Well management in the North Sea

The purpose of this paper is to describe a planning model for the management of approximately 130 petroleum-producing wells in the North Sea. The objective is to form a better basis for the decisions about which wells to produce from and which to shut down during a period. Every well is dealt with individually as the production potential and chemical composition are different. The total flow consists of six saleable components: gas, four NGL products, and oil. The production may be curtailed due to the capacities of the platforms, gathering centre, pipelines and refinery plants. The total gas production is available for fulfilling the gas contracts, injecting the gas into the reservoirs or using the gas as fuel. There exist contracts for some of the NGL products, while the rest of the NGL products and oil are sold on the free market. The well-management model is solved by means of a standard mathematical programming code, and computational results are given for a planning problem with four different data sets.     

Structuring production planning systems for computer applications

Activities in a job shop type mechanical company can be split in production, product cycle and production cycle. The corresponding flow in each of these are materials, manufacturing specifications and product requirements. Production planning will plan and control these flows. Basic data structures are a product model and a corresponding hierarchy linked to production resources. A planning system may be designed by combining a set of operation or building blocks. These are three types: user communication, data base management and basic operations. The basic operations cover all processing necessary in production planning and represent the fundamental building blocks. A list of basic operations is suggested.     

Supply chain optimization of petroleum organization under uncertainty in market demands and prices

A multi-period stochastic planning model has been developed and implemented for a supply chain network of a petroleum organization operating in an oil producing country under uncertain market conditions. The proposed supply chain network consists of all activities related to crude oil production, processing and distribution. Uncertainties were introduced in market demands and prices. A deterministic optimization model was first developed and tested. The impact of uncertainty on the supply chain was studied by performing a sensitivity analysis in which ±20% deviations were introduced in market demands and prices of different commodities. A stochastic formulation was then proposed, which is based on the two-stage problem with finite number of realizations. The proposed stochastic programming approach proved to be quite effective in developing resilient production plans in light of high degree of uncertainty in market conditions. The anticipated production plans have a considerably lower expected value of perfect information (EVPI). The main conclusion of this study is that for an oil producing country with oil processing capabilities, the impact of economic uncertainties may be tolerated by an appropriate balance between crude exports and processing capacities.     

An adaptive large neighborhood search algorithm for a selective and periodic inventory routing problem

We study a selective and periodic inventory routing problem (SPIRP) and develop an Adaptive Large Neighborhood Search (ALNS) algorithm for its solution. The problem concerns a biodiesel production facility collecting used vegetable oil from sources, such as restaurants, catering companies and hotels that produce waste vegetable oil in considerable amounts. The facility reuses the collected waste oil as raw material to produce biodiesel. It has to meet certain raw material requirements either from daily collection, or from its inventory, or by purchasing virgin oil. SPIRP involves decisions about which of the present source nodes to include in the collection program, and which periodic (weekly) routing schedule to repeat over an infinite planning horizon. The objective is to minimize the total collection, inventory and purchasing costs while meeting the raw material requirements and operational constraints. A single-commodity flow-based mixed integer linear programming (MILP) model was proposed for this problem in an earlier study. The model was solved with 25 source nodes on a 7-day cyclic planning horizon. In order to tackle larger instances, we develop an ALNS algorithm that is based on a rich neighborhood structure with 11 distinct moves tailored to this problem. We demonstrate the performance of the ALNS, and compare it with the MILP model on test instances containing up to 100 source nodes.     

Part type selection problem in flexible manufacturing systems: tabu search algorithms

Production planning in flexible manufacturing systems is concerned with the organization of production in order to satisfy a given master production schedule. The planning problem typically gives rise to several hierarchical subproblems which are then solved sequentially or simultaneously. In this paper, we address one of the subproblems: the part type selection problem. The problem is to determine a subset of part types having production requirements for immediate and simultaneous processing over the upcoming period of the planning horizon, subject to the tool magazine and processing time limitation. Several versions of tabu search (TS) algorithm are proposed for solving the problem. A systematic computational test is conducted to test the performance of the TS algorithms. The best TS algorithm developed is compared to a simulated annealing algorithm.     

Formulating and solving production planning problems

Production planning problems frequently involve the assignment of jobs or operations to machines. The simplest model of this problem is the well known assignment problem (AP). However, due to simplifying assumptions this model does not provide implementable solutions for many actual production planning problems. Extensions of the simple assignment model known as the generalized assignment problem (GAP) and the multi-resource generalized assignment problem (MRGAP) have been developed to overcome this difficulty. This paper presents an extension of the (MRGAP) to allow splitting individual batches across multiple machines, while considering the effect of setup times and setup costs. The extension is important for many actual production planning problems, including ones in the injection molding industry and in the metal cutting industry. We formulate models which are logical extensions of previous models which ignored batch splitting for the problem we address. We then give different formulations and suggest adaptations of a genetic algorithm (GA) and simulated annealing (SA). A systematic evaluation of these algorithms, as well as a Lagrangian relaxation (LR) approach, is presented.     

