A bi-objective coordination setup problem in a two-stage production system

This paper addresses a problem arising in the coordination between two consecutive departments of a production system, where parts are processed in batches, and each batch is characterized by two distinct attributes. Due to the lack of interstage buffering between the two stages, these departments have to follow the same batch sequence. In the first department, a setup occurs every time the first attribute of a new batch is different from the one of the previous batch. In the downstream department, there is a setup when the second attribute changes in two consecutive batches. The problem consists in finding a batch sequence optimizing the number of setups paid by each department. This case results in a particular bi-objective combinatorial optimization problem. We present a geometrical characterization for the feasible solution set of the problem, and we propose three effective heuristics, as shown by an extensive experimental campaign. The proposed approach can be also used to solve a class of single-objective problems, in which setup costs in the two departments are general increasing functions of the number of setups.     

Multi-item lot-sizing with joint set-up costs

We consider a multi-item lot-sizing problem with joint set-up costs and constant capacities. Apart from the usual per unit production and storage costs for each item, a set-up cost is incurred for each batch of production, where a batch consists of up to C units of any mix of the items. In addition, an upper bound on the number of batches may be imposed. Under widely applicable conditions on the storage costs, namely that the production and storage costs are nonspeculative, and for any two items the one that has a higher storage cost in one period has a higher storage cost in every period, we show that there is a tight linear program with O(mT ²) constraints and variables that solves the joint set-up multi-item lot-sizing problem, where m is the number of items and T is the number of time periods. This establishes that under the above storage cost conditions this problem is polynomially solvable. For the problem with backlogging, a similar linear programming result is described for the uncapacitated case under very restrictive conditions on the storage and backlogging costs. Computational results are presented to test the effectiveness of using these tight linear programs in strengthening the basic mixed integer programming formulations of the joint set-up problem both when the storage cost conditions are satisfied, and also when they are violated.     

Batch sizing and job sequencing on a single machine

We study a single-machine scheduling problem in which the items to be processed have to be batched as well as sequenced. Since processed items become available in batches, flow times are defined to be the same for all items in the same batch. A constant set-up delay is incurred between consecutive batches. For any fixed, but arbitrary item sequence, we present an algorithm that finds a sequence of batches such that the total flow time of the items is minimized; we prove that for a set ofn items, the algorithm runs inO(n) time. We show that, among all sequences, the one leading to the minimum flow time has the items in non-decreasing order of running times. Thus, the optimal algorithm for the combined problem, called thebatch-sizing problem, runs inO(n logn) time. We also prove that this algorithm yields an improved solution to a scheduling problem recently studied by Baker [1].     

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.     

Single machine batch scheduling to minimize the weighted number of late jobs

The single machine batch scheduling problem to minimize the weighted number of late jobs is studied. In this problem,n jobs have to be processed on a single machine. Each job has a processing time, a due date and a weight. Jobs may be combined to form batches containing contiguously scheduled jobs. For each batch, a constant set-up time is needed before the first job of this batch is processed. The completion time of each job in the batch coincides with the completion time of the last job in this batch. A job is late if it is completed after its due date. A schedule specifies the sequence of jobs and the size of each batch, i.e. the number of jobs it contains. The objective is to find a schedule which minimizes the weighted number of late jobs. This problem isNP-hard even if all due dates are equal. For the general case, we present a dynamic programming algorithm which solves the problem with equal weights inO(n ³) time. We formulate a certain scaled problem and show that our dynamic programming algorithm applied to this scaled problem provides a fully polynomial approximation scheme for the original problem. Each algorithm of this scheme has a time requirement ofO(n ³/ +n ³ logn). A side result is anO(n logn) algorithm for the problem of minimizing the maximum weight of late jobs.Supported by INTAS Project 93-257.     

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.     

