A robust optimization model for multi-product two-stage capacitated production planning under uncertainty

Production planning (PP) is one of the most important issues carried out in manufacturing environments which seeks efficient planning, scheduling and coordination of all production activities that optimizes the company’s objectives. In this paper, we studied a two-stage real world capacitated production system with lead time and setup decisions in which some parameters such as production costs and customer demand are uncertain. A robust optimization model is developed to formulate the problem in which minimization of the total costs including the setup costs, production costs, labor costs, inventory costs, and workforce changing costs is considered as performance measure. The robust approach is used to reduce the effects of fluctuations of the uncertain parameters with regards to all the possible future scenarios. A mixed-integer programming (MIP) model is developed to formulate the related robust production planning problem. In fact the robust proposed model is presented to generate an initial robust schedule. The performance of this schedule could be improved against of any possible occurrences of uncertain parameters. A case from an Iran refrigerator factory is studied and the characteristics of factory and its products are discussed. The computational results display the robustness and effectiveness of the model and highlight the importance of using robust optimization approach in generating more robust production plans in the uncertain environments. The tradeoff between solution robustness and model robustness is also analyzed.     

Robust production planning in a manufacturing environment with random yield: A case in sawmill production planning

This paper addresses a multi-period, multi-product sawmill production planning problem where the yields of processes are random variables due to non-homogeneous quality of raw materials (logs). In order to determine the production plans with robust customer service level, robust optimization approach is applied. Two robust optimization models with different variability measures are proposed, which can be selected based on the tradeoff between the expected backorder/inventory cost and the decision maker risk aversion level about the variability of customer service level. The implementation results of the proposed approach for a realistic-scale sawmill example highlights the significance of using robust optimization in generating more robust production plans in the uncertain environments compared with stochastic programming.     

A robust optimization model for a cross-border logistics problem with fleet composition in an uncertain environment

Since the implementation of the open-door policy in China, many Hong Kong-based manufacturers' production lines have moved to China to take advantage of the lower production cost, lower wages, and lower rental costs, and thus, the finished products must be transported from China to Hong Kong. It has been discovered that logistics management often encounters uncertainty and noisy data. In this paper, a robust optimization model is proposed to solve a cross-border logistics problem in an environment of uncertainty. By adjusting penalty parameters, decision-makers can determine an optimal long-term transportation strategy, including the optimal delivery routes and the optimal vehicle fleet composition to minimize total expenditure under different economic growth scenarios. We demonstrate the robustness and effectiveness of our model using the example of a Hong Kong-based manufacturing company. The analysis of the trade-off between model robustness and solution robustness is also presented.     

A robust approach to the chance-constrained knapsack problem

In this paper, the chance-constrained knapsack problem (CKP) is addressed. Relying on robust optimization, a tractable combinatorial algorithm is proposed to solve approximately CKP. For two specific classes of uncertain knapsack problems, it is proved to solve CKP at optimality.     

Integrated production planning and order acceptance under uncertainty: A robust optimization approach

The aim of this paper is to formulate a model that integrates production planning and order acceptance decisions while taking into account demand uncertainty and capturing the effects of congestion. Orders/customers are classified into classes based on their marginal revenue and their level of variability in order quantity (demand variance). The proposed integrated model provides the flexibility to decide on the fraction of demand to be satisfied from each customer class, giving the planner the choice of selecting among the highly profitable yet risky orders or less profitable but possibly more stable orders. Furthermore, when the production stage exceeds a critical utilization level, it suffers the consequences of congestion via elongated lead-times which results in backorders and erodes the firm’s revenue. Through order acceptance decisions, the planner can maintain a reasonable level of utilization and hence avoid increasing delays in production lead times. A robust optimization (RO) approach is adapted to model demand uncertainty and non-linear clearing functions characterize the relationship between throughput and workload to reflect the effects of congestion on production lead times. Illustrative simulation and numerical experiments show characteristics of the integrated model, the effects of congestion and variability, and the value of integrating production planning and order acceptance decisions.     