A stochastic aggregate production planning model in a green supply chain: Considering flexible lead times,nonlinear purchase and shortage cost functions

In this paper we develop a stochastic programming approach to solve a multi-period multi-product multi-site aggregate production planning problem in a green supply chain for a medium-term planning horizon under the assumption of demand uncertainty. The proposed model has the following features: (i) the majority of supply chain cost parameters are considered; (ii) quantity discounts to encourage the producer to order more from the suppliers in one period, instead of splitting the order into periodical small quantities, are considered; (iii) the interrelationship between lead time and transportation cost is considered, as well as that between lead time and greenhouse gas emission level; (iv) demand uncertainty is assumed to follow a pre-specified distribution function; (v) shortages are penalized by a general multiple breakpoint function, to persuade producers to reduce backorders as much as possible; (vi) some indicators of a green supply chain, such as greenhouse gas emissions and waste management are also incorporated into the model. The proposed model is first a nonlinear mixed integer programming which is converted into a linear one by applying some theoretical and numerical techniques. Due to the convexity of the model, the local solution obtained from linear programming solvers is also the global solution. Finally, a numerical example is presented to demonstrate the validity of the proposed model.     

Shipment planning at oil refineries using column generation and valid inequalities

In this paper we suggest an optimization model and a solution method for a shipment planning problem. This problem concerns the simultaneous planning of how to route a fleet of ships and the planning of which products to transport in these ships. The ships are used for moving products from oil refineries to storage depots. There are inventory levels to consider both at the refineries and at the depots. The inventory levels are affected by the process scheduling at the refineries and demand at the depots. The problem is formulated using an optimization model including an aggregated representation of the process scheduling at the refineries. Hence, we integrate the shipment planning and the process scheduling at the refineries. We suggest a solution method based on column generation, valid inequalities, and constraint branching. The solution method is tested on data provided by the Nynas oil refinery company and solutions are obtained within 4 hours, for problem instances of up to 3 refineries, 15 depots, and 4 products when considering a time horizon of 42 days.     

Optimization of the Daily Production Rates for an Offshore Oilfield

This paper presents a model to assist in setting the daily production rates for an offshore oilfield to achieve a quarterly production target. The produced crude oil is frequently accompanied by the production of gas, which has much lower value. Since there are environmental limits to the amount of gas that can be flared to waste, problems on gas-processing can very quickly limit oil output. With the commencement of natural decline in many oilfields in the North Sea, the loss of crude output as a result of gas constraints cannot be compensated in the same planning period. This makes the ultimate output, and hence the reward, more sensitive to the problems associated with gas-processing. The model uses a stochastic dynamic programming algorithm to maximize the financial reward. Gas-related limiting factors and the oil and gas plant downtime are considered. The user is allowed to interrogate the model and interact with it when major unforeseen restrictions are imposed on gas capacities. The output includes the optimal production rate and probability and cost of not achieving the target.     

A new lot sizing and scheduling heuristic for multi-site biopharmaceutical production

Biopharmaceutical manufacturing requires high investments and long-term production planning. For large biopharmaceutical companies, planning typically involves multiple products and several production facilities. Production is usually done in batches with a substantial set-up cost and time for switching between products. The goal is to satisfy demand while minimising manufacturing, set-up and inventory costs. The resulting production planning problem is thus a variant of the capacitated lot-sizing and scheduling problem, and a complex combinatorial optimisation problem. Inspired by genetic algorithm approaches to job shop scheduling, this paper proposes a tailored construction heuristic that schedules demands of multiple products sequentially across several facilities to build a multi-year production plan (solution). The sequence in which the construction heuristic schedules the different demands is optimised by a genetic algorithm. We demonstrate the effectiveness of the approach on a biopharmaceutical lot sizing problem and compare it with a mathematical programming model from the literature. We show that the genetic algorithm can outperform the mathematical programming model for certain scenarios because the discretisation of time in mathematical programming artificially restricts the solution space.     

Integrated planning of transportation and recycling for multiple plants based on process simulation

By-products accrue in all stages of industrial production networks. Legal requirements, shortening of primary resources and their increasing prices make their recycling more and more important. For the re-integration into the economic cycle the scope of common supply chain management is enlarged and so-called closed-loop supply chains with adapted and new planning tasks are developed. In process industries this requires a detailed modelling of the recycling processes. This is of special relevance for operational planning tasks in which an optimal usage of a given production system is envisaged. This contribution presents an integrated planning approach for a real-world case study from the zinc industry to achieve such an adequate process modelling. We consider the planning problem of a company that operates four metallurgical recycling plants and has to allocate residues from different sources to these recycling sites. The allocation determines the raw material mix used in the plants. This blending has an effect on the transportation costs and the costs and revenues of the individual technical processes in the recycling plants. Therefore in this problem transportation and recycling planning for multiple sites have to be regarded in an integrated way. The necessary detailed process modelling is achieved by the use of a flowsheet process simulation system to model each recycling plant individually. The models are used to derive linear input–output functions by multiple linear regression analyses. These are used in an integrated planning model to calculate the decision-relevant input and output flows that are dependent upon the allocation of the residues to the recycling sites. The model is embedded in a decision support system for the operational use. An example application and sensitivity analyses demonstrate and validate the approach and its potentials. The approach is transferable to other recycling processes as well as to other processes in process industries.     

