A dispatching rule-based approach to production scheduling in a printed circuit board manufacturing system

This paper focuses on a production-scheduling problem in a printed circuit board (PCB) manufacturing system that produces multiple product types with different due dates and different manufacturing processes. In the PCB manufacturing system, there is a number of serial workstations, and there are multiple parallel machines at each workstation. Also, setup operations are required at certain workstations or machines, and some product types have re-entrant flows. We develop new dispatching rules for scheduling at each workstation, considering the special features of PCB manufacturing. With the dispatching rules, we determine not only the start time of each lot at a machine but also the batch size of each product at each machine. Simulation experiments are carried out to test the performance of the production-scheduling method and dispatching rules devised in this study. Results show that the production-scheduling method suggested in this study performs better than methods with well-known dispatching rules and heuristic algorithms for lot sizing in terms of the total tardiness of orders.     

Joint production and preventive maintenance scheduling for a single degraded machine by considering machine failures

Production scheduling and maintenance planning are two interdependent issues that most often have been investigated independently. Although both preventive maintenance (PM) and minimal repair affect availability and failure rate of a machine, only a few researchers have considered this interdependency in the literature. Furthermore, most of the existing joint production and preventive maintenance scheduling methods assume that machine is available during the planning horizon and consider only a possible level for PM. In this research, an integrated model is proposed that coordinates preventive maintenance planning with single-machine scheduling to minimize the weighted completion time of jobs and maintenance cost, simultaneously. This paper not only considers multiple PM levels with different costs, times and reductions in the hazard rate of the machine, but also assumes that a machine failure may occur at any time. To illustrate the effectiveness of the suggested method, it is compared to two situations of no PM and a single PM level. Eventually, to tackle the suggested problem, multi-objective particle swarm optimization and non-dominated sorting genetic algorithm (NSGA-II) are employed and their parameters are tuned Furthermore, their performances are compared in terms of three metrics criteria.     

Minimizing the number of pickups on a multi-head placement machine

Multi-head gantry machines are becoming increasingly popular in surface mount technology (SMT), because they combine high printing speed with a moderate price. The optimization of their operation seems, however, to be very difficult. We formalize here a small subproblem of the scheduling problem of multi-headed SMT machines, namely the selection of nozzles which pick up and place components on printed circuit boards (PCB). The aim in this selection is to minimize the number of component pickups when manufacturing some PCB type. Given a sequence of component placement commands, a greedy nozzle usage policy picks, at each pickup, as many components next in the sequence as possible. If the nozzles are ‘universal’, that is, they can pick up any component, it is obvious that this policy is optimal. The situation gets more complicated once certain component types can be picked up only with certain nozzle types. We show that the greedy policy is optimal in this case, too. Finally, we do some experiments aimed at a better understanding of this subproblem.     

Heuristics approach to printed circuit board insertion problem

This paper studies the operation of a surface mount technology (SMT) machine which basically consists of three main movable parts: an X–Y table containing a printed circuit board (PCB), ten rotating ‘pick-and-place’ heads and a carriage feeder of reels. The machine inserts electronic components into defined positions on a PCB and the components are supplied from a set of reels each containing a tape of identical components. In the current production setup, the assembly plan comprising both the insertion sequence of components and the placement orders of the reels in the feeder is by human experience. Our study suggests that the problem is computationally difficult for its mathematical optimum with the insertion problem alone being NP-complete. We propose a heuristic solution technique of low computational complexity to find a better assembly plan comprising of the assembly sequence of electronic components and the placement order of the reels in the feeder. The algorithm developed combines the physical constraints of the SMT machine and a ‘grouping’ concept that takes advantage of the natural structure of a PCB. Using multiple reels in the PCB insertion problem are also considered. Simulated results are reported on a set of illustrative data.     

MODELING HARVEST SCHEDULING IN MULTIFUNCTIONAL PLANNING OF FORESTS FOR LONGTERM WATER YIELD OPTIMIZATION

In this study, wood production and hydrologic functions of forests were accommodated within a planning procedure for separate working circles (areas dedicated to certain forest functions) that were delineated according to an Ecosystem‐Based Functional Planning approach. Mixed integer goal programming was used as the optimization technique. The timing and scheduling of a maintenance cutting (partial harvest) was the decision variable in the modeling effort, and an original formulation was developed as a multiobjective planning procedure. Four sample planning strategies were developed and model outputs were evaluated according to these strategies. Spatial characteristics of stands were considered, and used to prohibit the regeneration of adjacent stands during the same time period. Because of the positive relationship between qualified water production and standing timber volume in the forest, the model attempts to maximize qualified water production levels by increasing standing volume stocks in the forest through the delay of regeneration activities.     

