Tactical level planning in float glass manufacturing with co-production,random yields and substitutable products

We investigate tactical level planning problems in float glass manufacturing. Float glass manufacturing is a process that has some unique properties such as uninterruptible production, random yields, partially controllable co-production compositions, complex relationships in sequencing of products, and substitutable products. Furthermore, changeover times and costs are very high, and production speed depends significantly on the product mix. These characteristics render measurement and management of the production capacity difficult. The motivation for this study is a real life problem faced at Trakya Cam in Turkey. Trakya Cam has multiple geographically separated production facilities. Since transportation of glass is expensive, logistics costs are high. In this paper, we consider multi-site aggregate planning, and color campaign duration and product mix planning. We develop a decision support system based on several mixed integer linear programming models in which production and transportation decisions are made simultaneously. The system has been fully implemented, and has been in use at Trakya Cam since 2005.     

Integrated cellular manufacturing systems design with production planning and dynamic system reconfiguration

This paper presents and analyzes a comprehensive model for the design of cellular manufacturing systems (CMS). A recurring theme in research is a piecemeal approach when formulating CMS models. In this paper, the proposed model, to the best of the authors’ knowledge, is the most comprehensive one to date with a more integrated approach to CMS design, where production planning and system reconfiguration decisions are incorporated. Such a CMS model has not been proposed before and it features the presence of alternate process routings, operation sequence, duplicate machines, machine capacity and lot splitting. The developed model is a mixed integer non-linear program. Linearization procedures are proposed to convert it into a linearized mixed integer programming formulation. Computational results are presented by solving some numerical examples, extracted from the existing literature, with the linearized formulation.     

Material compatibility constraints for make-to-order production planning

This paper defines a set of material compatibility constraints for use in order promising mixed integer programs. The constraints always represent a necessary condition for compatibility and, in certain cases, are both necessary and sufficient. The underlying analysis represents incompatibilities using bipartite graphs and applies results from the perfectly matchable subgraph polytope.     

A flexible MILP model for multiple-shift workforce planning under annualized hours

Flexibility in workforce planning is one of the best ways to respond to fluctuations of the demand. This paper proposes a flexible mixed integer linear programming (MILP) model to solve a multiple-shift workforce planning problem under annualized working hours. The model takes into account laws and collective agreements that impose constraints on overtime and holidays. We consider possible gradual hiring of full time and partial time workers. Several objectives are pursued such as balancing the workload of the employees or minimizing the workforce size. Computational experiments on a real life problem demonstrate the effectiveness of the model.     

A fuzzy-robust stochastic multiobjective programming approach for petroleum waste management planning

This paper proposes a fuzzy-robust stochastic multiobjective programming (FRSMOP) approach, which integrates fuzzy-robust linear programming and stochastic linear programming into a general multiobjective programming framework. A chosen number of noninferior solutions can be generated for reflecting the decision-makers’ preferences and subjectivity. The FRSMOP method can effectively deal with the uncertainties in the parameters expressed as fuzzy membership functions and probability distribution. The robustness of the optimization processes and solutions can be significantly enhanced through dimensional enlargement of the fuzzy constraints. The developed FRSMOP was then applied to a case study of planning petroleum waste-flow-allocation options and managing the related activities in an integrated petroleum waste management system under uncertainty. Two objectives are considered: minimization of system cost and minimization of waste flows directly to landfill. Lower waste flows directly to landfill would lead to higher system costs due to high transportation and operational costs for recycling and incinerating facilities, while higher waste flows directly to landfill corresponding to lower system costs could not meet waste diversion objective environmentally. The results indicate that uncertainties and complexities can be effectively reflected, and useful information can be generated for providing decision support.     

Integer linear programming formulation of the material requirements planning problem

Lot sizing procedures for discrete and dynamic demand form a distinct class of inventory control problems, usually referred to asmaterial requirements planning. A general integer programming formulation is presented, covering an extensive range of problems: single-item, multi-item, and multi-level optimization; conditions on lot sizes and time phasing; conditions on storage and production capacities; and changes in production and storage costs per unit. The formulation serves as a uniform framework for presenting a problem and a starting point for developing and evaluating heuristic and tailor-made optimum-seeking techniques.     

