The two-dimensional cutting stock problem revisited

In the strip packing problem (a standard version of the two-dimensional cutting stock problem), the goal is to pack a given set of rectangles into a vertical strip of unit width so as to minimize the total height of the strip needed. The k-stage Guillotine packings form a particularly simple and attractive family of feasible solutions for strip packing. We present a complete analysis of the quality of k-stage Guillotine strip packings versus globally optimal packings: k=2 stages cannot guarantee any bounded asymptotic performance ratio. k=3 stages lead to asymptotic performance ratios arbitrarily close to 1.69103; this bound is tight. Finally, k=4 stages yield asymptotic performance ratios arbitrarily close to 1.Steve Seiden died in a tragic accident on June 11, 2002. This paper resulted from a number of email discussions between the authors in spring 2002.     

One-dimensional cutting stock optimization in consecutive time periods

The paper deals with the general one-dimensional cutting stock problem (G1D-CSP), where optimization is not limited to a single order. Stock cutting is treated as a permanent business process in a company in which consecutive order sets need to be fulfilled either for production needs or for its customers. Exact demand for future orders is not known in advance. The unutilized and partly utilized stock lengths left after fulfilling current order sets are stored and used later. The goal is the reduction of trim loss and costs over a broader time-span. A new approach is suggested where previously developed method for G1D-CSP is modified. Several practical examples of the cutting process for several consecutive order sets are presented. An extension to a currently used typology for cutting stock problems is proposed.     

Heuristic for the rectangular two-dimensional single stock size cutting stock problem with two-staged patterns

Two-staged patterns are often used in manufacturing industries to divide stock plates into rectangular items. A heuristic algorithm is presented to solve the rectangular two-dimensional single stock size cutting stock problem with two-staged patterns. It uses the column-generation method to solve the residual problems repeatedly, until the demands of all items are satisfied. Each pattern is generated using a procedure for the constrained single large object placement problem to guarantee the convergence of the algorithm. The computational results of benchmark and practical instances indicate the following: (1) the algorithm can solve most instances to optimality, with the gap to optimality being at most one plate for those solutions whose optimality is not proven and (2) for the instances tested, the algorithm is more efficient (on average) in reducing the number of plates used than a published algorithm and a commercial stock cutting software package.     

A heuristic for the one-dimensional cutting stock problem with usable leftover

A heuristic algorithm for the one-dimensional cutting stock problem with usable leftover (residual length) is presented. The algorithm consists of two procedures. The first is a linear programming procedure that fulfills the major portion of the item demand. The second is a sequential heuristic procedure that fulfills the remaining portion of the item demand. The algorithm can balance the cost of the consumed bars, the profit from leftovers and the profit from shorter stocks reduction. The computational results show that the algorithm performs better than a recently published algorithm.     

Alternative configurations for cutting machines in a tube cutting mill

In a steel tube mill where an endless stream of steel tube is supplied from a manufacturing facility, trim waste is never made regardless of cutting patterns used and the standard cutting stock problem seems meaningless. Therefore, the continuous stock cutting problem with setup is introduced to minimize the sum of cutting time and pattern changing time to meet the given demand. We propose a new configuration of cutting machines to achieve higher production efficiency, namely the open-ended configuration as opposed to the traditional closed-ended configuration, thereby two variants of the problem are defined. We propose linear formulations for both problems using binary expansion of the number of pieces of different types in a pattern. Furthermore, we define the time for pattern change as a linear function of the number of knives used in the pattern to be more realistic. Computational studies suggest that the open-ended cutting machine may improve the production time by up to 44% and that our linear formulations are more efficient than the existing ones.     

An integrated cutting stock and sequencing problem

In this paper an integrated problem formulated as an integer linear programming problem is presented to find an optimal solution to the cutting stock problem under particular pattern sequencing constraints. The solution uses a Lagrangian approach. The dual problem is solved using a modified subgradient method. A heuristic for the integrated problem is also presented. The computational results obtained from a set of unidimensional instances that use these procedures are reported.     