A note on “A mixed integer programming model for advanced planning and scheduling (APS)”

In a recent paper, Chen and Ji [Chen, K., Ji, P., 2007. A mixed integer programming model for advanced planning and scheduling (APS). European Journal of Operational Research 181, 515–522] develop a mixed integer programming model for advanced planning and scheduling problem that considers capacity constraints and precedence relations between the operations. The orders require processing of several operations on eligible machines. The model presented in the above paper works for the case where each operation can be processed on only one machine. However, machine eligibility means that only a subset of machines are capable of processing a job and this subset may include more than one machine. We provide a general model for advanced planning and scheduling problems with machine eligibility. Our model can be used for problems where there are alternative machines that an operation can be assigned to.     

Schedule execution for two-machine flow-shop with interval processing times

This paper addresses the issue of how to best execute the schedule in a two-phase scheduling decision framework by considering a two-machine flow-shop scheduling problem in which each uncertain processing time of a job on a machine may take any value between a lower and upper bound. The scheduling objective is to minimize the makespan. There are two phases in the scheduling process: the off-line phase (the schedule planning phase) and the on-line phase (the schedule execution phase). The information of the lower and upper bound for each uncertain processing time is available at the beginning of the off-line phase while the local information on the realization (the actual value) of each uncertain processing time is available once the corresponding operation (of a job on a machine) is completed. In the off-line phase, a scheduler prepares a minimal set of dominant schedules, which is derived based on a set of sufficient conditions for schedule domination that we develop in this paper. This set of dominant schedules enables a scheduler to quickly make an on-line scheduling decision whenever additional local information on realization of an uncertain processing time is available. This set of dominant schedules can also optimally cover all feasible realizations of the uncertain processing times in the sense that for any feasible realizations of the uncertain processing times there exists at least one schedule in this dominant set which is optimal. Our approach enables a scheduler to best execute a schedule and may end up with executing the schedule optimally in many instances according to our extensive computational experiments which are based on randomly generated data up to 1000 jobs. The algorithm for testing the set of sufficient conditions of schedule domination is not only theoretically appealing (i.e., polynomial in the number of jobs) but also empirically fast, as our extensive computational experiments indicate.     

具有可变配送费用和固定配送时刻的单机排序问题

研究了单机环境下生产与配送的协同排序问题.有多个工件需要在一台机器上进行加工,加工完的工件需要分批配送到一个客户.每批工件只能在固定的几个配送时刻出发,不同的配送时刻对应着不同的配送费用.我们的目标是找到生产与配送的协同排序,极小化排序的时间费用与配送费用的加权和.研究了排序理论中主要的四个目标函数,构建了单机情况下的具体模型,分析了问题的复杂性,对于配送费用单调非增的情况给出了它们的最优算法.     

Integrated production and maintenance planning for parallel machine system considering cost of rejection

Production scheduling and maintenance planning have interdependencies but been often considered and optimized independently in practice and in the literature. Furthermore, product quality has direct relationship with maintenance planning. This paper proposes an integrated approach for production scheduling and maintenance planning for parallel machine system considering the effect of cost of rejection. The approach aims to determine optimal production schedule and maintenance plan such that overall operations cost is minimized. A simulation-based optimization approach is used to solve the problem. A numerical investigation is performed to illustrate the approach. The integrated approach shows between 0.6 and 35.8% improvement in term of overall operations cost over independent approach for various scenarios. The results indicate that simultaneous consideration of production scheduling and maintenance planning results into better system performance.     

A two-stage heuristic for disassembly scheduling with assembly product structure

Disassembly scheduling, one of the important operational problems in disassembly systems, is the problem of determining the ordering and disassembly schedules of used or end-of-life products while satisfying the demand of their parts or components over a certain planning horizon. This paper considers products with assembly structure for the objective of minimizing the sum of purchase, set up, inventory holding, and disassembly operation costs, and suggests a two-stage heuristic, in which an initial solution is obtained in the form of the minimal latest ordering and disassembly schedule, and then improved iteratively considering trade-offs among different cost factors. To show the performance of the heuristic, computational experiments were done on the example obtained from the literature and a number of randomly generated test problems, and the results show that the heuristic can give optimal or very near-optimal solutions within very short computation times.     