Surrogate duality for robust optimization

Robust optimization problems, which have uncertain data, are considered. We prove surrogate duality theorems for robust quasiconvex optimization problems and surrogate min–max duality theorems for robust convex optimization problems. We give necessary and sufficient constraint qualifications for surrogate duality and surrogate min–max duality, and show some examples at which such duality results are used effectively. Moreover, we obtain a surrogate duality theorem and a surrogate min–max duality theorem for semi-definite optimization problems in the face of data uncertainty.     

Collaborative production planning of supply chain under price and demand uncertainty

This research is motivated by an automobile manufacturing supply chain network. It involves a multi-echelon production system with material supply, component fabrication, manufacturing, and final product distribution activities. We address the production planning issue by considering bill of materials and the trade-offs between inventories, production costs and customer service level. Due to its complexity, an integrated solution framework which combines scatter evolutionary algorithm, fuzzy programming and stochastic chance-constrained programming are combined to jointly take up the issue. We conduct a computational study to evaluate the model. Numerical results using the proposed algorithm confirm the advantage of the integrated planning approach. Compared with other solution methodologies, the supply chain profits from the proposed approach consistently outperform, in some cases up to 13% better. The impacts of uncertainty in demand, material price, and other parameters on the performance of the supply chain are studied through sensitivity analysis. We found the proposed model is effective in developing robust production plans under various market conditions.     

A robust optimization model for dynamic market with uncertain production cost

This article presents a robust optimization formulation for dealing with production cost uncertainty in an oligopolistic market scenario. It is not uncommon that players in the market face an equilibrium selling price but uncertain production costs. We show that, based on a nominal problem, the robust optimization formulation can be derived as a variational inequality with control and state variables. This convenient approach may be applied for computing optimal solutions efficiently, which help manufacturers dramatically and rapidly reform production and distribution schedules such that they can compete in the market successfully.     

A fuzzy linear programming based approach for tactical supply chain planning in an uncertainty environment

This paper models supply chain (SC) uncertainties by fuzzy sets and develops a fuzzy linear programming model for tactical supply chain planning in a multi-echelon, multi-product, multi-level, multi-period supply chain network. In this approach, the demand, process and supply uncertainties are jointly considered. The aim is to centralize multi-node decisions simultaneously to achieve the best use of the available resources along the time horizon so that customer demands are met at a minimum cost. This proposal is tested by using data from a real automobile SC. The fuzzy model provides the decision maker (DM) with alternative decision plans with different degrees of satisfaction.     

A robust optimization approach to reduce the bullwhip effect of supply chains with vendor order placement lead time delays in an uncertain environment

Supply chain management is important for companies and organizations to improve their business and enhance competitiveness in the global marketplace. The bullwhip effect problem of supply chain systems with vendor order placement lead time delays in an uncertain environment is addressed in this paper. Among the numerous causes of bullwhip effect, we focus on uncertainties with respect to demand, production process, supply chain structure, inventory policy implementation and especially vendor order placement lead time delays. Minimizing the negative effect of these uncertainties in inducing bullwhip effect creates a need for developing dynamical inventory policy that increases responsiveness to demand and decreases volatility in inventory replenishment. First, a dynamic model of supply chain with above uncertainties is developed. Then, a novel uncertainty-dependent robust inventory control method using inventory position information is proposed. Additionally, the maximum allowable vendor order placement lead time delay that ensures the stability of supply chains and the suppression of bullwhip effect under the proposed inventory control policy is explored and measured. We find that vendor order placement lead time delays do play important role in supply chain dynamics and contribute to its turbulence and volatility. The effectiveness and flexibility of proposed method is verified through simulation study.     

Algorithm robust for the bicriteria discrete optimization problem

We apply Algorithm Robust to various problems in multiple objective discrete optimization. Algorithm Robust is a general procedure that is designed to solve bicriteria optimization problems. The algorithm performs a weight space search in which the weights are utilized in min-max type subproblems. In this paper, we experiment with Algorithm Robust on the bicriteria knapsack problem, the bicriteria assignment problem, and the bicriteria minimum cost network flow problem. We look at a heuristic variation that is based on controlling the weight space search and has an indirect control on the sample of efficient solutions generated. We then study another heuristic variation which generates samples of the efficient set with quality guarantees. We report results of computational experiments.     

