A hybrid method for large-scale short-term scheduling of make-and-pack production processes

Due to the ongoing trend towards increased product variety, fast-moving consumer goods such as food and beverages, pharmaceuticals, and chemicals are typically manufactured through so-called make-and-pack processes. These processes consist of a make stage, a pack stage, and intermediate storage facilities that decouple these two stages. In operations scheduling, complex technological constraints must be considered, e.g., non-identical parallel processing units, sequence-dependent changeovers, batch splitting, no-wait restrictions, material transfer times, minimum storage times, and finite storage capacity. The short-term scheduling problem is to compute a production schedule such that a given demand for products is fulfilled, all technological constraints are met, and the production makespan is minimised. A production schedule typically comprises 500–1500 operations. Due to the problem size and complexity of the technological constraints, the performance of known mixed-integer linear programming (MILP) formulations and heuristic approaches is often insufficient.     

带有退化效应和序列相关运输时间的排序问题

考虑带有退化效应和序列相关运输时间的单机排序问题. 工件的加工时间是其开工时间的简单线性增加函数. 当机器单个加工工件时, 极小化最大完工时间、(加权)总完工时间和总延迟问题被证明是多项式可解的, EDD序对于极小化最大延迟问题不是最优排序, 另外, 就交货期和退化率一致情形给出了一最优算法. 当机器可分批加工工件时, 分别就极小化最大完工时间和加权总完工时间问题提出了多项式时间最优算法.     

On scheduling an unbounded batch machine

A batch machine is a machine that can process up to c jobs simultaneously as a batch, and the processing time of the batch is equal to the longest processing time of the jobs assigned to it. In this paper, we deal with the complexity of scheduling an unbounded batch machine, i.e., c=+∞. We prove that minimizing total tardiness is binary NP-hard, which has been an open problem in the literature. Also, we establish the pseudopolynomial solvability of the unbounded batch machine scheduling problem with job release dates and any regular objective. This is distinct from the bounded batch machine and the classical single machine scheduling problems, most of which with different release dates are unary NP-hard. Combined with the existing results, this paper provides a nearly complete mapping of the complexity of scheduling an unbounded batch machine.     

Admission policies for the customized stochastic lot scheduling problem with strict due-dates

This papers considers admission control and scheduling of customer orders in a production system that produces different items on a single machine. Customer orders drive the production and belong to product families, and have family dependent due-date, size, and reward. When production changes from one family to another a setup time is incurred. Moreover, if an order cannot be accepted, it is considered lost upon arrival. The problem is to find a policy that accepts/rejects and schedules orders such that long run profit is maximized. This problem finds its motivation in batch industries in which suppliers have to realize high machine utilization while delivery times should be short and reliable and the production environment is subject to long setup times.We model the joint admission control/scheduling problem as a Markov decision process (MDP) to gain insight into the optimal control of the production system and use the MDP to benchmark the performance of a simple heuristic acceptance/scheduling policy. Numerical results show that the heuristic performs very well compared with the optimal policy for a wide range of parameter settings, including product family asymmetries in arrival rate, order size, and order reward.     

Minimizing the weighted number of tardy jobs with due date assignment and capacity-constrained deliveries for multiple customers in supply chains

In this paper, an integrated due date assignment and production and batch delivery scheduling problem for make-to-order production system and multiple customers is addressed. Consider a supply chain scheduling problem in which n orders (jobs) have to be scheduled on a single machine and delivered to K customers or to other machines for further processing in batches. A common due date is assigned to all the jobs of each customer and the number of jobs in delivery batches is constrained by the batch size. The objective is to minimize the sum of the total weighted number of tardy jobs, the total due date assignment costs and the total batch delivery costs. The problem is NP-hard. We formulate the problem as an Integer Programming (IP) model. Also, in this paper, a Heuristic Algorithm (HA) and a Branch and Bound (B&B) method for solving this problem are presented. Computational tests are used to demonstrate the efficiency of the developed methods.     

