Solving one-dimensional cutting stock problems exactly with a cutting plane algorithm

When solving the one-dimensional cutting stock problem (1D CSP) as an integer linear programming problem one has to overcome computational difficulties arising from the integrality condition and a huge number of variables. In the Gilmore–Gomory approach the corresponding continuous relaxation is solved via column generation techniques followed by an appropriate rounding of the in general non-integer solution. Obviously, there is no guarantee of obtaining an optimal solution in this way but it is extremely effective in practice. However, in two- and three-dimensional cutting stock problems the heuristics are not so good which necessitates the research of effective exact methods. In this paper we present an exact solution approach for the 1D CSP which is based on a combination of the cutting plane method and the column generation technique. Results of extensive computational experiments are reported.     

Branch-and-Price Algorithms for the One-Dimensional Cutting Stock Problem

We compare two branch-and-price approaches for the cutting stock problem. Each algorithm is based on a different integer programming formulation of the column generation master problem. One formulation results in a master problem with 0–1 integer variables while the other has general integer variables. Both algorithms employ column generation for solving LP relaxations at each node of a branch-and-bound tree to obtain optimal integer solutions. These different formulations yield the same column generation subproblem, but require different branch-and-bound approaches. Computational results for both real and randomly generated test problems are presented.     

New developments in the primal–dual column generation technique

The optimal solutions of the restricted master problems typically leads to an unstable behavior of the standard column generation technique and, consequently, originates an unnecessarily large number of iterations of the method. To overcome this drawback, variations of the standard approach use interior points of the dual feasible set instead of optimal solutions. In this paper, we focus on a variation known as the primal–dual column generation technique which uses a primal–dual interior point method to obtain well-centered non-optimal solutions of the restricted master problems. We show that the method converges to an optimal solution of the master problem even though non-optimal solutions are used in the course of the procedure. Also, computational experiments are presented using linear-relaxed reformulations of three classical integer programming problems: the cutting stock problem, the vehicle routing problem with time windows, and the capacitated lot sizing problem with setup times. The numerical results indicate that the appropriate use of a primal–dual interior point method within the column generation technique contributes to a reduction of the number of iterations as well as the running times, on average. Furthermore, the results show that the larger the instance, the better the relative performance of the primal–dual column generation technique.     

A branch-and-cut-and-price algorithm for one-dimensional stock cutting and two-dimensional two-stage cutting

The one-dimensional cutting stock problem (1D-CSP) and the two-dimensional two-stage guillotine constrained cutting problem (2D-2CP) are considered in this paper. The Gilmore–Gomory models of these problems have very strong continuous relaxations providing a good bound in an LP-based solution approach. In recent years, there have been several efforts to attack the one-dimensional problem by LP-based branch-and-bound with column generation (called branch-and-price) and by general-purpose Chvátal–Gomory cutting planes. In this paper we investigate a combination of both approaches, i.e., the LP relaxation at each branch-and-price node is strengthened by Chvátal–Gomory and Gomory mixed-integer cuts. The branching rule is that of branching on variables of the Gilmore–Gomory formulation. Tests show that, for 1D-CSP, general-purpose cuts are useful only in exceptional cases. However, for 2D-2CP their combination with branching is more effective than either approach alone and mostly better than other methods from the literature.     

Aggregation bounds in stochastic linear programming

Stochastic linear programs become extremely large and complex as additional uncertainties and possible future outcomes are included in their formulation. Row and column aggregation can significantly reduce this complexity, but the solutions of the aggregated problem only provide an approximation of the true solution. In this paper, error bounds on the value of the optimal solution of the original problem are obtained from the solution of the aggregated problem. These bounds apply for aggregation of both random variables and time periods.     

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.     

Modeling multistage cutting stock problems

In multistage cutting stock problems (CSP) the cutting process is distributed over several successive stages. Every stage except the last one produces intermediate products. The list of intermediate products may be given or arbitrary. The goal is to minimize the total amount of material taken out of stock to cut finished products sufficient to meet customer demands. If the intermediate sizes are given, the column generation technique can be applied to multistage cutting problems. If the intermediate sizes are not given then another dimension is added to the problem complexity. We propose a special procedure for this case that dynamically generates both rows (intermediate sizes) and columns (patterns). We refer to this method as row-and-column generation. The method uses an auxiliary problem embedded into the frame of the revised simplex algorithm. It is a non-linear knapsack problem that can be solved efficiently. In contrast to the column generation method the developed technique cannot guarantee the optimal solution. However, the results of computational experiments are very promising and prove that the method is a valuable addition to the set of tools for modeling and solving multistage CSPs.     

