. Therefore, the processing time of a batch is the sum of the processing times of all jobs grouped into the corresponding batch. An iterative method is developed for solving this specific problem. This approach alternates between varying batch sizes using an efficient heuristic and sequencing batches based on variable neighborhood search (VNS). Computational results demonstrate that the iterative heuristic outperforms heuristics based on a fixed batch size and list scheduling.     

Batching deteriorating items with applications in computer communication and reverse logistics

We study two deterministic scheduling problems that combine batching and deterioration features. In both problems, there is a certain demand for identical good quality items to be produced in batches. In the first problem, each batch is assigned an individual machine that requires a cost and a time to be activated. All the machines are identical, work in parallel, and always produce good quality items. All the items are available at time zero and they deteriorate while waiting for production. Deterioration results in a linear increase of time and cost of production. In the second problem, there is a single machine that produces good quality as well as defective items in batches. Each batch is preceded by a setup time and requires a setup cost. Defective items have to be reworked on the same machine. They deteriorate while waiting for rework. At a time to be decided, the machine switches from production to rework defective items of the current batch. After rework, every defective item has the required good quality. In both problems, the objective is to find batch partitioning such that a linear combination of the production cost and production completion time is minimized. The two problems are observed at computer service providers and also reverse logistics. In computer service providers, machines and items correspond to communication service channels and information transfer tasks, respectively. We reduce both problems to minimizing a function of one variable representing the number of batches. In an optimal solution of either problem, there are at most two different batch sizes. Linear time algorithms are proposed for both problems.     

Single Machine Batch Scheduling Problem with Resource Dependent Setup and Processing Time in the Presence of Fuzzy Due Date

We consider a batch scheduling problem on a single machine which processes jobs with resource dependent setup and processing time in the presence of fuzzy due-dates given as follows:1. There are n independent non-preemptive and simultaneously available jobs processed on a single machine in batches. Each job j has a processing time and a due-date.2. All jobs in a batch are completed together upon the completion of the last job in the batch. The batch processing time is equal to the sum of the processing times of its jobs. A common machine setup time is required before the processing of each batch.3. Both the job processing times and the setup time can be compressed through allocation of a continuously divisible resource. Each job uses the same amount of the resource. Each setup also uses the same amount of the resource.4. The due-date of each job is flexible. That is, a membership function describing non-decreasing satisfaction degree about completion time of each job is defined.5. Under above setting, we find an optimal batch sequence and resource values such that the total weighted resource consumption is minimized subject to meeting the job due-dates, and minimal satisfaction degree about each due-date of each job is maximized. But usually we cannot optimize two objectives at a time. So we seek non-dominated pairs i.e. the batch sequence and resource value, after defining dominance between solutions.A polynomial algorithm is constructed based on linear programming formulations of the corresponding problems.     

分类数很大时的成组排序问题

成组排序具有深刻的实际应用背景,是近年来国外研究得较多的一个热点.已有的某些动态规划算法的复杂性随分类数的增长呈指数型增长趋势,本文用“归并”和解不超过四个新的子问题的方法把分类数较大时的问题转化为分类数较小时的相应问题,简化了问题的求解.     

Models for scheduling charges in continuous casting: application to a Brazilian steel plant

In this paper we propose models for the scheduling of charges considering the alternatives of intermix slabs or setups between consecutive jobs. The study is motivated by the practical need of a steel plant in Brazil to reduce costs in a low volumes/wide range of products environment. An intermix slab is formed when two jobs with different grades and/or widths are processed without stopping the machine. This may generate a poor material, which has low commercial value or is used as scrap. The machine may also be stopped between two consecutive jobs to allow a setup. The setup operation has an associated cost, but no intermix slab is created. Thus, the scheduling problem consists of defining the sequence of charges and whether an intermix slab or a setup operation must take place to minimize the total cost. We report computational experiments on real data. This study, by comparing results with actual schedules planned, shows that significant cost savings upon practice can be achieved by running the proposed models on standard optimization packages.     

A hybrid two-stage flowshop with part family,batch production,major and minor set-ups

In this paper, we consider a two-stage hybrid flowshop with a single machine at stage 1 and multiple identical machines at stage 2. The flowshop is characterized by major and minor setups, part families and batch production allowing split and no split at stage 2. The parts within a family share a major setup and the parts in a batch share a minor setup. The objective of our problem is to minimize the makespan. We develop two allocation policies with one as a traditional way (called Forward Heuristic) and the other as a non-traditional way (called Backward Heuristic). We also develop several effective sequence rules to further improve the makespan. The computational results show that the Backward Heuristic, in general, is superior to the Forward Heuristic. The sequence rules developed in this paper also perform better than the traditional sequence rules such as SPT and LPT.     

An evaluation of heuristics for scheduling a non-delay permutation flow shop with family setups to minimize total earliness and tardiness

This paper presents several procedures for developing non-delay schedules for a permutation flow shop with family setups when the objective is to minimize total earliness and tardiness. These procedures consist of heuristics that were found to be effective for minimizing total tardiness in flow shops without family setups, modified to consider family setups and the total earliness and tardiness objective. These procedures are tested on several problem sets with varying conditions. The results show that variable greedy algorithms are effective when solving small problems, but using a genetic algorithm that includes a neighbourhood defined by the sequence of batches of jobs belonging to the same set-up family is effective when solving medium- or large-sized problems. The results also show that if setup times can be reduced a significant reduction in total earliness and tardiness could result.     