Solving a chemical batch scheduling problem by local search

In this paper the following chemical batch scheduling problem is considered: a set of orders has to be processed on a set of facilities. For each order a given amount of a product must be produced by means of chemical reactions before a given deadline. The production consists of a sequence of processes whereby each process has to be performed by one facility out of a given subset of facilities allowed for this process. The processing times depend on the choice of the facility and the processing is done in batch mode with given minimum and maximum sizes. The problem is to assign the processes to the facilities, splitting them into batches, and scheduling these batches in order to produce the demands within the given deadlines. For the scheduling part of the problem we present an approach based on the following steps. First, a procedure to calculate the minimum number of batches needed to satisfy the demands is presented. Based on this, the given problem is modeled in two different ways: as a general shop scheduling problem with set-up times or as scheduling problem with positive time-lags. Finally, a two-phase tabu search method is presented which is based on the two different formulations of the problem. The method is tested on some real world data. This revised version was published online in June 2006 with corrections to the Cover Date.     

具有线性恶化效应的在线分批排序问题

本文研究一类具有线性恶化效应的单机在线分批排序问题,工件$J_j$的加工时间为$p_j=b_j+\alpha t$, 其中$b_j$为基本加工时间, $\alpha>0$为恶化率, $t$是开工时间. 工件的到达时间是未知的, 工件的基本加工时间只有在工件到达之后才能知道.多个工件可以作为一批被机器同时加工, 批的加工时间为该批中工件最大加工时间.本文对于目标为极小化makespan的批容量无限的单机问题给出一个在线算法$\beta H^\infty$,并证明其竞争比和问题的下界相同, 进而算法是最优的.     

A coupling cutting stock-lot sizing problem in the paper industry

An important production programming problem arises in paper industries coupling multiple machine scheduling with cutting stocks. Concerning machine scheduling: how can the production of the quantity of large rolls of paper of different types be determined. These rolls are cut to meet demand of items. Scheduling that minimizes setups and production costs may produce rolls which may increase waste in the cutting process. On the other hand, the best number of rolls in the point of view of minimizing waste may lead to high setup costs. In this paper, coupled modeling and heuristic methods are proposed. Computational experiments are presented.     

考虑货架存放期的经济批量排产问题的求解

在化工、造纸、制药、钢铁等工业生产中，一台设备或一条生产线可以生产多种产品的情况很常见。在生产中，如何安排各类产品的生产顺序以及生产数量显得十分重要。这类问题通常称作经济批量排产问题，这类问题是生产库存中的经典问题。本文研究的经济批量排产问题考虑了产品货架存放期因素，针对以往研究的不足，本文提出用批量变动方法求解该类问题，由计算结果显示，按照这种排产方法花费的成本要低于其他两种经济批量排产问题常用的方法。     

中间品储存约束的多工序批量加工排序问题研究

本文结合生产实际情况，考虑了有限的中间品储存能力所带来的影响，对具有中间品储存约束的多工序批量加工排序问题进行研究。文中利用状态-任务-网络概念和层级模型方法，构建了基于混合整数线性规划的修正排序模型，应用标准优化软件求解。最后用一个算例来说明所构建模型的有效性。     

Multi-item lot-sizing with joint set-up costs

We consider a multi-item lot-sizing problem with joint set-up costs and constant capacities. Apart from the usual per unit production and storage costs for each item, a set-up cost is incurred for each batch of production, where a batch consists of up to C units of any mix of the items. In addition, an upper bound on the number of batches may be imposed. Under widely applicable conditions on the storage costs, namely that the production and storage costs are nonspeculative, and for any two items the one that has a higher storage cost in one period has a higher storage cost in every period, we show that there is a tight linear program with O(mT ²) constraints and variables that solves the joint set-up multi-item lot-sizing problem, where m is the number of items and T is the number of time periods. This establishes that under the above storage cost conditions this problem is polynomially solvable. For the problem with backlogging, a similar linear programming result is described for the uncapacitated case under very restrictive conditions on the storage and backlogging costs. Computational results are presented to test the effectiveness of using these tight linear programs in strengthening the basic mixed integer programming formulations of the joint set-up problem both when the storage cost conditions are satisfied, and also when they are violated.     

Improved MILP models for two-machine flowshop with batch processing machines

In this paper, we consider the problem of scheduling jobs in a flowshop with two batch processing machines such that the makespan is minimized. Batch processing machines are frequently encountered in many industrial environments such as heat treatment operations in a steel foundry and chemical processes performed in tanks or kilns. Improved Mixed Integer Linear Programming (MILP) models are presented for the flowshop problem with unlimited or zero intermediate storage. An MILP-based heuristic is also developed for the problem. Computational experiments show that the new MILP models can significantly improve the original ones. Also, the heuristic can obtain the optimal solutions for all the test problem instances.     