The cutting stock problem and integer rounding

An integer programming problem is said to have the integer round-up property if its optimal value is given by the least integer greater than or equal to the optimal value of its linear programming relaxation. In this paper we prove that certain classes of cutting stock problems have the integer round-up property. The proof of these results relies upon the decomposition properties of certain knapsack polyhedra.This research was partially supported by National Science Foundation grants ECS-8005350 and 81-13534 to Cornell University.     

Heuristic and exact methods for the cutting sequencing problem

Cutting stock problems deal with the generation of a set of cutting patterns that minimizes waste. Sometimes it is also important to find the processing sequence of this set of patterns to minimize the maximum queue of partially cut orders. In such instances a cutting sequencing problem has to be solved. This paper presents a new mathematical model and a three-phase approach for the cutting sequencing problem. In the first phase, a greedy algorithm produces a good starting solution that is improved in the second phase by a tabu search, or a generalized local search procedure, while, in the last phase, the problem is optimally solved by an implicit enumeration procedure that uses the best solution previously found as an upper bound. Computing experience, based on 300 randomly generated problems, shows the good performance of the heuristic methods presented.     

The one-dimensional cutting stock problem with due dates

The one-dimensional cutting stock problem is the problem of cutting stock material into shorter lengths, in order to meet demand for these shorter lengths while minimizing waste. In industrial cutting operations, it may also be necessary to fill the orders for these shorter lengths before a given due date. We propose new optimization models and solution procedures which solve the cutting stock problem when orders have due dates. We evaluate our approach using data from a large manufacturer of reinforcement steel and show that we are able to solve industrial-size problems, while also addressing common cutting considerations such as aggregation of orders, multiple stock lengths and cutting different types of material on the same machine. In addition, we evaluate operational performance in terms of resulting waste and tardiness of orders using our model in a rolling horizon framework.     

A comparative numerical analysis for the guillotine two-dimensional cutting problem

In this work, the behavior of four algorithms in the resolution of the two-dimensional constrained guillotine cutting problem is analyzed. This problem is concerned about the way a set of pieces should be cut from a plate of greater dimensions, considering guillotine cutting and a constrained number of times a piece can be cut from the plate. In this study three combinatorial and two heuristic methods are considered. In the combinatorial methods from the set of pieces, a minimum loss layout is constructively generated based on Wang's algorithm. In addition, an evolutionary and an annealing type approach are considered. All of these models have been implemented on a high performance Silicon Graphics machine. Performance of each algorithm is analyzed both in terms of percentage waste and running time. In order to do that, a set of 1000 instances are classified according to their combinatorial degree and subsequently evaluated. This revised version was published online in June 2006 with corrections to the Cover Date.     

A note on the approximability of cutting stock problems

Cutting stock problems and bin packing problems are basically the same problems. They differ essentially on the variability of the input items. In the first, we have a set of items, each item with a given multiplicity; in the second, we have simply a list of items (each of which we may assume to have multiplicity 1). Many approximation algorithms have been designed for packing problems; a natural question is whether some of these algorithms can be extended to cutting stock problems. We define the notion of “well-behaved” algorithms and show that well-behaved approximation algorithms for one, two and higher dimensional bin packing problems can be translated to approximation algorithms for cutting stock problems with the same approximation ratios.     

An integrated approach to the one-dimensional cutting stock problem in coronary stent manufacturing

This paper presents a two-stage approach for pattern generation and cutting plan determination of the one-dimensional cutting stock problem. Calculation of the total number of patterns that will be cut and generation of the cutting patterns are performed in the first stage. On the other hand, the second stage determines the cutting plan. The proposed approach makes use of two separate integer linear programming models. One of these models is employed by the first stage to generate the cutting patterns through a heuristic procedure with the objective of minimizing trim loss. The cutting patterns obtained from Stage 1 are then fed into the second stage. In this stage, another integer linear programming model is solved to form a cutting plan. The objective of this model is to minimize a generalized total cost function consisting of material inputs, number of setups, labor hours and overdue time; subject to demand requirements, material availability, regular and overtime availability, and due date constraints. The study also demonstrates an implementation of the proposed approach in a coronary stent manufacturer. The case study focuses on the cutting phase of the manufacturing process followed by manual cleaning and quality control activities. The experiments show that the proposed approach is suitable to the conditions and requirements of the company.     