Computational study of a column generation algorithm for bin packing and cutting stock problems

This paper reports on our attempt to design an efficient exact algorithm based on column generation for the cutting stock problem. The main focus of the research is to study the extend to which standard branch-and-bound enhancement features such as variable fixing, the tightening of the formulation with cutting planes, early branching, and rounding heuristics can be usefully incorporated in a branch-and-price algorithm. We review and compare lower bounds for the cutting stock problem. We propose a pseudo-polynomial heuristic. We discuss the implementation of the important features of the integer programming column generation algorithm and, in particular, the implementation of the branching scheme. Our computational results demonstrate the efficiency of the resulting algorithm for various classes of bin packing and cutting stock problems. Received October 18, 1996 / Revised version received May 14, 1998?Published online July 19, 1999     

Comparison of bundle and classical column generation

When a column generation approach is applied to decomposable mixed integer programming problems, it is standard to formulate and solve the master problem as a linear program. Seen in the dual space, this results in the algorithm known in the nonlinear programming community as the cutting-plane algorithm of Kelley and Cheney-Goldstein. However, more stable methods with better theoretical convergence rates are known and have been used as alternatives to this standard. One of them is the bundle method; our aim is to illustrate its differences with Kelley’s method. In the process we review alternative stabilization techniques used in column generation, comparing them from both primal and dual points of view. Numerical comparisons are presented for five applications: cutting stock (which includes bin packing), vertex coloring, capacitated vehicle routing, multi-item lot sizing, and traveling salesman. We also give a sketchy comparison with the volume algorithm. This research has been supported by Inria New Investigation Grant “Convex Optimization and Dantzig-Wolfe Decomposition”.     

An iterative sequential heuristic procedure to a real-life 1.5-dimensional cutting stock problem

This paper addresses a real-life 1.5D cutting stock problem, which arises in a make-to-order plastic company. The problem is to choose a subset from the set of stock rectangles to be used for cutting into a number of smaller rectangular pieces so as to minimize total production cost and meet orders. The total production cost includes not only material wastage, as in traditional cutting stock problems, but also production time. A variety of factors are taken into account, like cutter knife changes, machine restrictions, due dates and other work in progress limitations. These restrictions make the combinatorial structure of the problem more complex. As a result, existing algorithms and mathematical models are no longer appropriate. Thus we developed a new 1.5D cutting stock model with multiple objectives and multi-constraints and solve this problem in an incomplete enumerative way. The computational results show that the solution procedure is easy to implement and works very well.     

New integer programming formulations and an exact algorithm for the ordered cutting stock problem

Apart from trim loss minimization, there are many other issues concerning cutting processes that arise in real production systems. One of these is related to the number of stacks that need to be opened near the cutting machines. Many researchers have worked in the last years on cutting stock problems with additional constraints on the number of open stacks. In this paper, we address a related problem: the Ordered Cutting Stock Problem (OCSP). In this case, a stack is opened for every new client's order, and it is closed only when all the items of that order are cut. The OSCP has been introduced recently in the literature. Our aim is to provide further insight into this problem. This paper describes three new integer programming formulations for solving it, and an exact algorithm based on column generation, branch-and-bound and cutting planes. We report on computational experiments on a set of random instances. The results show that good lower bounds can be computed quickly, and that optimal solutions can be found in a reasonable amount of time.     

Solving binary cutting stock problems by column generation and branch-and-bound

We present an algorithm for the binary cutting stock problem that employs both column generation and branch-and-bound to obtain optimal integer solutions. We formulate a branching rule that can be incorporated into the subproblem to allow column generation at any node in the branch-and-bound tree. Implementation details and computational experience are discussed.This research was supported by NSF and AFOSR grant DDM-9115768     

Column generation and sequential heuristic procedure for solving an irregular shape cutting stock problem

The research addressing two-dimensional (2D) irregular shape packing has largely focused on the strip packing variant of the problem. However, it can be argued that this is a simplification. The materials from which pieces are required to be cut will ultimately have a fixed length either due to the physical dimensions of the material or through constraints on the cutting machinery. Hence, in order to cut all the pieces, multiple sheets may be required. From this scenario arises the 2D irregular shape cutting stock problem. In this paper, we will present implementations of cutting stock approaches adapted to handle irregular shapes, including two approaches based on column generation (CG) and a sequential heuristic procedure. In many applications, setup costs can be reduced if the same pattern layout is cut from multiple sheets; hence there is a trade-off between material waste and number of patterns. Therefore, we describe the formulation and implementation of an adaptation of the CG method to control the number of different patterns. CG is a common method for the cutting stock problem; however, when the pieces are irregular the sub-problem cannot be solved optimally. Hence we implement CG and solve the sub-problem using the beam search heuristic. Further, we introduce a version of CG for instances where the number of rows is less than the number of columns.     

