A decomposition approach for the General Lotsizing and Scheduling Problem for Parallel production Lines

This paper presents a novel solution heuristic to the General Lotsizing and Scheduling Problem for Parallel production Lines (GLSPPL). The GLSPPL addresses the problem of simultaneously deciding about the sizes and schedules of production lots on parallel, heterogeneous production lines with respect to scarce capacity, sequence-dependent setup times and deterministic, dynamic demand of multiple products. Its objective is to minimize inventory holding, sequence-dependent setup and production costs. The new heuristic iteratively decomposes the multi-line problem into a series of single-line problems, which are easier to solve. Different approaches for decomposition and for the iteration between a modified multi-line master problem and the single-line subproblems are proposed. They are compared with an existing solution method for the GLSPPL by means of medium-sized and large practical problem instances from different types of industries. The new methods prove to be superior with respect to both solution quality and computation time.     

An Enhanced TSP-Based Heuristic for Makespan Minimization in a Flow Shop with Setup Times

This paper presents an enhanced heuristic for minimizing the makespan of the flow shop scheduling problem with sequence-dependent setup times. The procedure transforms an instance of the problem into an instance of the traveling salesman problem by introducing a cost function that penalizes for both large setup times and bad fitness of schedule. This hybrid cost function is an improvement over earlier approaches that penalized for setup times only, ignoring the flow shop aspect of the problem. To establish good parameter values, each component of the heuristic was evaluated computationally over a wide range of problem instances. In the testing stage, an experimental comparison with a greedy randomized adaptive search procedure revealed the conditions and data attributes where the proposed procedure works best.     

Metaheuristic algorithms for balancing robotic assembly lines with sequence-dependent robot setup times

Industries are incorporating robots into assembly lines due to their greater flexibility and reduced costs. Most of the reported studies did not consider scheduling of tasks or the sequence-dependent setup times in an assembly line, which cannot be neglected in a real-world scenario. This paper presents a study on robotic assembly line balancing, with the aim of minimizing cycle time by considering sequence-dependent setup times. A mathematical model for the problem is formulated and CPLEX solver is utilized to solve small-sized problems. A recently developed metaheuristic Migrating Birds Optimization (MBO) algorithm and set of metaheuristics have been implemented to solve the problem. Three different scenarios are tested (with no setup time, and low and high setup times). The comparative experimental study demonstrates that the performance of the MBO algorithm is superior for the tested datasets. The outcomes of this study can help production managers improve their production system in order to perform the assembly tasks with high levels of efficiency and quality.     

Algorithms for common due-date assignment and sequencing on a single machine with sequence-dependent setup times

This paper focuses on the single machine sequencing and common due-date assignment problem for the objective of minimizing the sum of the penalties associated with earliness, tardiness and due-date assignment. Unlike the previous research articles on this class of scheduling problem, we consider sequence-dependent setup times that make the problem much more difficult. To solve the problem, a branch and bound algorithm, which incorporates the method to obtain lower and upper bounds as well as a dominance property to reduce the search space, is suggested that gives the optimal solutions for small-sized instances. Heuristic algorithms are suggested to obtain solutions for large-sized problems within a reasonable computation time. The performances of both the optimal and heuristic algorithms, in computational experiments on randomly generated test instances, are reported.     

Heuristics for the flow line problem with setup costs

This paper presents two new heuristics for the flowshop scheduling problem with sequence-dependent setup times (SDSTs) and makespan minimization objective. The first is an extension of a procedure that has been very successful for the general flowshop scheduling problem. The other is a greedy randomized adaptive search procedure (GRASP) which is a technique that has achieved good results on a variety of combinatorial optimization problems. Both heuristics are compared to a previously proposed algorithm based on the traveling salesman problem (TSP). In addition, local search procedures are developed and adapted to each of the heuristics. A two-phase lower bounding scheme is presented as well. The first phase finds a lower bound based on the assignment relaxation for the asymmetric TSP. In phase two, attempts are made to improve the bound by inserting idle time. All procedures are compared for two different classes of randomly generated instances. In the first case where setup times are an order of magnitude smaller than the processing times, the new approaches prove superior to the TSP-based heuristic; for the case where both processing and setup times are identically distributed, the TSP-based heuristic outperforms the proposed procedures.     

A bicriteria m-machine flowshop scheduling with sequence-dependent setup times

In this study, a bicriteria m-machine flowshop scheduling with sequence-dependent setup times is considered. The objective function of the problem is minimization of the weighted sum of total completion time and makespan. Only small size problems with up to 6 machines and 18 jobs can be solved by the proposed integer programming model. Also the model is tested on an example. We also proposed three heuristic approaches for solving large jobs problems. To solve the large sizes problems up to 100 jobs and 10 machines, special heuristics methods is used. Results of computational tests show that the proposed model is effective in solving problems.     

