Improved state space relaxation for constrained two-dimensional guillotine cutting problems

Christofides and Hadjiconstantinou (1995) introduced a dynamic programming state space relaxation for obtaining upper bounds for the Constrained Two-dimensional Guillotine Cutting Problem. The quality of those bounds depend on the chosen item weights, they are adjusted using a subgradient-like algorithm. This paper proposes Algorithm X, a new weight adjusting algorithm based on integer programming that provably obtains the optimal weights. In order to obtain even better upper bounds, that algorithm is generalized into Algorithm X2 for obtaining optimal two-dimensional item weights. We also present a full hybrid method, called Algorithm X2D, that computes those strong upper bounds but also provides feasible solutions obtained by: (1) exploring the suboptimal solutions hidden in the dynamic programming matrices; (2) performing a number of iterations of a GRASP based primal heuristic; and (3) executing X2H, an adaptation of Algorithm X2 to transform it into a primal heuristic. Extensive experiments with instances from the literature and on newly proposed instances, for both variants with and without item rotation, show that X2D can consistently deliver high-quality solutions and sharp upper bounds. In many cases the provided solutions are certified to be optimal.     

Stock cutting to minimize cutting length

In this paper we investigate the following problem: Given two convex P_in, and P_out where P_in is completely contained in P_out, we wish to find a sequence of ‘guillotine cuts’ to cut out P_in from P_out such that the total length of the cutting sequence is minimized. This problem has applications in stock cutting where a particular shape or design (in this case the polygon P_in) needs to be cut out of a given piece of parent material (the polygon P_out) using only guillotine cuts and where it is desired to minimize the cutting sequence length to improve the cutting time required per piece. We first prove some properties of the optimal solution to the problem and then give an approximation scheme for the problem that, given an error range δ, produces a cutting sequence whose total length is atmost δ more than that of the optimal cutting sequence. Then it is shown that this problem has optimal solutions that lie in the algebraic extension of the field that the input data belongs to — hence due to this algebraic nature of the problem, an approximation scheme is the best that can be achieved. Extensions of these results are also studied in the case where the polygons P_in and P_out are non-convex.     

An improved typology of cutting and packing problems

The number of publications in the area of Cutting and Packing (C&P) has increased considerably over the last two decades. The typology of C&P problems introduced by Dyckhoff [Dyckhoff, H., 1990. A typology of cutting and packing problems. European Journal of Operational Research 44, 145–159] initially provided an excellent instrument for the organisation and categorisation of existing and new literature. However, over the years also some deficiencies of this typology became evident, which created problems in dealing with recent developments and prevented it from being accepted more generally. In this paper, the authors present an improved typology, which is partially based on Dyckhoff’s original ideas, but introduces new categorisation criteria, which define problem categories different from those of Dyckhoff. Furthermore, a new, consistent system of names is suggested for these problem categories. Finally, the practicability of the new scheme is demonstrated by using it as a basis for a categorisation of the C&P literature from the years between 1995 and 2004.     

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.     

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.     

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.     

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].     

Solving real-world cutting stock-problems in the paper industry: Mathematical approaches,experience and challenges

We discuss cutting stock problems (CSPs) from the perspective of the paper industry and the financial impact they make. Exact solution approaches and heuristics have been used for decades to support cutting stock decisions in that industry. We have developed polylithic solution techniques integrated in our ERP system to solve a variety of cutting stock problems occurring in real world problems. Among them is the simultaneous minimization of the number of rolls and the number of patterns while not allowing any overproduction. For two cases, CSPs minimizing underproduction and CSPs with master rolls of different widths and availability, we have developed new column generation approaches. The methods are numerically tested using real world data instances. An assembly of current solved and unsolved standard and non-standard CSPs at the forefront of research are put in perspective.     

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.     

Routing in grid graphs by cutting planes

In this paper we study the following problem, which we call the weighted routing problem. Let be given a graphG = (V, E) with non-negative edge weightsw _{e +} and letN,N 1, be a list of node sets. The weighted routing problem consists in finding mutually disjoint edge setsS ₁,...,S _N such that, for eachk {1, ...,N}, the subgraph (V(S _k),S _k) contains an [s, t]-path for alls, t T _k and the sum of the weights of the edge sets is minimal. Our motivation for studying this problem arises from the routing problem in VLSI-design, where given sets of points have to be connected by wires. We consider the weighted routing problem from a polyhedral point of view. We define an appropriate polyhedron and try to (partially) describe this polyhedron by means of inequalities. We describe our separation algorithms for some of the presented classes of inequalities. Based on these separation routines we have implemented a branch and cut algorithm. Our algorithm is applicable to an important subclass of routing problems arising in VLSI-design, namely to switchbox routing problems where the underlying graph is a grid graph and the list of node sets is located on the outer face of the grid. We report on our computational experience with this class of problem instances.     

A coupling cutting stock-lot sizing problem in the paper industry

An important production programming problem arises in paper industries coupling multiple machine scheduling with cutting stocks. Concerning machine scheduling: how can the production of the quantity of large rolls of paper of different types be determined. These rolls are cut to meet demand of items. Scheduling that minimizes setups and production costs may produce rolls which may increase waste in the cutting process. On the other hand, the best number of rolls in the point of view of minimizing waste may lead to high setup costs. In this paper, coupled modeling and heuristic methods are proposed. Computational experiments are presented.     

Roll cutting in the curtain industry,or: A well-solvable allocation problem

We study the problem of cutting a number of pieces of the same length from n rolls of different lengths so that the remaining part of each utilized roll is either sufficiently short or sufficiently long. A piece is ‘sufficiently short’, if it is shorter than a pre-specified threshold value δ_min, so that it can be thrown away as it cannot be used again for cutting future orders. And a piece is ‘sufficiently long’, if it is longer than a pre-specified threshold value δ_max (with δ_max > δ_min), so that it can reasonably be expected to be usable for cutting future orders of almost any length. We show that this problem, faced by a curtaining wholesaler, is solvable in O(nlogn) time by analyzing a non-trivial class of allocation problems.     