Optimal methods for batch processing problem with makespan and maximum lateness objectives

In this paper we consider the problem of scheduling n jobs on a single batch processing machine in which jobs are ordered by two customers. Jobs belonging to different customers are processed based on their individual criteria. The considered criteria are minimizing makespan and maximum lateness. A batching machine is able to process up to b jobs simultaneously. The processing time of each batch is equal to the longest processing time of jobs in the batch. This kind of batch processing is called parallel batch processing. Optimal methods for three cases are developed: unbounded batch capacity, b > n, with compatible job groups and bounded batch capacity, b  n, with compatible and non compatible job groups. Each job group represents a different class of customers and the concept of being compatible means that jobs which are ordered by different customers are allowed to be processed in a same batch. We propose an optimal method for the problem with incompatible groups and unbounded batches. About the case when groups are incompatible and bounded batches, our proposed method is considered as optimal when the group with maximum lateness objective has identical processing times. We regard this method, however, as a heuristic when these processing times are different. When groups are compatible and batches are bounded we consider another problem by assuming the same processing times for the group which has the maximum lateness objective and propose an optimal method for this problem.     

Optimizing a Multi-Stage Production Process

When articles are made by a sequence of processes, it is often necessary to make discrete batches for each process. These may not be the same size for each stage in the sequence. Two procedures are given for determining the optimum batch sizes, i.e. the batch sizes giving the lowest total for the set-up and investment costs.     

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.     

Single-machine scheduling of multi-operation jobs without missing operations to minimize the total completion time

We consider the problem of scheduling multi-operation jobs on a singe machine to minimize the total completion time. Each job consists of several operations that belong to different families. In a schedule each family of job operations may be processed as batches with each batch incurring a set-up time. A job is completed when all of its operations have been processed. We first show that the problem is strongly NP-hard even when the set-up times are common and each operation is not missing. When the operations have identical processing times and either the maximum set-up time is sufficiently small or the minimum set-up time is sufficiently large, the problem can be solved in polynomial time. We then consider the problem under the job-batch restriction in which the operations of each batch is partitioned into operation batches according to a partition of the jobs. We show that this case of the problem can be solved in polynomial time under a certain condition.     

Class clustering destroys delay differentiation in priority queues

This paper considers a discrete-time priority queueing model with one server and two types (classes) of customers. Class-1 customers have absolute (service) priority over class-2 customers. New customer batches enter the system at the rate of one batch per slot, according to a general independent arrival process, i.e., the batch sizes (total numbers of arrivals) during consecutive time slots are i.i.d. random variables with arbitrary distribution. All customers entering the system during the same time slot (i.e., belonging to the same arrival batch) are of the same type, but customer types may change from slot to slot, i.e., from batch to batch. Specifically, the types of consecutive customer batches are correlated in a Markovian way, i.e., the probability that any batch of customers has type 1 or 2, respectively, depends on the type of the previous customer batch that has entered the system. Such an arrival model allows to vary not only the relative loads of both customer types in the arrival stream, but also the amount of correlation between the types of consecutive arrival batches. The results reveal that the amount of delay differentiation between the two customer classes that can be achieved by the priority mechanism strongly depends on the amount of such interclass correlation (or, class clustering) in the arrival stream. We believe that this phenomenon has been largely overlooked in the priority-scheduling literature.     

Process selection and sequencing in a two-agents production system

This paper addresses a coordination problem concerning two production agents in a manufacturing system. The two agents have a set of processes which must be carried out on some common resource. They can use the resource individually, but in general there may be an overall advantage in concurrently performing certain processes. The problem is to select concurrent processes and to sequence them with the aim of minimizing the total number of set-ups. In particular, a decomposition approach is proposed, in which first the concurrent processes are selected, by solving a generalized network flow problem, and then an optimal process sequencing is efficiently found.AMS classification: 05C85, 90B10, 05C45Paper previously processed by Francesco Archetti for Ricerca Operativa     

