Integrated pulp and paper mill planning and scheduling

This article describes a real-world production planning and scheduling problem occurring at an integrated pulp and paper mill (P&P) which manufactures paper for cardboard out of produced pulp. During the cooking of wood chips in the digester, two by-products are produced: the pulp itself (virgin fibers) and the waste stream known as black liquor. The former is then mixed with recycled fibers and processed in a paper machine. Here, due to significant sequence-dependent setups in paper type changeovers, sizing and sequencing of lots have to be made simultaneously in order to efficiently use capacity. The latter is converted into electrical energy using a set of evaporators, recovery boilers and counter-pressure turbines. The planning challenge is then to synchronize the material flow as it moves through the pulp and paper mills, and energy plant, maximizing customer demand (as backlogging is allowed), and minimizing operation costs. Due to the intensive capital feature of P&P, the output of the digester must be maximized. As the production bottleneck is not fixed, to tackle this problem we propose a new model that integrates the critical production units associated to the pulp and paper mills, and energy plant for the first time. Simple stochastic mixed integer programming based local search heuristics are developed to obtain good feasible solutions for the problem. The benefits of integrating the three stages are discussed. The proposed approaches are tested on real-world data. Our work may help P&P companies to increase their competitiveness and reactiveness in dealing with demand pattern oscillations. (C) 2012 Elsevier Ltd. All rights reserved.

Asynchronous teams for joint lot-sizing and scheduling problem in flow shops

The integrated production scheduling and lot-sizing problem in a flow shop environment consists of establishing production lot sizes and allocating machines to process them within a planning horizon in a production line with machines arranged in series. The problem considers that demands must be met without backlogging, the capacity of the machines must be respected, and machine setups are sequence-dependent and preserved between periods of the planning horizon. The objective is to determine a production schedule to minimise the setup, production and inventory costs. A mathematical model from the literature is presented, as well as procedures for obtaining feasible solutions. However, some of the procedures have difficulty in obtaining feasible solutions for large-sized problem instances. In addition, we address the problem using different versions of the Asynchronous Team (A-Team) approach. The procedures were compared with literature heuristics based on Mixed Integer Programming. The proposed A-Team procedures outperformed the literature heuristics, especially for large instances. The developed methodologies and the results obtained are presented.

Accelerating benders decomposition with heuristicmaster problem solutions

In this paper, a general scheme for generating extra cuts during the execution of a Benders decomposition algorithm is presented. These cuts are based on feasible and infeasible master problem solutions generated by means of a heuristic. This article includes general guidelines and a case study with a fixed charge network design problem. Computational tests with instances of this problem show the efficiency of the strategy. The most important aspect of the proposed ideas is their generality, which allows them to be used in virtually any Benders decomposition implementation.

Bootstrap confidence intervals for industrial recurrent event data

Industrial recurrent event data where an event of interest can be observed more than once in a single sample unit are presented in several areas, such as engineering, manufacturing and industrial reliability. Such type of data provide information about the number of events, time to their occurrence and also their costs. Nelson (1995) presents a methodology to obtain asymptotic confidence intervals for the cost and the number of cumulative recurrent events. Although this is a standard procedure, it can not perform well in some situations, in particular when the sample size available is small. In this context, computer-intensive methods such as bootstrap can be used to construct confidence intervals. In this paper, we propose a technique based on the bootstrap method to have interval estimates for the cost and the number of cumulative events. One of the advantages of the proposed methodology is the possibility for its application in several areas and its easy computational implementation. In addition, it can be a better alternative than asymptotic-based methods to calculate confidence intervals, according to some Monte Carlo simulations. An example from the engineering area illustrates the methodology.

An analysis of Taguchi's on-line quality monitoring procedure for variables based on the results of a sequence of inspections

In this paper, a procedure for the on-line process control of variables is proposed. This procedure consists of inspecting the m-th item from every m produced items and deciding, at each inspection, whether the process is out-of-control. Two sets of limits, warning (µ0 ± W) and control (µ0 ± C), are used. If the value of the monitored statistic falls beyond the control limits or if a sequence of h observations falls between the warning limits and the control limits, the production is stopped for adjustment; otherwise, production goes on. The properties of an ergodic Markov chain are used to obtain an expression for the average cost per item. The parameters (the sampling interval m, the widths of the warning, the control limits W and C(W < C), and the sequence length (h) are optimized by minimizing the cost function. A numerical example illustrates the proposed procedure.

Comparison between the complete Bayesian method and empirical Bayesian method for ARCH models using Brazilian financial time series

In this work we compared the estimates of the parameters of ARCH models using a complete Bayesian method and an empirical Bayesian method in which we adopted a non-informative prior distribution and informative prior distribution, respectively. We also considered a reparameterization of those models in order to map the space of the parameters into real space. This procedure permits choosing prior normal distributions for the transformed parameters. The posterior summaries were obtained using Monte Carlo Markov chain methods (MCMC). The methodology was evaluated by considering the Telebras series from the Brazilian financial market. The results show that the two methods are able to adjust ARCH models with different numbers of parameters. The empirical Bayesian method provided a more parsimonious model to the data and better adjustment than the complete Bayesian method.