T-shape homogenous block patterns for the two-dimensional cutting problem

This paper presents an algorithm for unconstrained T-shape homogenous block cutting patterns of rectangular pieces. A vertical cut divides the stock sheet into two segments. Each segment consists of sections that have the same length and direction. A section contains a row of homogenous blocks. A homogenous block consists of homogenous strips of the same piece type. Each cut on the block produces just one strip. The directions of two strips cut successively from a block are either parallel or orthogonal. The algorithm uses a dynamic programming recursion to generate optimal blocks, solves knapsack problems to obtain the block layouts on the sections and the section layout on segments of various lengths, and optimally selects two segments to compose the cutting pattern. The computational results indicate that the algorithm is efficient in improving material usage, and the computation time is reasonable.     

Simplest optimal cutting patterns for equal rectangles

This paper presents branch-and-bound algorithms that can guarantee the simplest optimal cutting patterns of equal rectangles. An existing linear algorithm determines the global upper bound exactly. The branching process ends when a branch of a lower bound equal to the global upper bound is found.     

Complete and robust no-fit polygon generation for the irregular stock cutting problem

The no-fit polygon is a construct that can be used between pairs of shapes for fast and efficient handling of geometry within irregular two-dimensional stock cutting problems. Previously, the no-fit polygon (NFP) has not been widely applied because of the perception that it is difficult to implement and because of the lack of generic approaches that can cope with all problem cases without specific case-by-case handling. This paper introduces a robust orbital method for the creation of no-fit polygons which does not suffer from the typical problem cases found in the other approaches from the literature. Furthermore, the algorithm only involves two simple geometric stages so it is easily understood and implemented. We demonstrate how the approach handles known degenerate cases such as holes, interlocking concavities and jigsaw type pieces and we give generation times for 32 irregular packing benchmark problems from the literature, including real world datasets, to allow further comparison with existing and future approaches.     

A BRANCH-AND-PRICE ALGORITHM FOR SOLVING THE CUTTING STRIPS PROBLEM

After giving a suitable model for the cutting strips problem, we present a branch-and-price algorithm for it by combining the column generation technique and the branch-and-hound method with LP relaxations. Some theoretical issues and implementation details about the algorithm are discussed, including the solution of the pricing subproblem, the quality of LP relaxations, the branching scheme as well as the column management. Finally, preliminary computarional experience is reported.     

A column generation heuristic for the two-dimensional two-staged guillotine cutting stock problem with multiple stock size

We consider a two-dimensional cutting stock problem where stock of different sizes is available, and a set of rectangular items has to be obtained through two-staged guillotine cuts. We propose a heuristic algorithm, based on column generation, which requires as its subproblem the solution of a two-dimensional knapsack problem with two-staged guillotines cuts. A further contribution of the paper consists in the definition of a mixed integer linear programming model for the solution of this knapsack problem, as well as a heuristic procedure based on dynamic programming. Computational experiments show the effectiveness of the proposed approach, which obtains very small optimality gaps and outperforms the heuristic algorithm proposed by Cintra et al. [3].     

New upper bounds for the two-dimensional orthogonal non-guillotine cutting stock problem

The two-dimensional orthogonal non-guillotine cutting stockproblem (NGCP) appears in many industries (e.g. the wood andsteel industries) and consists of cutting a rectangular mastersurface into a number of rectangular pieces, each with a givensize and value. The pieces must be cut with their edges alwaysparallel to the edges of the master surface (orthogonal cuts).The objective is to maximize the total value of the pieces cut. New upper bounds on the optimal solution to the NGCP are described.The new bounding procedures are obtained by different relaxationsof a new mathematical formulation of the NGCP. Various proceduresfor strengthening the resulting upper bounds and reducing thesize of the original problem are discussed. The proposed newupper bounds have been experimentally evaluated on test problemsderived from the literature. Comparisons with previous boundingprocedures from the literature are given. The computationalresults indicate that these bounds are significantly betterthan the bounds proposed in the literature.