Machine duplication and part subcontracting in the presence of alternative cell locations in manufacturing cell design

In this paper a model and a solution algorithm are reported to simultaneously deal with the processes of machine duplication and part subcontracting in the presence of two significant design issues in cellular manufacturing systems: (i) alternative cell locations; and (ii) the maximum number of machines assigned to a cell. As the problem, formulated as a polynomial programming model, is shown NP-hard in the strong sense, a higher-level heuristic algorithm based upon a concept known as ‘tabu search’ is presented. An example (small) problem is solved to demonstrate the functionality of the algorithm. Additionally, the small problem is solved for its optimal solution under different scenarios, both with linear single-row and linear double-row layout arrangements, and the solutions obtained are shown to match with those obtained with the heuristic algorithm. A comparison of six different versions of tabu search-based heuristics (TSH 1–TSH 6) is performed to investigate the impact of long-term memory and the use of fixed versus variable tabu-list sizes. A carefully constructed statistical experiment, based on randomised complete-block design, is used to test the performance on three different problem structures, classified as small, medium and large. The results show that TSH 6 with variable tabu-list size and long-term memory based on minimal frequencies is preferred for the single-row layout, while TSH 4 with variable tabu-list size and no long-term memory is preferred for the double-row layout. When subject to budgetary restrictions, the proposed approach can be used by parts manufacturing companies to determine which of the following three actions should be undertaken for each bottleneck part: bottleneck part left as in the initial solution, all the bottleneck machines connected to it are duplicated, or the part subcontracted.     

Design of manufacturing cells in the presence of alternative cell locations and material transporters

This paper addresses two significant issues in the design of cellular manufacturing (CM) systems: (i) the availability of alternative locations for a cell, and (ii) the use of alternative routes to move part loads between cells when the capacity of the material transporter (MT) employed is limited. In addition, several other important factors in the design of CM systems including machine capacity limitations, batches of part demands, non-consecutive operations of parts, and maximum number of machines assigned to a cell are considered. A nonlinear programming model, comprised of binary and general integer variables, is formulated for the research problem. A higher-level heuristic solution algorithm based upon a concept known as ‘tabu search’ is presented for solving industry-size problems. Six different versions of the heuristic are developed to investigate the impact of long-term memory and the use of fixed versus variable tabu-list sizes. Explicit method-based techniques are developed to convert the original nonlinear programming model into an equivalent mixed (binary)-integer linear programming model in order to test the efficacy of the proposed solution technique for solving small problem instances. The solutions obtained from the heuristics have average deviation of less than 3% of the optimal solutions, and require less than a minute in comparison with optimizing methods that needed 1–10 h of computation time. A carefully designed statistical experiment is used to compare the performance of the heuristics by solving three different problem structures, ranging from four to 30 parts, and three to nine locations. The experiment shows that as the problem size increases, the tabu-search-based heuristic using fixed tabu list size and long-term memory based on minimal frequency strategy is preferred over the other heuristics.     

Meta-heuristic approaches with memory and evolution for a multi-product production/distribution system design problem

We consider a multi-product two-stage production/distribution system design problem (PDSD) where a fixed number of capacitated distribution centers are to be located with respect to capacitated suppliers (plants) and retail locations (customers) while minimizing the total costs in the system. We present a mixed-integer problem formulation that facilitates the development of efficient heuristic procedures. We provide meta-heuristic procedures, including a population-based scatter search with path relinking and trajectory-based local and tabu search, for the solution of the problem. We also develop efficient construction heuristics and transshipment heuristics that are incorporated into the heuristic procedures for the solution of subproblems. We present extensive computational results that show the high performance of the solution approaches. We obtain smaller than 1.0% average optimality gaps with acceptable runtimes, even for relatively large problems. The computational results also demonstrate the effectiveness of the construction and transshipment heuristics that impact the solution quality and overall runtimes.     

Simulated annealing and tabu search approaches to unidirectional flowpath design for Automated Guided Vehicle Systems

In this paper, we address the flowpath design issue of Automated Guided Vehicle Systems (AGVSs). In particular, we concentrate on the design of unidirectional flowpaths (i.e. vehicles are restricted to travel only in one direction along a given segment of the flowpath). We have developed intelligent heuristics — simulated annealing and tabu search algorithms for the design of unidirectional AGVSs. Different versions of simulated annealing and tabu search algorithms are implemented. Our extensive computational results indicate that both simulated annealing and tabu search yield solutions of adequate quality for all practical purposes. A tabu search implementation with the use of a frequency-based memory structure dominates all tested heuristics in terms of solution quality (i.e. percent deviation from optimality), with an impressive average performance over 45 test problems of less than 0.85% deviation from optimality.     

A one-step tabu search algorithm for manufacturing cell design

As part of the cellular manufacturing design process, machines must be grouped in cells and the corresponding part families must be assigned. Limits on both the number of machines per cell and the number of parts per family can be considered. A weighted sum of intracell voids and intercellular moves is used to evaluate the quality of the solutions. We present a tabu search algorithm that systematically explores feasible machine cells configurations determining the corresponding part families using a linear network flow model. The performance of this tabu search is benchmarked against two simulated annealing approaches, another tabu search approach and three heuristics: (ZODIAC, GRAFICS and MST).     