Production planning with load dependent lead times: an update of research

Lead times impact the performance of the supply chain significantly. Although there is a large body of literature concerning queuing models for the analysis of the relationship between capacity utilization and lead times, and another body of work on control and order release policies that take lead times into consideration, there have been relatively few aggregate planning models that recognize the (nonlinear) relationship between the planned utilization of capacity and lead times. In this paper we provide an in-depth discussion of the state-of-the art in this area, with particular attention to those models that are appropriate at the aggregate planning level. An earlier version of this paper appeared in 4OR 3, 257–302, 2005.     

A robust desirability function method for multi-response surface optimization considering model uncertainty

A robust desirability function approach to simultaneously optimizing multiple responses is proposed. The approach considers the uncertainty associated with the fitted response surface model. The uniqueness of the proposed method is that it takes account of all values in the confidence interval rather than a single predicted value for each response and then defines the robustness measure for the traditional desirability function using the worst case strategy. A hybrid genetic algorithm is developed to find the robust optima. The presented method is compared with its conventional counterpart through an illustrated example from the literature.     

Characterizing robust set containments and solutions of uncertain linear programs without qualifications

Qualification-free dual characterizations are given for robust polyhedral set containments where a robust counterpart of an uncertain polyhedral set is contained in another polyhedral set or a polyhedral set is contained in a robust counterpart of an uncertain polyhedral set. These results are used to characterize robust solutions of uncertain linear programs, where the uncertainty is defined in terms of intervals or l₁-balls. The hidden separable sub-linearity of the robust counterparts allows qualification-free dual characterizations.     

A two-stage model for a day-ahead paratransit planning problem

We consider a dynamic planning problem for paratransit transportation. The focus is on a decision to take one day ahead: which requests to serve with own vehicles, and which requests to subcontract to taxis? We call this problem the day-ahead paratransit planning problem. The developed model is a non-standard two-stage integer recourse model. Both stages consist of two consecutive optimization problems: the clustering of requests into routes, and the assignment of these routes to vehicles. To solve this model, a genetic algorithm approach is used. Computational results are presented for randomly generated data sets.     

Time-dependent optimization of a multi-item uncertain supply chain network: A hybrid approximation algorithm

We consider the uncertain least cost shipping problem. The input is a multi-item supply chain network with time-evolving uncertain costs and capacities. Exploiting the operational law of uncertainty theory, a mathematical model of the problem is established and the indeterminacy factors are tackled. We use the scaling idea together with transformation approach and uncertainty programming to develop a hybrid algorithm to optimize and obtain the uncertainty distribution of the total shipping cost. We analyze the practical performance of the algorithm and present an illustrative example.     

A robust optimization approach to wine grape harvesting scheduling

Optimization models are increasingly being used in agricultural planning. However, the inherent uncertainties present in agriculture make it difficult. In recent years, robust optimization has emerged as a methodology that allows dealing with uncertainty in optimization models, even when probabilistic knowledge of the phenomenon is incomplete. In this paper, we consider a wine grape harvesting scheduling optimization problem subject to several uncertainties, such as the actual productivity that can be achieved when harvesting. We study how effective robust optimization is solving this problem in practice. We develop alternative robust models and show results for some test problems obtained from actual wine industry problems.     

Selected topics in robust convex optimization

Robust Optimization is a rapidly developing methodology for handling optimization problems affected by non-stochastic “uncertain-but- bounded” data perturbations. In this paper, we overview several selected topics in this popular area, specifically, (1) recent extensions of the basic concept of robust counterpart of an optimization problem with uncertain data, (2) tractability of robust counterparts, (3) links between RO and traditional chance constrained settings of problems with stochastic data, and (4) a novel generic application of the RO methodology in Robust Linear Control.      

A robust robust optimization result

We study the loss in objective value when an inaccurate objective is optimized instead of the true one, and show that “on average” this loss is very small, for an arbitrary compact feasible region.