Accelerating convergence of cutting plane algorithms for disjoint bilinear programming

This paper presents two linear cutting plane algorithms that refine existing methods for solving disjoint bilinear programs. The main idea is to avoid constructing (expensive) disjunctive facial cuts and to accelerate convergence through a tighter bounding scheme. These linear programming based cutting plane methods search the extreme points and cut off each one found until an exhaustive process concludes that the global minimizer is in hand. In this paper, a lower bounding step is proposed that serves to effectively fathom the remaining feasible region as not containing a global solution, thereby accelerating convergence. This is accomplished by minimizing the convex envelope of the bilinear objective over the feasible region remaining after introduction of cuts. Computational experiments demonstrate that augmenting existing methods by this simple linear programming step is surprisingly effective at identifying global solutions early by recognizing that the remaining region cannot contain an optimal solution. Numerical results for test problems from both the literature and an application area are reported.     

A cutting plane method from analytic centers for stochastic programming

The stochastic linear programming problem with recourse has a dual block-angular structure. It can thus be handled by Benders' decomposition or by Kelley's method of cutting planes; equivalently the dual problem has a primal block-angular structure and can be handled by Dantzig-Wolfe decomposition—the two approaches are in fact identical by duality. Here we shall investigate the use of the method of cutting planes from analytic centers applied to similar formulations. The only significant difference form the aforementioned methods is that new cutting planes (or columns, by duality) will be generated not from the optimum of the linear programming relaxation, but from the analytic center of the set of localization.This research has been supported by the Fonds National de la Recherche Scientifique Suisse (grant # 12-26434.89), NSERC-Canada and FCAR-Quebec.Corresponding author.     

A worst case analysis of a dynamic programming-based heuristic algorithm for 2D unconstrained guillotine cutting

In this paper, a dynamic programming-based recursive method is proposed for solving an unconstrained 2D rectangular cutting problem. The algorithm is an incomplete method, in which some intricate cutting patterns may not be obtained. The worst case performance of the algorithm is evaluated and some theoretical analyses for the algorithm are performed. Compared to traditional dynamic programming, this algorithm gives a high percentage of optimal solutions (94.84%, 86.67% and 77.83% for small, medium and large sized unweighted instances, 99.67%, 99.50% and 97.00% for small, medium and large sized weighted instances) but features a far lower computational complexity. Computational results are also presented for some known benchmarks.     

Optimizing constrained subtrees of trees

Given a treeG = (V, E) and a weight function defined on subsets of its nodes, we consider two associated problems. The first, called the rooted subtree problem, is to find a maximum weight subtree, with a specified root, from a given set of subtrees.The second problem, called the subtree packing problem, is to find a maximum weight packing of node disjoint subtrees chosen from a given set of subtrees, where the value of each subtree may depend on its root.We show that the complexity status of both problems is related, and that the subtree packing problem is polynomial if and only if each rooted subtree problem is polynomial. In addition we show that the convex hulls of the feasible solutions to both problems are related: the convex hull of solutions to the packing problem is given by pasting together the convex hulls of the rooted subtree problems.We examine in detail the case where the set of feasible subtrees rooted at nodei consists of all subtrees with at mostk nodes. For this case we derive valid inequalities, and specify the convex hull whenk 4.Research supported in part by Nato Collaborative Research Grant CRG 900281, Science Program SC1-CT91-620 of the EEC, and contract No 26 of the programme Pôle d'attraction interuniversitaire of the Belgian government.     

Facet inequalities from simple disjunctions in cutting plane theory

The duality between facets of the convex hull of disjunctive sets and the extreme points of reverse polars of these sets is utilized to establish simple rules for the derivation of all facet cuts for simple disjunctions, namely, elementary disjunctions in nonnegative variables. These rules generalize the cut generation procedure underlying polyhedral convexity cuts with negative edge extensions. The latter are also shown to possess some interesting properties with respect to a biextremal problem that maximizes the distance, from the origin, of the nearest point feasible to the cut. A computationally inexpensive procedure is given to generate facet cuts for simple disjunctions which are dominant with respect to any specified preemptive ordering of variables.     

The elixir of life: using a maintenance, repair and replacement model based on virtual and operating age in the water industry

Processing equipment in the water industry is subject to decayand requires maintenance, repair and eventual replacement. Thechallenge of competition within the water industry and the accompanyingregulatory regime requires that actions be integrated and costeffective. This is an industry, which has considerable dataon the failure of its equipment, but until recently very fewmodels of the maintenance process have been built. This paper describes the context of this problem for cleanwater processing where the equipment is that required to purifywater. It proposes a model based on the virtual and operatingage of the components. The operating age reflects the true ageof the equipment while the virtual age allows for the cumulativeeffect of maintenance actions performed on the equipment. Themodel also allows for different types of equipment by describingdegradation by Cox's proportional hazards model. Thus the specialfeatures of the equipment and environment in which the equipmentoperates are described by a set of characteristics, which modifythe hazard rate of the failure time of the equipment. This approachusing Cox's model with virtual and operating age can be appliedto other processing industries including the gas industry andthe ‘dirty water’ side of the water industry. The model is formulated as a stochastic dynamic programmingor Markov decision process and the form of the optimal policyis determined. This shows that repair and replacement shouldonly be performed when the equipment has failed and describesgeneral conditions when replacement is appropriate. The optimalpolicy is calculated numerically using the value iteration algorithmfor a specific example based on data on failure.