Tabu search and GRASP for the maximum diversity problem

In this paper, we develop new heuristic procedures for the maximum diversity problem (MDP). This NP-hard problem has a significant number of practical applications such as environmental balance, telecommunication services or genetic engineering. The proposed algorithm is based on the tabu search methodology and incorporates memory structures for both construction and improvement. Although proposed in seminal tabu search papers, memory-based constructions have often been implemented in naïve ways that disregard important elements of the fundamental tabu search proposals. We will compare our tabu search construction with a memory-less design and with previous algorithms recently developed for this problem. The constructive method can be coupled with a local search procedure or a short-term tabu search for improved outcomes. Extensive computational experiments with medium and large instances show that the proposed procedure outperforms the best heuristics reported in the literature within short computational times.     

Complete Local Search with Memory

Neighborhood search heuristics like local search and its variants are some of the most popular approaches to solve discrete optimization problems of moderate to large size. Apart from tabu search, most of these heuristics are memoryless. In this paper we introduce a new neighborhood search heuristic that makes effective use of memory structures in a way that is different from that in common implementations of tabu search. We report computational experiments with this heuristic on the traveling salesperson problem and the subset sum problem.     

An efficient tabu search procedure for the p-Median Problem

In this paper we present a new solution heuristic for the p-Median Problem. The algorithm is based on tabu search principles, and uses short term and long term memory, as well as strategic oscillation and random tabu list sizes. Our proposed procedure is compared with two other move heuristics: a well-known interchange heuristic and a recent hybrid heuristic. In computational tests on networks ranging in size up to 500 nodes the new heuristic is found to be superior with respect to the quality of solutions produced.     

Assignment of add–drop multiplexer (ADM) rings and digital cross-connect system (DCS) mesh in telecommunication networks

This paper discusses a design of a hybrid ring–mesh network in a survivable communication network. Given a set of traffic demands, the problem is to assign each traffic demand to rings and mesh such that the cost of add–drop multiplexer (ADM) and digital cross-connect system (DCS) equipment required is minimized. This assignment problem can be considered together with the fibre routing of nodes on rings and mesh. As a solution procedure, a tabu search is developed with recency-based short-term and frequency-based long-term memory structures. In computational experiments, the proposed tabu search is compared with the solutions obtained by the branch and bound procedure of CPLEX. We see that the tabu search provides a nearly optimal solution within sufficiently short time periods for all test problems with a gap of approximately 1–4% from the lower bound.     

Search Heuristics for Resource Constrained Project Scheduling

We develop a search procedure for project scheduling problems with multiple resource constraints as well as precedence constraints. The procedure is applied to three popular search heuristics, simulated annealing, tabu search and genetic algorithms. In the heuristics, a solution is represented with a string of numbers each of which denotes priority of each activity. The priorities are used to select an activity for scheduling among competing ones. The search heuristics with this encoding method can always generate feasible neighbourhood solutions for a given solution. Moreover, this encoding method is very flexible in that problems with objective functions of a general functional form (such as a nonlinear function) and complex constraints can be considered without much difficulty. Results of computational tests on the performance of the search heuristics showed that the search heuristics, especially the simulated annealing and tabu search algorithms worked better than existing heuristics.     

A tabu search approach for solving a difficult forest harvesting machine location problem

This paper deals with two main problems in forest harvesting. The first is that of selecting the locations for the machinery to haul logs from the points where they are felled to the roadside. The second consists in designing the access road network connecting the existing road network with the points where machinery is installed. Their combination induces a very important and difficult problem to solve in forest harvesting. It can be formulated as a combination of two difficult optimization problems: a plant location problem and a fixed charge network flow problem. In this paper, we propose a solution approach based on tabu search. The proposed heuristic includes several enhancements of the basic tabu search framework. The main difficulty lies in evaluating neighboring solutions, which involves decisions related to location of machinery and to road network arcs. Hence, the neighborhood is more complex than in typical applications of metaheuristics. Minimum spanning tree algorithms and Steiner tree heuristics are used to deal with this problem. Numerical results indicate that the heuristic approach is very attractive and leads to better solutions than those provided by state-of-the-art integer programming codes in limited computation times, with solution times significantly smaller. The numerical results do not vary too much when typical parameters such as the tabu tenure are modified, except for the dimension of neighborhood.     

An empirical study of hyperheuristics for managing very large sets of low level heuristics

Hyperheuristics give us the appealing possibility of abstracting the solution method from the problem, since our hyperheuristic, at each decision point, chooses between different low level heuristics rather than different solutions as is usually the case for metaheuristics. By assembling low level heuristics from parameterised components we may create hundreds or thousands of low level heuristics, and there is increasing evidence that this is effective in dealing with every eventuality that may arise when solving different combinatorial optimisation problem instances since at each iteration the solution landscape is amenable to at least one of the low level heuristics. However, the large number of low level heuristics means that the hyperheuristic has to intelligently select the correct low level heuristic to use, to make best use of available CPU time. This paper empirically investigates several hyperheuristics designed for large collections of low level heuristics and adapts other hyperheuristics from the literature to cope with these large sets of low level heuristics on a difficult real-world workforce scheduling problem. In the process we empirically investigate a wide range of approaches for setting tabu tenure in hyperheuristic methods, for a complex real-world problem. The results show that the hyperheuristic methods described provide a good way to trade off CPU time and solution quality.     