活动长度有限制的多工序批量加工生产计划研究

当前的化工制造中,有很多工厂使用柔性制造设备,并采用批生产模式来组织生产.由于对设备进行准备和清理的成本比较大,加工的排序一般采用多批次加工同一种产品的活动（campaign）模式.在实际的生产中,由于需要保证产品质量和减少库存,应该考虑限制活动的最大长度.本文针对活动长度有限制的多工序批量加工问题进行研究,利用状态-任务-网络概念和层级模型方法,提出了修正的活动计划模型.该模型是基于混合整数线性规划模型,并且以供应网络内总生产成本和物流成本最小化作为目标函数.最后用一个算例来说明所构建模型的有效性.     

Age Process, Workload Process, Sojourn Times, and Waiting Times in a Discrete Time SM[K]/PH[K]/1/FCFS Queue

In this paper, we study a discrete time queueing system with multiple types of customers and a first-come-first-served (FCFS) service discipline. Customers arrive according to a semi-Markov arrival process and the service times of individual customers have PH-distributions. A GI/M/1 type Markov chain for a generalized age process of batches of customers is introduced. The steady state distribution of the GI/M/1 type Markov chain is found explicitly and, consequently, the steady state distributions of the age of the batch in service, the total workload in the system, waiting times, and sojourn times of different batches and different types of customers are obtained. We show that the generalized age process and a generalized total workload process have the same steady state distribution. We prove that the waiting times and sojourn times have PH-distributions and find matrix representations of those PH-distributions. When the arrival process is a Markov arrival process with marked transitions, we construct a QBD process for the age process and the total workload process. The steady state distributions of the waiting times and the sojourn times, both at the batch level and the customer level, are obtained from the steady state distribution of the QBD process. A number of numerical examples are presented to gain insight into the waiting processes of different types of customers.AMS subject classification: 60K25, 60J10This revised version was published online in June 2005 with corrected coverdate     

Markovian polling systems with mixed service disciplines and retrial customers

A Markovian polling model with a mixture of exhaustive and gated type stations is considered. The cuttomers are ofn different tppes and arrive to the system acccording to the Poisson distribution, in batches containing customers of all types (correlated batch arrivals). The customers who find upon arrival the server unavailable repeat their arrival individually after a random amount of time (retrial customers). The service timesT _i and the switchover timesV _ij are arbitrarily distributed with different distributions for the different stations. For such a model we obtain formulae for the expected number of customers in each station in a steady state. Our formulae hold also for zero switchover periods and can easily be adapted to hold for the corresponding ordinary Markovian mixed polling models with/without switchover times and correlated batch arrivals. Numerical calculations are finally used to observe system's performance.     

Analyzing the finite buffer batch arrival queue under Markovian service process: GIX/MSP/1/N

We consider a batch arrival finite buffer single server queue with inter-batch arrival times are generally distributed and arrivals occur in batches of random size. The service process is correlated and its structure is presented through Markovian service process (MSP). The model is analyzed for two possible customer rejection strategies: partial batch rejection and total batch rejection policy. We obtain steady-state distribution at pre-arrival and arbitrary epochs along with some important performance measures, like probabilities of blocking the first, an arbitrary, and the last customer of a batch, average number of customers in the system, and the mean waiting times in the system. Some numerical results have been presented graphically to show the effect of model parameters on the performance measures. The model has potential application in the area of computer networks, telecommunication systems, manufacturing system design, etc.      

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.     

Stochastic comparisons of series and parallel systems with randomized independent components

Consider a series or parallel system of independent components and assume that the components are randomly chosen from two different batches, with the components of the first batch being more reliable than those of the second. In this note it is shown that the reliability of the system increases, in usual stochastic order sense, as the random number of components chosen from the first batch increases in increasing convex order. As a consequence, we establish a result analogous to the Parrondo’s paradox, which shows that randomness in the number of components extracted from the two batches improves the reliability of the series system.     

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.     

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.