A heuristic approach for big bucket multi-level production planning problems

Multi-level production planning problems in which multiple items compete for the same resources frequently occur in practice, yet remain daunting in their difficulty to solve. In this paper, we propose a heuristic framework that can generate high quality feasible solutions quickly for various kinds of lot-sizing problems. In addition, unlike many other heuristics, it generates high quality lower bounds using strong formulations, and its simple scheme allows it to be easily implemented in the Xpress-Mosel modeling language. Extensive computational results from widely used test sets that include a variety of problems demonstrate the efficiency of the heuristic, particularly for challenging problems.     

Demilitarized zone planning: A multiobjective approach

The demilitarized zone has been used frequently as a means to separate conflicting nations. Imposition of a buffer zone free from military activities is considered to be an effective first step to restore peace between hostile nations. The demilitarized zone is usually patrolled by third-party forces to discourage military hostilities. This paper deals with the problem of allocating the third-party supervisory forces in order to assure effective policing of demilitarized zones where there are multiple and conflicting objectives.     

A prolog-based decision support system for computer capacity planning

This paper describes a project to implement a decision support system for computer capacity planning. The system provides an intelligent interface to the various models needed for this type of planning by assisting the user in model formulation, data manipulation, model execution, interpretation and manipulation of results. The implementation strategy is based on the integration of relational model and database management with logic. A modified version of a Prolog interpreter is utilized as the vehicle for this integrated strategy.This research was supported by Sandia National Laboratories Grant No. 56-3737. Sandia is managed by AT&T Technologies for the U.S. Department of Energy.     

The management of intrusion detection: Configuration,inspection, and investment

This paper analyzes intrusion detection decisions in the presence of multiple alarm types, which differ in occurrence probabilities, damage and investigation costs. Specifically, multi-period optimization models are used to study three critical decisions associated with intrusion detection: (i) Allocation of the investigation budget to different periods and to different alarm types; (ii) Configuration of an intrusion detection system (IDS), i.e. choosing a false alarm rate for a given IDS; and (iii) Allocation of an appropriate amount of the investigation budget in the presence of alternative investment opportunities. Three models that cascade onto each other are presented. We minimize the sum of security costs including damages, due to ignored alarms, the investigation cost and the undetected intrusion cost. We show that it can be optimal to ignore non-critical alarms in order to allocate more of the investigation budget to critical alarms that may occur in the future. We establish that the security costs decrease as the investigation budget increases. Our last model deals with security investments—in the form of an investigation budget. The investigation budget must be increased until the rate of increase in savings in security costs due to the additional budget are equal to the internal rate of return of an organization. These analyses are done with explicit (derived) cost functions, as opposed to implicit (assumed) cost functions. We conclude by providing additional managerial insights and numerical examples.     

Multi-product production planning: A goal programming approach

Cost minimization multi-product production problems with static production resource usage and internal product flow requirements have been solved by linear programming (LP) with input/output analysis. If the problem is complicated by interval resource estimates, interval linear programming (ILP) can be used. The solution of realistic problems by the above method is cumbersome. This paper suggests that linear goal programming (LGP) can be used to model a multi-product production system. LGP's unique modeling capabilities are used to solve a production planning problem with variable resource parameters. Input/output analysis is used to determine the technological coefficients for the goal constraints and is also used to derive an information sub-model that is used to reduce the number of variable resource goal constraints. Preliminary findings suggest that the LGP approach is more cost-efficient (in terms of CPU time) and in addition provides valuable information for aggregate planning.     

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.     

Allocating modelling resources in distributed model management systems

Due to the growing popularity of distributed computing systems and the increased level of modelling activity in most organizations, significant benefits can be realized through the implementation of distributed model management systems (DMMS). These systems can be defined as a collection of logically related modelling resources distributed over a computer network. In several ways, functions of DMMS are isomorphic to those of distributed database systems. In general, this paper examines issues viewed as central to the development of distributed model bases (DMB). Several criteria relevant to the overall DMB design problem are discussed. Specifically, this paper focuses on the problem of distributing decision models and tools (solvers), henceforth referred to as theModel Allocation Problem (MAP), to individual computing sites in a geographically dispersed organization. In this research, a 0/1 integer programming model is formulated for the MAP, and an efficient dual ascent heuristic is proposed. Our extensive computational study shows in most instances heuristic-generated solutions which are guaranteed to be within 1.5–7% of optimality. Further, even problems with 420 integer and 160,000 continuous variables took no more than 60 seconds on an IBM 3090-600E computer.     