Development of a new approach for deterministic supply chain network design

This paper proposes a mixed integer linear programming model and solution algorithm for solving supply chain network design problems in deterministic, multi-commodity, single-period contexts. The strategic level of supply chain planning and tactical level planning of supply chain are aggregated to propose an integrated model. The model integrates location and capacity choices for suppliers, plants and warehouses selection, product range assignment and production flows. The open-or-close decisions for the facilities are binary decision variables and the production and transportation flow decisions are continuous decision variables. Consequently, this problem is a binary mixed integer linear programming problem. In this paper, a modified version of Benders’ decomposition is proposed to solve the model. The most difficulty associated with the Benders’ decomposition is the solution of master problem, as in many real-life problems the model will be NP-hard and very time consuming. In the proposed procedure, the master problem will be developed using the surrogate constraints. We show that the main constraints of the master problem can be replaced by the strongest surrogate constraint. The generated problem with the strongest surrogate constraint is a valid relaxation of the main problem. Furthermore, a near-optimal initial solution is generated for a reduction in the number of iterations.     

An automated planning engine for biopharmaceutical production

We introduce an optimization-based production planning tool for the biotechnology industry. The industry’s planning problem is unusually challenging because the entire production process is regulated by multiple external agencies – such as the US Food and Drug Administration – representing countries where the biopharmaceutical is to be sold. The model is structured to precisely capture the constraints imposed by current and projected regulatory approvals of processes and facilities, as well as capturing the outcomes of quality testing and processing options, facility capacities and initial status of work-in-process. The result is a supply chain “Planning Engine” that generates capacity-feasible batch processing schedules for each production facility within the biomanufacturing supply chain and an availability schedule for finished product against a known set of demands and regulations. Developing the formulation based on distinct time grids tailored for each facility, planning problems with more than 27,000 boolean variables, more than 130,000 linear variables and more than 80,000 constraints are automatically formulated and solved within a few hours. The Planning Engine’s development and implementation at Bayer Healthcare’s Berkeley, CA manufacturing site is described.     

The Application of Preprocessing and Cutting Plane Techniques for a Class of Production Planning Problems

This paper investigates properties of integer programming models for a class of production planning problems. The models are developed within a decision support system to advise a sales team of the products on which to focus their efforts in gaining new orders in the short term. The products generally require processing on several manufacturing cells and involve precedence relationships. The cells are already (partially) committed with products for stock and to satisfy existing orders and therefore only the residual capacities of each cell in each time period of the planning horizon are considered. The determination of production recommendations to the sales team that make use of residual capacities is a nontrivial optimization problem. Solving such models is computationally demanding and techniques for speeding up solution times are highly desirable. An integer programming model is developed and various preprocessing techniques are investigated and evaluated. In addition, a number of cutting plane approaches have been applied. The performance of these approaches which are both general and application specific is examined.     

A robust optimization model for multi-site production planning problem in an uncertain environment

This paper addresses the multi-site production planning problem for a multinational lingerie company in Hong Kong subject to production import/export quotas imposed by regulatory requirements of different nations, the use of manufacturing factories/locations with regard to customers’ preferences, as well as production capacity, workforce level, storage space and resource conditions at the factories. In this paper, a robust optimization model is developed to solve multi-site production planning problem with uncertainty data, in which the total costs consisting of production cost, labor cost, inventory cost, and workforce changing cost are minimized. By adjusting penalty parameters, production management can determine an optimal medium-term production strategy including the production loading plan and workforce level while considering different economic growth scenarios. The robustness and effectiveness of the developed model are demonstrated by numerical results. The trade-off between solution robustness and model robustness is also analyzed.     

基于仿真优化的炼钢生产批调度求解方法

论文针对钢铁企业炼钢工序具有高温、高能耗、复杂工况的实际特征,从中提炼出生产批调度问题,其工件根据其实际工艺属性可分为多个簇,基于给定的工件簇,决策工件的分批和调度情况,综合考虑工件之间的切换费用,以及工件提前、拖期所导致的惩罚,使得总的生产成本期望最小化,从而降低生产成本;针对该问题,考虑工件的处理时间、工件的加工属性具有不确定性,基于仿真优化思想,建立数学模型,并基于大数定理,对模型目标函数进行近似;提出基于样本近似方法的求解框架,通过随机抽样的方法获得不同规模的样本,针对不同规模的样本,提出Filter & Fan算法对问题进行求解;最后,通过基于实际数据的计算实验验证所提算法的有效性。