Scheduling coordination problems in supply chain planning

Scheduling algorithms and their role in supply chain planning are topics that have been discussed in scheduling literature for many years. Based on examples and experience with commercial supply chain planning software, this paper presents background information about production planning and scheduling functionality in commercial supply chain planning software and interesting scheduling coordination problems in supply chain planning for researchers. We first provide an overview of different planning activities in supply chain planning, while taking into consideration existing functionalities that are available in commercial supply chain planning software. As a second step, we show three scheduling coordination problems in supply chain planning, namely the integration of production planning and production scheduling, the integration of sales order confirmation and production scheduling and the integration of VMI planning and production scheduling. We conclude this paper with a detailed discussion of an implementation of a supply chain planning solution at the tissue producer SCA Hygiene in Sweden. This paper expresses the authors opinion and does not represent an official statement from SAP.     

单件订货型生产中基于任务的生产能力研究

在单件订货型生产过程的计划、控制及管理中,生产能力的评估具有十分重要的意义和作用.生产能力包括两个方面:一是技术和设备性能相关的生产能力,一是生产时间相关的生产能力.前者主要是定性的,相对来说易于评估;后者是定量的,由于单件订货型生产的特点,使得这种生产能力成为任务相关的.通过对单件订货型生产中生产时间相关生产能力特点的分析,针对设备和工序任务,提出了基于任务的生产能力的概念及一些相关的定义;并进一步给出了生产能力的计算算法.     

Search heuristics for a flowshop scheduling problem in a printed circuit board assembly process

We consider a scheduling problem in a factory producing printed circuit boards (PCBs). The PCB assembly process in this factory can be regarded as a flowshop which has two special characteristics: jobs have sequence dependent setup times and each job consists of a lot (batch) of identical PCBs. Because of the latter characteristic, it is possible to start a job on a following machine before the job is entirely completed on a previous machine, that is, there is time-lag between machines. In this paper, we propose several heuristics, including taboo search (TS) and simulated annealing (SA) methods, for this generalized flowshop scheduling problem with the objective of minimizing mean tardiness. We compare suggested heuristics after series of tests to find appropriate values for parameters needed for the two search algorithms, TS and SA. Results of computational tests on randomly generated test problems are reported.     

Using real time information for effective dynamic scheduling

In many production processes real time information may be obtained from process control computers and other monitoring systems, but most existing scheduling models are unable to use this information to effectively influence scheduling decisions in real time. In this paper we develop a general framework for using real time information to improve scheduling decisions, which allows us to trade off the quality of the revised schedule against the production disturbance which results from changing the planned schedule. We illustrate how our framework can be used to select a strategy for using real time information for a single machine scheduling model and discuss how it may be used to incorporate real time information into scheduling the complex production processes of steel continuous caster planning.     

Single-machine scheduling with maintenance and repair rate-modifying activities

Most papers in the scheduling field are based on the assumption that machines are always available at constant speed. However, in industry applications, it is very common for a machine to be in subnormal condition after running for a certain period of time. Motivated by a problem commonly found in the surface-mount technology of electronic assembly lines, this paper deals with scheduling problems involving repair and maintenance rate-modifying activities. When a machine is running at less than an efficient speed, a production planner can decide to stop the machine and maintain it or wait and maintain it later. If the choice is made to continue running the machine without fixing it, it is possible that the machine will break down and repair will be required immediately. Both maintenance and repair activities can change the machine speed from a sub-normal production rate to a normal one. Hence, we call them rate-modifying activities. Our purpose here is to simultaneously sequence jobs and schedule maintenance activity to optimize regular performance measures. In this paper, we assume that processing time is deterministic, while machine break down is a random process following certain distributions. We consider two types of processing cases: resumable and nonresumable. We study problems with objective functions such as expected makespan, total expected completion time, maximum expected lateness, and expected maximum lateness, respectively. Several interesting results are obtained, especially for the nonresumable case.     