A Semidefinite Programming Based Polyhedral Cut and Price Approach for the Maxcut Problem

We investigate solution of the maximum cut problem using a polyhedral cut and price approach. The dual of the well-known SDP relaxation of maxcut is formulated as a semi-infinite linear programming problem, which is solved within an interior point cutting plane algorithm in a dual setting; this constitutes the pricing (column generation) phase of the algorithm. Cutting planes based on the polyhedral theory of the maxcut problem are then added to the primal problem in order to improve the SDP relaxation; this is the cutting phase of the algorithm. We provide computational results, and compare these results with a standard SDP cutting plane scheme. Research supported in part by NSF grant numbers CCR–9901822 and DMS–0317323. Work done as part of the first authors Ph.D. dissertation at RPI.     

A hybrid approach based on genetic algorithms to solve the problem of cutting structural beams in a metalwork company

This work presents a hybrid approach based on the use of genetic algorithms to solve efficiently the problem of cutting structural beams arising in a local metalwork company. The problem belongs to the class of one-dimensional multiple stock sizes cutting stock problem, namely 1-dimensional multiple stock sizes cutting stock problem. The proposed approach handles overproduction and underproduction of beams and embodies the reusability of remnants in the optimization process. Along with genetic algorithms, the approach incorporates other novel refinement algorithms that are based on different search and clustering strategies. Moreover, a new encoding with a variable number of genes is developed for cutting patterns in order to make possible the application of genetic operators. The approach is experimentally tested on a set of instances similar to those of the local metalwork company. In particular, comparative results show that the proposed approach substantially improves the performance of previous heuristics.     

Reducing the number of cuts in generating three-staged cutting patterns

Three-staged guillotine patterns are widely used in the manufacturing industry to cut stock plates into rectangular items. The cutting cost often increases with the number of cuts required. This paper focuses on the rectangular two-dimensional cutting stock problem, where three-staged guillotine patterns are used, and the objective is to minimize the sum of plate and cutting costs. The column generation framework is used to solve the problem. It uses a pattern-generation procedure to obtain the patterns. The cutting cost is considered in both the pattern-generation procedure and the objective of the linear programming formulation. The computational results indicate that the approach can reduce the number of cuts, without increasing the plate cost.     

Integrated lot-sizing and one-dimensional cutting stock problem with usable leftovers

This paper addresses the integration of the lot-sizing problem and the one-dimensional cutting stock problem with usable leftovers (LSP-CSPUL). This integration aims to minimize the cost of cutting items from objects available in stock, allowing the bringing forward production of items that have known demands in a future planning horizon. The generation of leftovers, that will be used to cut future items, is also allowed and these leftovers are not considered waste in the current period. Inventory costs for items and leftovers are also considered. A mathematical model for the LSP-CSPUL is proposed to represent this problem and an approach, using the simplex method with column generation, is proposed to solve the linear relaxation of this model. A heuristic procedure, based on a relax-and-fix strategy, was also proposed to find integer solutions. Computational tests were performed and the results show the contributions of the proposed mathematical model, as well as, the quality of the solutions obtained using the proposed method.

     

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.     

Mixed-integer column generation algorithms and the probabilistic maximum satisfiability problem

The column generation approach to large-scale linear programming is extended to the mixed-integer case. Two general algorithms, a dual and a primal one, are presented. Both involve finding k-best solutions to combinatorial optimization subproblems. Algorithms for these subproblems must be tailored to each specific application. Their use is illustrated by applying them to a new combinatorial optimization problem with applications in Artificial Intelligence: Probabilistic Maximum Satisfiability. This problem is defined as follows: consider a set of logical sentences together with probabilities that they are true, assume this set of sentences is not satisfiable in the probabilistic sense, i.e., there is no probability distribution on the set of possible worlds (truth assignments to the sentences corresponding to at least one truth assignment to the logical variables they contain) such that for each sentence the sum of probabilities of the possible worlds in which it is true is equal to its probability of being true; determine a minimum set of sentences to be deleted in order to make the remaining set of sentences satisfiable. Computational experience with both algorithms is reported on.