A new method for decision making in multi-objective optimization problems

Many engineering sectors are challenged by multi-objective optimization problems. Even if the idea behind these problems is simple and well established, the implementation of any procedure to solve them is not a trivial task. The use of evolutionary algorithms to find candidate solutions is widespread. Usually they supply a discrete picture of the non-dominated solutions, a Pareto set. Although it is very interesting to know the non-dominated solutions, an additional criterion is needed to select one solution to be deployed. To better support the design process, this paper presents a new method of solving non-linear multi-objective optimization problems by adding a control function that will guide the optimization process over the Pareto set that does not need to be found explicitly. The proposed methodology differs from the classical methods that combine the objective functions in a single scale, and is based on a unique run of non-linear single-objective optimizers.

Heuristics for minimizing the maximum within-clusters distance

The clustering problem consists in finding patterns in a data set in order to divide it into clusters with high within-cluster similarity. This paper presents the study of a problem, here called MMD problem, which aims at finding a clustering with a predefined number of clusters that minimizes the largest within-cluster distance (diameter) among all clusters. There are two main objectives in this paper: to propose heuristics for the MMD and to evaluate the suitability of the best proposed heuristic results according to the real classification of some data sets. Regarding the first objective, the results obtained in the experiments indicate a good performance of the best proposed heuristic that outperformed the Complete Linkage algorithm (the most used method from the literature for this problem). Nevertheless, regarding the suitability of the results according to the real classification of the data sets, the proposed heuristic achieved better quality results than C-Means algorithm, but worse than Complete Linkage.

Multiobjective engineering design optimization problems: a sensitivity analysis approach

This paper proposes two new approaches for the sensitivity analysis of multiobjective design optimization problems whose performance functions are highly susceptible to small variations in the design variables and/or design environment parameters. In both methods, the less sensitive design alternatives are preferred over others during the multiobjective optimization process. While taking the first approach, the designer chooses the design variable and/or parameter that causes uncertainties. The designer then associates a robustness index with each design alternative and adds each index as an objective function in the optimization problem. For the second approach, the designer must know, a priori, the interval of variation in the design variables or in the design environment parameters, because the designer will be accepting the interval of variation in the objective functions. The second method does not require any law of probability distribution of uncontrollable variations. Finally, the authors give two illustrative examples to highlight the contributions of the paper.

Análise das relações entre estratégia de produção, práticas e desempenho operacional

Este trabalho teve o objetivo de verificar quais são as melhores práticas de produção para o setor moveleiro no Brasil, mediante a análise das relações entre as práticas de produção implantadas e prioridades competitivas e, também, entre indicadores de desempenho. A revisão teórica centrou em definir o pressuposto para o estudo das melhores práticas e realizar uma sistematização da literatura. Posteriormente, foi desenvolvida a pesquisa prática mediante uma survey em 99 empresas. Para a análise dos dados, foi empregada a técnica de modelagem de equações estruturais com o método de estimação dos mínimos quadrados ponderados. Os resultados revelaram que as práticas nas áreas de desenvolvimento de novos produtos, recursos humanos e planejamento e controle de produção estavam alinhadas à estratégia de produção e contribuíram para a melhoria de indicadores de desempenho operacional, sendo assim consideradas melhores práticas para o contexto estudado. Foram feitas discussões e sugestões para pesquisas futuras.

Memória operacional fonológica e consciência fonológica em escolares ao final do ciclo I do ensino fundamental

OBJETIVO: Investigar o desempenho de crianças ao final do Ciclo I do Ensino Fundamental em memória operacional fonológica e consciência fonológica, bem como a possível relação entre essas habilidades nesta faixa de escolaridade. MÉTODOS: O grupo de pesquisa foi composto por 29 sujeitos de ambos os gêneros, com média de idade de 10 anos, todos regularmente matriculados no 5º ano do Ensino Fundamental com ausência de alterações de linguagem oral e/ou escrita. Foi realizada a avaliação da memória operacional fonológica com a utilização do Teste de Repetição de Pseudopalavras e, posteriormente, utilizou-se o Instrumento de Avaliação Sequencial - CONFIAS para avaliar a consciência fonológica. RESULTADOS: Os escolares apresentaram desempenho adequado na memória operacional fonológica independente da similaridade da pseudopalavra. Para a consciência fonológica, observou-se desempenho melhor no nível silábico e inferior ao esperado para o nível fonêmico. Apesar de muitos estudos afirmarem a correlação entre a memória operacional fonológica e a consciência fonológica, esta não foi observada nesta amostra. CONCLUSÃO: A ausência de correlação encontrada entre essas habilidades traz reflexões quanto a possíveis fatores extrínsecos que podem influenciar o desempenho em consciência fonológica.