A hybrid approach for single-machine tardiness problems with sequence-dependent setup times

Scheduling problems in real systems often require sequence-dependent setup times. The topic of sequence-dependent setup times has not been addressed adequately, and improved competitiveness is thus not achieved. This study proposes a hybrid approach that takes advantage of simulated annealing (SA) and tabu search (TS) to solve single-machine tardiness problems with sequence-dependent setup times. To verify the proposed approach, experiments were conducted on benchmark problem sets that included both the weighted and un-weighted tardiness problems. The results show that the performance of the hybrid approach is superior to that of the SA, genetic algorithm, TS and ant colony optimization approaches, and is comparable with the Tabu-VNS approach. And the proposed approach found new upper bound values for many benchmark problems with an acceptable computational time.     

Minimizing total tardiness in parallel machine scheduling with setup times: An adaptive memory-based GRASP approach

This paper deals with the problem of scheduling jobs in uniform parallel machines with sequence-dependent setup times in order to minimize the total tardiness relative to job due dates. We propose GRASP versions that incorporate adaptive memory principles for solving this problem. Long-term memory is used in the construction of an initial solution and in a post-optimization procedure which connects high quality local optima by means of path relinking. Computational tests are carried out on a set of benchmark instances and the proposed GRASP versions are compared with heuristic methods from the literature.     

Minimizing sum of completion times on a single machine with sequence-dependent family setup times

This paper presents a branch-and-bound (B&B) algorithm for minimizing the sum of completion times in a single-machine scheduling setting with sequence-dependent family setup times. The main feature of the B&B algorithm is a new lower bounding scheme that is based on a network formulation of the problem. With extensive computational tests, we demonstrate that the B&B algorithm can solve problems with up to 60 jobs and 12 families, where setup and processing times are uniformly distributed in various combinations of the [1,50] and [1,100] ranges.     

A profit-maximizing economic lot scheduling problem with price optimization

The economic lot scheduling problem (ELSP) is a well known problem that focuses on scheduling the production of multiple items on a single machine such that inventory and setup costs are minimized. In this paper, we extend the ELSP to include price optimization with the objective to maximize profits. A solution approach based on column generation is provided and shown to produce very close to optimal results with short solution times on a set of test problems. The results are discussed and recommendations for further research are provided.     

Carryover sequence-dependent group scheduling with the integration of internal and external setup times

This paper addresses a group scheduling problem in a two-machine flow shop with a bicriteria objective and carryover sequence-dependent setup times. This special type of group scheduling problem typically arises in the assembly of printed circuit boards (PCBs). The objective is to sequence all board types in a board group as well as board groups themselves in a way that the objective function is minimized. We introduce the carryover sequence-dependent setup on machines, and call it internal setup. As an opportunity for manufacturers to decrease the costs, the focus is to completely eliminate the role of the kitting staff. Thus, we introduce the external setup (kitting) time for the next board group and require it to be performed by the machine operator during the time he is idle. Consequently, the internal and external setup times are integrated in this research, and to the best of our knowledge it is for the first time a research on PCB group scheduling is performed by integrating both setups. In order to solve this problem, first a mathematical model is developed. Then a heuristic together with two other meta-heuristic algorithms (one based on tabu search and the other based on genetic algorithm) are proposed and their efficiency and effectiveness on several problems are tested. Also a statistical experimental design is performed in order to evaluate the impact of different factors on the performance of the algorithms.     

Multiple machine continuous setup lotsizing with sequence-dependent setups

We address the short-term production planning and scheduling problem coming from the glass container industry. A furnace melts the glass that is distributed to a set of parallel molding machines. Both furnace and machine idleness are not allowed. The resulting multi-machine multi-item continuous setup lotsizing problem with a common resource has sequence-dependent setup times and costs. Production losses are penalized in the objective function since we deal with a capital intensive industry. We present two mixed integer programming formulations for this problem, which are reduced to a network flow type problem. The two formulations are improved by adding valid inequalities that lead to good lower bounds. We rely on a Lagrangian decomposition based heuristic for generating good feasible solutions. We report computational experiments for randomly generated instances and for real-life data on the aforementioned problem, as well as on a discrete lotsizing and scheduling version.     

Joint rolling-horizon scheduling of materials processing and lot-sizing with sequence-dependent setups

A lot sizing and scheduling problem from a foundry is considered in which key materials are produced and then transformed into many products on a single machine. A mixed integer programming (MIP) model is developed, taking into account sequence-dependent setup costs and times, and then adapted for rolling horizon use. A relax-and-fix (RF) solution heuristic is proposed and computationally tested against a high-performance MIP solver. Three variants of local search are also developed to improve the RF method and tested. Finally the solutions are compared with those currently practiced at the foundry.     