Exploiting process plan flexibility in production scheduling: A multi-objective approach

When solving a product/process design problem, we must exploit the available degrees of freedom to cope with a variety of issues. Alternative process plans can be generated for a given product, and choosing one of them has implications on manufacturing functions downstream, including planning/scheduling. Flexible process plans can be exploited in real time to react to machine failures, but they are also relevant for off-line scheduling. On the one hand, we should select a process plan in order to avoid creating bottleneck machines, which would deteriorate the schedule quality; on the other one we should aim at minimizing costs. Assessing the tradeoff between these possibly conflicting objectives is difficult; actually, it is a multi-objective problem, for which available scheduling packages offer little support. Since coping with a multi-objective scheduling problem with flexible process plans by an exact optimization algorithm is out of the question, we propose a hierarchical approach, based on a decomposition into a machine loading and a scheduling sub-problem. The aim of machine loading is to generate a set of efficient (non-dominated) solutions with respect to the load balancing and cost objectives, leaving to the user the task of selecting a compromise solution. Solving the machine loading sub-problem essentially amounts to selecting a process plan for each job and to routing jobs to the machines; then a schedule must be determined. In this paper we deal only with the machine loading sub-problem, as many scheduling methods are already available for the problem with fixed process plans. The machine loading problem is formulated as a bicriterion integer programming model, and two different heuristics are proposed, one based on surrogate duality theory and one based on a genetic descent algorithm. The heuristics are tested on a set of benchmark problems.     

Operator non-availability periods

In the scheduling literature, the notion of machine non-availability periods is well known, for instance for maintenance. In our case of planning chemical experiments, we have special periods (the week-ends, holidays, vacations) where the chemists are not available. However, human intervention by the chemists is required to handle the starting and termination of the experiments. This gives rise to a new type of scheduling problems, namely problems of finding schedules that respect the operator non-availability periods. These problems are analyzed on a single machine with the makespan as criterion. Properties are described and performance ratios are given for list scheduling and other polynomial-time algorithms.     

Branch-and-price approach for the multi-skill project scheduling problem

This work introduces a procedure to solve the multi-skill project scheduling problem (MSPSP) (Néron and Baptista, International symposium on combinatorial, optimization (CO’2002), 2002). The MSPSP mixes both the classical resource constrained project scheduling problem and the multi-purpose machine model. The aim is to find a schedule that minimizes the completion time (makespan) of a project, composed of a set of activities. In addition, precedence relations and resources constraints are considered. In this problem, resources are staff members that master several skills. Thus, a given number of workers must be assigned to perform each skill required by an activity. Practical applications include the construction of buildings, as well as production and software development planning. We present a column generation approach embedded within a branch-and-price (B&P) procedure that considers a given activity and time-based decomposition approach. Obtained results show that the proposed B&P procedure is able to reach optimal solutions for several small and medium sized instances in an acceptable computational time. Furthermore, some previously open instances were optimally solved.     

Scheduling flexible machining and assembly systems

Most scheduling papers consider flexible machining and assembly systems as being independent. In this paper, a heuristic two-level scheduling algorithm for a system consisting of a machining and an assembly subsystem is developed. It is shown that the upper level problem is equivalent to the two machine flow shop problem. The algorithm at the lower level schedules jobs according to the established product and part priorities. Related issues, such as batching, due dates, process planning and alternative routes, are discussed. The algorithm and associated concepts are illustrated on a number of numerical examples.     

Heuristic Approaches for a Scheduling Problem in the Plastic Molding Department of an Audio Company

A production scheduling problem for making plastic molds of hi-fi models is considered. The objective is to minimize the total machine makespan in the presence of due dates, variable lot size, multiple machine types, sequence dependent, machine dependent setup times, and inventory limits. Goal programming and load balancing are applied to select the set of machine types and assign mold types to machines, resulting in a set of single-machine scheduling problems. A mixed-integer program (MIP) is formulated for the general problem but could solve only small instances. A single-machine scheduling heuristic is designed to adopt a production sequence from a travelling salesman solution. The start time of every cycle is determined by a simplified MIP. Production cycles are defined to equalize the stockout times of mold types. A post-processing step reduces the number of setups in the last cycle. Results using real-life data are promising. Characteristics giving rise to high machine utilization are discussed.