Optimizing production and transportation in a commit-to-delivery business mode

In problems involving the simultaneous optimization of production and transportation, the requirement that an order can only be shipped once its production has been completed is a natural one. One example is a problem of optimizing shipping costs subject to a production capacity constraint studied recently by Stecke and Zhao. Here we present an integer programming formulation for the case in which only completed orders can be shipped that leads to very tight dual bounds and enables one to solve instances of significant size to optimality.     

Aggregate production planning for process industries under oligopolistic competition

We consider a competitive version of the traditional aggregate production planning model with capacity constraints. In the general case, multiple products are produced by a few competing producers (oligopoly) with limited capacities. Production quantities, prices and consequently profits depend on production and allocation decisions of each producer. In addition, there is competition for the raw material whose supplies are limited, and where prices reflect these limitations. Such situations have recently occurred in several process industry settings including petro-refining, petrochemicals, basic chemicals, cement, fertilizers, pharmaceuticals, rubber, paper, food processing and metals. We use a successive “Bertrand–Cournot” framework to address this problem and to determine optimal production quantities, prices and profits at the producers and at the raw material supplier. Our analysis allows a new way to understand and evaluate the marginal value of additional capacity when there is competition for the market and raw materials.     

A compromised large-scale neighborhood search heuristic for capacitated air cargo loading planning

Cost effectiveness is central to the air freight forwarders. In this work, we study how an air freight forwarder should plan its cargo loading in order to minimize the total freight cost given a limited number of rented containers. To solve the problem efficiently for practical implementation, we propose a new large-scale neighborhood search heuristic. The proposed large-scale neighborhood relaxes the subset-disjoint restriction made in the existing literature; the relaxation risks a possibility of infeasible exchanges while at the same time it avoids the potentially large amount of checking effort required to enforce the subset-disjoint restriction. An efficient procedure is then used to search for improvement in the neighborhood. We have also proposed a subproblem to address the difficulties caused by the fixed charges. The compromised large-scale neighborhood (CLSN) search heuristic has shown stably superior performance when compared with the traditional large-scale neighborhood search and the mixed integer programming model.     

Minimax production planning in failure-prone manufacturing systems

In this paper, we consider a minimax production planning model of a flexible manufacturing system with machines that are subject to random breakdown and repair. The objective is to choose the rate of production that minimizes the related minimax cost of production and inventory/shortage. The value function is shown to be the unique viscosity solution to the associated Hamilton-Jacobi-Isaacs equation. Under certain conditions, it is shown that the value function is continuously differentiable. A verification theorem is given to provide a sufficient condition for optimal control. Finally, two examples are solved explicitly.This research was supported by the Natural Sciences and Engineering Research Council of Canada under Grants OGP0036444 and A4169.     

Machine reliability and preventive maintenance planning for cellular manufacturing systems

The paper proposes a preventive maintenance (PM) planning model for the performance improvement of cellular manufacturing systems (CMS) in terms of machine reliability, and resource utilization. In a CMS, parts are processed by a group of interdependent machines, where machine reliability plays an important role in the performance improvement of the cell. Assuming that machine failure times follow a Weibull distribution, the proposed model determines a PM interval and a schedule for performing PM actions on each machine in the cell by minimizing the total maintenance cost and the overall probability of machine failures. The model uses a combined cost and reliability based approach, and optimizes maintenance costs by administering a group maintenance policy subject to a desirable machine reliability threshold. The study also proposes a CMS design model that integrates the above PM concepts into the design process. Illustrative examples are presented to demonstrate the applicability of the proposed approach.     

Linear programming with stochastic processes as parameters as applied to production planning

In formulating stochastic programming with recourse models, the parameters of the linear programs are usually assumed to be random variables with known distributions. In this paper, the requirement vector parameter is assumed to be a stochastic process { _i (t),tT,i=1,...,m}. The properties of the deterministic equivalents for the cases of the discrete and continuous index setT are derived. The results of the paper are applied to a multi-item production planning model with continuous (periodic) review of the stock on hand of various items.