Balancing and lot-sizing mixed-model lines in the footwear industry

This report describes the full research proposal for the project \Balancing and lot-sizing mixed-model lines in the footwear industry", to be developed as part of the master program in Engenharia Electrotécnica e de Computadores - Sistemas de Planeamento Industrial of the Instituto Superior de Engenharia do Porto. The Portuguese footwear industry is undergoing a period of great development and innovation. The numbers speak for themselves, Portugal footwear exported 71 million pairs of shoes to over 130 countries in 2012. It is a diverse sector, which covers different categories of women, men and children shoes, each of them with various models. New and technologically advanced mixed-model assembly lines are being projected and installed to replace traditional mass assembly lines. Obviously there is a need to manage them conveniently and to improve their operations. This work focuses on balancing and lot-sizing stitching mixed-model lines in a real world environment. For that purpose it will be fundamental to develop and evaluate adequate effective solution methods. Different objectives may be considered, which are relevant for the companies, such as minimizing the number of workstations, and minimizing the makespan, while taking into account a lot of practical restrictions. The solution approaches will be based on approximate methods, namely by resorting to metaheuristics. To show the impact of having different lots in production the initial maximum amount for each lot is changed and a Tabu Search based procedure is used to improve the solutions. The developed approaches will be evaluated and tested. A special attention will be given to the solution of real applied problems. Future work may include the study of other neighbourhood structures related to Tabu Search and the development of ways to speed up the evaluation of neighbours, as well as improving the balancing solution method.

Production decisions and lot sizing for automotive stamping

A discrete event model was used to examine the effect of machine downtime and operating policy on the long-run average cost of an automotive stamping line. Operating policy refers to the selection of a target batch size and the circumstances under which a line stoppage will lead to the current batch being abandoned. It is assumed that the abandon/resume decision is based solely on the severity of the problem (i.e., repair cost) and the fraction of the batch completed. A method of identifying low-cost operating policies is presented using data obtained from a real stamping plant. It is found that, within a single part framework, this approach results in significantly lower average costs than are currently achieved. It is also demonstrated that by varying the model parameters it is possible to measure the potential benefits arising from process modifications (e.g., decreased die-set times). This can be used to identify the areas where improvements will have the greatest impact on cost and is particularly useful when assessing the expected return on a potential investment. A multiple-part extension to the model is suggested and the potential benefits discussed.

Reformulation and a Lagrangian heuristic for lot sizing problem on parallel machines

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

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.

Models for capacitated lot-sizing problem with backlogging, setup carryover and crossover

Setup operations are significant in some production environments. It is mandatory that their production plans consider some features, as setup state conservation across periods through setup carryover and crossover. The modelling of setup crossover allows more flexible decisions and is essential for problems with long setup times. This paper proposes two models for the capacitated lot-sizing problem with backlogging and setup carryover and crossover. The first is in line with other models from the literature, whereas the second considers a disaggregated setup variable, which tracks the starting and completion times of the setup operation. This innovative approach permits a more compact formulation. Computational results show that the proposed models have outperformed other state-of-the-art formulation.

Non-stationary stochastic inventory lot-sizing with emission and service level constraints in a carbon cap-and-trade system

Firms worldwide are taking major initiatives to reduce the carbon footprint of their supply chains in response to the growing governmental and consumer pressures. In real life, these supply chains face stochastic and non-stationary demand but most of the studies on inventory lot-sizing problem with emission concerns consider deterministic demand. In this paper, we study the inventory lot-sizing problem under non-stationary stochastic demand condition with emission and cycle service level constraints considering carbon cap-and-trade regulatory mechanism. Using a mixed integer linear programming model, this paper aims to investigate the effects of emission parameters, product- and system-related features on the supply chain performance through extensive computational experiments to cover general type business settings and not a specific scenario. Results show that cycle service level and demand coefficient of variation have significant impacts on total cost and emission irrespective of level of demand variability while the impact of product's demand pattern is significant only at lower level of demand variability. Finally, results also show that increasing value of carbon price reduces total cost, total emission and total inventory and the scope of emission reduction by increasing carbon price is greater at higher levels of cycle service level and demand coefficient of variation. The analysis of results helps supply chain managers to take right decision in different demand and service level situations.