Single machine scheduling with sequence-dependent family setups to minimize maximum lateness

Motivated by a real-life scheduling problem in a steel wire factory in China,this paper considers the single machine scheduling problem with sequence-dependent family setup times to minimize maximum lateness. In view of the NP-hard nature of the problem, structural (dominance and neighbourhood)properties of the problem are described and used in the tabu search algorithms to find optimal or near-optimal schedules. These proposed structural properties quickly exclude unpromising and/or non-improving neighbours from further search.Empirical results on the randomly generated and real-life problem instances from a factory in China show that the proposed heuristic algorithms utilizing the structural properties can obtain optimal or near optimal solutions with a reasonable computational effort.     

A production scheduling heuristic for an electronics manufacturer with sequence-dependent setup costs

In this paper, we develop a three-step heuristic to address a production scheduling problem at a high volume assemble-to-order electronics manufacturer. The heuristic provides a solution for scheduling multiple product families on parallel, identical production lines so as to minimize setup costs. The heuristic involves assignment, sequencing, and time scheduling steps, with an optimization approach developed for each step. For the most complex step, the sequencing step, we develop a greedy randomized adaptive search procedure (GRASP). We compare the setup costs resulting from the use of our scheduling heuristic against a heuristic previously developed and implemented at the electronics manufacturer that assumes approximately equal, sequence-independent, setup costs. By explicitly considering the sequence-dependent setup costs and applying GRASP, our empirical results show a reduction in setups costs for an entire factory of 14–21% with a range of single production line reductions from 0% to 49%.     

经济批量排产问题的改进算法:设定最高允许高度

经济批量排产问题是指在生产准备费用与库存费用最低的情况下,协调地、周期性地生产多种产品的问题.由于此问题是NP-hard的,人们一种致力于寻找快速地求解高质量的近似最优解的方法.在将生产次数舍入为2的幂次后,误差小,获得可行解的速度快.研究的经济批量排产问题考虑了产品货架存放期因素.指出了Dobson算法的不足,并提出了基于2的幂次条件的改进算法.改进算法设定了最高允许高度,首先给部分箱进行装箱.由于能获得高质量的生产排产,因此,算法能获得2的幂次条件下的高质量解.给出一个算例,计算结果显示,算法结果更优.     

Emergency response in natural disaster management: Allocation and scheduling of rescue units

Natural disasters, such as earthquakes, tsunamis and hurricanes, cause tremendous harm each year. In order to reduce casualties and economic losses during the response phase, rescue units must be allocated and scheduled efficiently. As this problem is one of the key issues in emergency response and has been addressed only rarely in literature, this paper develops a corresponding decision support model that minimizes the sum of completion times of incidents weighted by their severity. The presented problem is a generalization of the parallel-machine scheduling problem with unrelated machines, non-batch sequence-dependent setup times and a weighted sum of completion times – thus, it is NP-hard. Using literature on scheduling and routing, we propose and computationally compare several heuristics, including a Monte Carlo-based heuristic, the joint application of 8 construction heuristics and 5 improvement heuristics, and GRASP metaheuristics. Our results show that problem instances (with up to 40 incidents and 40 rescue units) can be solved in less than a second, with results being at most 10.9% up to 33.9% higher than optimal values. Compared to current best practice solutions, the overall harm can be reduced by up to 81.8%.     

Stochastic single machine scheduling problem as a multi-stage dynamic random decision process

In this work, we study a stochastic single machine scheduling problem in which the features of learning effect on processing times, sequence-dependent setup times, and machine configuration selection are considered simultaneously. More precisely, the machine works under a set of configurations and requires stochastic sequence-dependent setup times to switch from one configuration to another. Also, the stochastic processing time of a job is a function of its position and the machine configuration. The objective is to find the sequence of jobs and choose a configuration to process each job to minimize the makespan. We first show that the proposed problem can be formulated through two-stage and multi-stage Stochastic Programming models, which are challenging from the computational point of view. Then, by looking at the problem as a multi-stage dynamic random decision process, a new deterministic approximation-based formulation is developed. The method first derives a mixed-integer non-linear model based on the concept of accessibility to all possible and available alternatives at each stage of the decision-making process. Then, to efficiently solve the problem, a new accessibility measure is defined to convert the model into the search of a shortest path throughout the stages. Extensive computational experiments are carried out on various sets of instances. We discuss and compare the results found by the resolution of plain stochastic models with those obtained by the deterministic approximation approach. Our approximation shows excellent performances both in terms of solution accuracy and computational time.

     

A branch and bound method for the job-shop problem with sequence-dependent setup times

This paper deals with the job-shop scheduling problem with sequence-dependent setup times. We propose a new method to solve the makespan minimization problem to optimality. The method is based on iterative solving via branch and bound decisional versions of the problem. At each node of the branch and bound tree, constraint propagation algorithms adapted to setup times are performed for domain filtering and feasibility check. Relaxations based on the traveling salesman problem with time windows are also solved to perform additional pruning. The traveling salesman problem is formulated as an elementary shortest path problem with resource constraints and solved through dynamic programming. This method allows to close previously unsolved benchmark instances of the literature and also provides new lower and upper bounds.