Column generation heuristics for multiple machine, multiple orders per job scheduling problems

Front opening unified pods (FOUPs) are used to store and transport silicon wafers in 300-mm semiconductor wafer fabs. To achieve production efficiencies, wafers are grouped together in FOUPs without regard to the originating customer placing the order. In the resulting multiple orders per job (moj) scheduling problem, scheduling is performed at the FOUP (i.e., aggregated order) level, while scheduling performance is assessed per individual customer order. Column generation heuristics are presented for single and parallel machine moj scheduling problems to minimize total weighted order completion time. The proposed heuristics obtain near-optimal solutions very quickly, outperforming competing approaches in the literature.     

具有学习-遗忘效应的半导体批调度问题研究

半导体生产制造系统具有大规模、工艺繁杂、随机性大、可重入等显著特点。以半导体最终测试阶段批处理调度为基础,把学习-遗忘效应应用到典型半导体批调度问题中,构建基于学习-遗忘效应的批调度模型。分别结合调度问题和调度模型对双层算法(粒子群算法&萤火虫算法)进行设计,通过仿真实验检验了双层算法在求解具有学习遗忘效应的批调度模型方面的可行性和有效性,并对比分析以最大完工时间为优化目标的实验结果,探讨学习遗忘效应对半导体批调度问题的影响程度,对实际半导体生产具有重要指导意义。     

Scheduling jobs with release dates on parallel batch processing machines to minimize the makespan

Batch processing happens in many different industries, in which a number of jobs are processed simultaneously as a batch. In this paper we develop two heuristics for the problem of scheduling jobs with release dates on parallel batch processing machines to minimize the makespan and analyze their worst-case performance ratios. We also present a polynomial-time optimal algorithm for a special case of the problem where the jobs have equal processing times.     

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。     

Machine-Shop Problems: An Operational Research Approach

Production planning and scheduling in a batch production environment presents management with many problems, ranging from long-term capital investment in machine tools to short-term batch sequencing. This paper, which is aimed at the production manager, introduces the general concept of model building and then discusses the more specific technique of computer simulation modelling. A simple example of the latter is used to illustrate the basic properties of such a model and then the actual model currently being used is described. The possible applications of such models are discussed and developed. Finally, a case study is presented which shows how the model has been employed in an actual production environment.     

Scheduling a single machine with multiple job processing ability to minimize makespan

This paper investigates a new problem, called single machine scheduling with multiple job processing ability, which is derived from the production of the continuous walking beaming reheating furnace in iron and steel industry. In this problem, there is no batch and the jobs enter and leave the machine one by one and continuously, which is different from general single machine batch scheduling problem where the jobs in a batch share the same start and departure time. Therefore, the start time and the departure time of a job depend on not only the job sequence but also the machine capacity. This problem is also different from the single semi-continuous batching machine scheduling recently studied in the literature, where the jobs are processed in batch mode and a new batch cannot be started for processing until the processing of the previous batch is completed though jobs in the same batch enter and leave the machine one by one. The objective of this problem is to minimize the makespan. We formulate this problem as a mixed integer linear programming model and propose a particle swarm optimization (PSO) algorithm for this problem. Computational results on randomly generated instances show that the proposed PSO algorithm is effective.     

Order acceptance and scheduling with earliness and tardiness penalties

This paper addresses a production scheduling problem in a single-machine environment, where a job can be either early, on time, late, or rejected. In order acceptance and scheduling contexts, it is assumed that the production capacity of a company is overloaded. The problem is therefore to decide which orders to accept and how to sequence their production. In contrast with the existing literature, the considered problem jointly takes into account the following features: earliness and tardiness penalties (which can be linear or quadratic), sequence-dependent setup times and costs, rejection penalties, and the possibility of having idle times. The practical relevance of this new NP-hard problem is discussed and various solution methods are proposed, ranging from a basic greedy algorithm to refined metaheuristics (e.g., tabu search, the adaptive memory algorithm, population-based approaches loosely inspired on ant algorithms). The methods are compared for instances with various structures containing up to 200 jobs. For small linear instances, the metaheuristics are favorably compared with an exact formulation using CPLEX 12.2. Managerial insights and recommendations are finally given.