A tabu search approach for the single machine mean tardiness problem

In this paper, a tabu search approach is proposed for solving the single machine mean tardiness scheduling problem. Simulation experiment results obtained from the tabu search approach and three other heuristics are compared. Although computation time is increased, the results indicate that the proposed approach provides a much better solution than the other three approaches.     

Categorized Assignment Scheduling: a Tabu Search Approach

The assignment problem (AP) and bottleneck assignment problem (BAP) are well studied in operational research literature. In this paper we consider two related problems which simultaneously generalize both AP and BAP. Unlike AP and BAP, these generalizations are strongly NP-complete. We propose two heuristics to solve these generalized problems: one based on a greedy principle and the other based on tabu search. Computational results are presented which show that these heuristics, when used together, produce good quality solutions. Our adaptation of tabu search also gives some new insight into the application of tabu search on permutation problems.     

Diversification strategies in tabu search algorithms for the maximum clique problem

The purpose of this study is to develop some understanding of the benefits that can be derived from the inclusion of diversification strategies in tabu search methods. To do so, we discuss the implementation of various diversification strategies in several tabu search heuristics developed for the maximum clique problem. Computational results on a large set of randomly generated test problems are reported and compared to assess the impact of these techniques on solution quality and running time.     

Optimizing heuristic search in forest planning

Heuristic search methods are being used more and more in forest planning since the current formulations of exact methods such as linear programming are not suitable to all today's planning problems. A practical problem with most heuristics is that their performance greatly depends on the parameters that guide their search process. The effect of parameters is hard to know without extensive tests, but these tests cannot be conducted in forest planning practice, because of lacking time and experience. This study presented a method that uses Hooke and Jeeves direct search to optimize the parameters of a heuristic, taking into account the allowed computing time. The method was used to optimize three local-improvement heuristics in a non-spatial and a spatial forest planning problem, and with a short and long computing time. The heuristics were simulated annealing, threshold accepting, and tabu search, all of which are used in forestry. The results were logical and showed that while the optimal values of some parameters were rather constant the others were sensitive to problem type, allowed computing time, or problem size. The objective function value of the forest planning problem was not sensitive to small changes in the parameters of the heuristics. However, because computing time was very sensitive to many parameters, there was not much freedom to set the parameters if both the quality of the solution and speed of the algorithm had to be maintained.     

Local search heuristics for single-machine scheduling with batching to minimize the number of late jobs

Local search heuristics are developed for a problem of scheduling jobs on a single machine. Jobs are partitioned into families, and a set-up time is necessary when there is a switch in processing jobs from one family to jobs of another family. The objective is to minimize the number of late jobs. Four alternative local search methods are proposed: multi-start descent, simulated annealing, tabu search and a genetic algorithm. The performance of these heuristics is evaluated on a large set of test problems. The best results are obtained with the genetic algorithm; multi-start descent also performs quite well.     

Solving the flight perturbation problem with meta heuristics

When there is a perturbation in a carefully constructed aircraft schedule, e.g. an aircraft breakdown, it is important to minimize the negative consequences of this disturbance. Here, a tabu search and a simulated annealing approach to the flight perturbation problem are presented. The heuristics use a tree-search algorithm to find new schedules for the aircraft, and utilize a path relinking strategy to explore paths between structurally different solutions. The computational results indicate that the solution strategies, especially the tabu search, can be successfully used to solve the flight perturbation problem.     

Heuristics for the dynamic facility layout problem with unequal-area departments

The dynamic facility layout problem (DFLP) is the problem of finding positions of departments on the plant floor for multiple periods (material flows between departments change during the planning horizon) such that departments do not overlap, and the sum of the material handling and rearrangement costs is minimized. In this paper, the departments may have unequal-areas and free orientations, and the layout for each period is generated on the continuous plant floor. Because of the complexity of the problem, only small-size problems can be solved in reasonable time using exact techniques. As a result, a boundary search (construction) technique, which places departments along the boundaries of already placed departments, is developed for the DFLP. The solution is improved using a tabu search heuristic. The heuristics were tested on some instances from the DFLP and static facility layout problem (SFLP) literature. The results obtained demonstrate the effectiveness of the heuristics.     

Genetic and hybrid algorithms for graph coloring

Some genetic algorithms are considered for the graph coloring problem. As is the case for other combinatorial optimization problems, pure genetic algorithms are outperformed by neighborhood search heuristic procedures such as tabu search. Nevertheless, we examine the performance of several hybrid schemes that can obtain solutions of excellent quality. For some graphs, we illustrate that genetic operators can fulfill long-term strategic functions for a tabu search implementation that is chiefly founded on short-term memory strategies.