Batch scheduling and common due-date assignment on a single machine

We consider the problem of scheduling n groups of jobs on a single machine where three types of decisions are combined: scheduling, batching and due-date assignment. Each group includes identical jobs and may be split into batches; jobs within each batch are processed jointly. A sequence independent machine set-up time is needed between each two consecutively scheduled batches of different groups. A due-date common to all jobs has to be assigned. A schedule specifies the size of each batch, i.e. the number of jobs it contains, and a processing order for the batches. The objective is to determine a value for the common due-date and a schedule so as to minimize the sum of the due date assignment penalty and the weighted number of tardy jobs. Several special cases of this problem are shown to be ordinary NP-hard. Some cases are solved in O(n log n) time. Two pseudopolynomial dynamic programming algorithms are presented for the general problem, as well as a fully polynomial approximation scheme.     

Fabrication scheduling on a single machine with due date constraints

There is a fabrication machine available for processing a set of jobs. Each job is associated with a due date and consists of two parts, one is common among all products and the other is unique to itself. The unique components are processed individually and the common parts are grouped into batches for processing. A constant setup time is incurred when each batch is formed. The completion time of a job is defined as the time when both of its unique and common components are completed. In this paper, we consider two different objectives. The first problem seeks to minimize the maximum tardiness, and the second problem is to minimize the number of tardy jobs. To minimize the maximum tardiness, we propose a dynamic programming algorithm that optimally solves the problem in polynomial time. Next, we show NP-hardness proof and design a pseudo-polynomial time dynamic programming algorithm for the problem of minimizing the number of tardy jobs.     

Batch scheduling of deteriorating reworkables

The problem of scheduling the production of new and recoverable defective items of the same product manufactured on the same facility is studied. Items are processed in batches. Each batch comprises two sub-batches processed consecutively. In the first sub-batch, all the items are newly manufactured. Some of them are of the required good quality and some are defective. The defective items are remanufactured in the second sub-batch. They deteriorate while waiting for rework. This results in increased time and cost for their remanufacturing. All the items in the same sub-batch complete at the same time, which is the completion time of the last item in the sub-batch. Each remanufactured defective item is of the required good quality. It is assumed that the percentage of defective items in each batch is the same. A setup time is required to start batch processing and to switch from manufacturing to remanufacturing. The demands for good quality items over time are given. The objective is to find batch sizes such that the total setup and inventory holding cost is minimized and all the demands are satisfied. Dynamic programming algorithms are presented for the general problem and some important special cases.     

Solving a chemical batch scheduling problem by local search

In this paper the following chemical batch scheduling problem is considered: a set of orders has to be processed on a set of facilities. For each order a given amount of a product must be produced by means of chemical reactions before a given deadline. The production consists of a sequence of processes whereby each process has to be performed by one facility out of a given subset of facilities allowed for this process. The processing times depend on the choice of the facility and the processing is done in batch mode with given minimum and maximum sizes. The problem is to assign the processes to the facilities, splitting them into batches, and scheduling these batches in order to produce the demands within the given deadlines. For the scheduling part of the problem we present an approach based on the following steps. First, a procedure to calculate the minimum number of batches needed to satisfy the demands is presented. Based on this, the given problem is modeled in two different ways: as a general shop scheduling problem with set-up times or as scheduling problem with positive time-lags. Finally, a two-phase tabu search method is presented which is based on the two different formulations of the problem. The method is tested on some real world data. This revised version was published online in June 2006 with corrections to the Cover Date.     

多台机器流水作业中存在调整时间的Lot—streaming问题

多台机器流水作业的Lot-streaming问题（简称LS）,以往的研究都不考虑调整时间,固定分批数,寻找最优分批大小;本文对机器引入调整时间,研究同时决定最优分批数及分批大小,并给出了相应最优算法。     

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.     

Serial-batching scheduling with time-dependent setup time and effects of deterioration and learning on a single-machine

This paper deals with serial-batching scheduling problems with the effects of deterioration and learning, where time-dependent setup time is also considered. In the proposed scheduling models, all jobs are first partitioned into serial batches, and then all batches are processed on a single serial-batching machine. The actual job processing time is a function of its starting time and position. In addition, a setup time is required when a new batch is processed, and the setup time of the batches is time-dependent, i.e., it is a linear function of its starting time. Structural properties are derived for the problems of minimizing the makespan, the number of tardy jobs, and the maximum earliness. Then, three optimization algorithms are developed to solve them, respectively.     

Single machine batch scheduling with resource dependent setup and processing times

Jobs are processed by 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 common for all batches. Both the job processing times and the setup time can be compressed through allocation of a continuously divisible resource. Each job uses the same amount of the resource. Each setup also uses the same amount of the resource, which may be different from that for the jobs. Polynomial time algorithms are presented to find an optimal batch sequence and resource values such that either the total weighted resource consumption is minimized, subject to meeting job deadlines, or the maximum job lateness is minimized, subject to an upper bound on the total weighted resource consumption. The algorithms are based on linear programming formulations of the corresponding problems.