GRASP heuristic with path-relinking for the multi-plant capacitated lot sizing problem

This paper addresses the independent multi-plant, multi-period, and multi-item capacitated lot sizing problem where transfers between the plants are allowed. This is an NP-hard combinatorial optimization problem and few solution methods have been proposed to solve it. We develop a GRASP (Greedy Randomized Adaptive Search Procedure) heuristic as well as a path-relinking intensification procedure to find cost-effective solutions for this problem. In addition, the proposed heuristics is used to solve some instances of the capacitated lot sizing problem with parallel machines. The results of the computational tests show that the proposed heuristics outperform other heuristics previously described in the literature. The results are confirmed by statistical tests. (C) 2009 Elsevier B.V. All rights reserved.

An approach for solving the lot-sizing problem of a market-driven foundry

Foundries can be found all over Brazil and they are very important to its economy. In 2008, a mixed integer-programming model for small market-driven foundries was published, attempting to minimize delivery delays. We undertook a study of that model. Here, we present a new approach based on the decomposition of the problem into two sub-problems: production planning of alloys and production planning of items. Both sub-problems are solved using a Lagrangian heuristic based on transferences. An important aspect of the proposed heuristic is its ability to take into account a secondary practice objective solution: the furnace waste. Computational tests show that the approach proposed here is able to generate good quality solutions that outperform prior results. Journal of the Operational Research Society (2010) 61, 108-114. doi:10.1057/jors.2008.151

An approach using Lagrangian/surrogate relaxation for lot-sizing with transportation costs

Neste trabalho estuda-se um problema de dimensionamento de lotes e distribuição que envolve além de custos de estoques, produção e preparação, custos de transportes para o armazém da empresa. Os custos logísticos estão associados aos contêineres necessários para empacotar os produtos produzidos. A empresa negocia um contrato de longo prazo onde um custo fixo por período é associado ao transporte dos itens, em contrapartida um limite de contêineres é disponibilizado com custo mais baixo que o custo padrão. Caso ocorra um aumento ocasional de demanda, novos contêineres podem ser utilizados, no entanto, seu custo é mais elevado. Um modelo matemático foi proposto na literatura e resolvido utilizando uma heurística Lagrangiana. No presente trabalho a resolução do problema por uma heurística Lagrangiana/surrogate é avaliada. Além disso, é considerada uma extensão do modelo da literatura adicionando restrições de capacidade e permitindo atraso no atendimento a demanda. Testes computacionais mostraram que a heurística Lagrangiana/surrogate é competitiva especialmente quando se têm restrições de capacidade apertada.

Um modelo de otimização inteira mista e heurísticas relax and fix para a programação da produção de fábricas de refrigerantes de pequeno porte

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

A hybrid multi-population genetic algorithm applied to solve the multi-level capacitated lot sizing problem with backlogging

The present paper proposes a new hybrid multi-population genetic algorithm (HMPGA) as an approach to solve the multi-level capacitated lot sizing problem with backlogging. This method combines a multi-population based metaheuristic using fix-and-optimize heuristic and mathematical programming techniques. A total of four test sets from the MULTILSB (Multi-Item Lot-Sizing with Backlogging) library are solved and the results are compared with those reached by two other methods recently published. The results have shown that HMPGA had a better performance for most of the test sets solved, specially when longer computing time is given. © 2012 Elsevier Ltd.

Hybrid methods for lot sizing on parallel machines

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

QoS-oriented sesource allocation and scheduling of multiple composite web services in a hybrid cloud using a random-key genetic algorithm

In cloud computing resource allocation and scheduling of multiple composite web services is an important challenge. This is especially so in a hybrid cloud where there may be some free resources available from private clouds but some fee-paying resources from public clouds. Meeting this challenge involves two classical computational problems. One is assigning resources to each of the tasks in the composite web service. The other is scheduling the allocated resources when each resource may be used by more than one task and may be needed at different points of time. In addition, we must consider Quality-of-Service issues, such as execution time and running costs. Existing approaches to resource allocation and scheduling in public clouds and grid computing are not applicable to this new problem. This paper presents a random-key genetic algorithm that solves new resource allocation and scheduling problem. Experimental results demonstrate the effectiveness and scalability of the algorithm.

QoS-oriented resource allocation and scheduling of multiple composite Web services in a hybrid cloud using a random-key genetic algorithm

In cloud computing resource allocation and scheduling of multiple composite web services is an important challenge. This is especially so in a hybrid cloud where there may be some free resources available from private clouds but some fee-paying resources from public clouds. Meeting this challenge involves two classical computational problems. One is assigning resources to each of the tasks in the composite web service. The other is scheduling the allocated resources when each resource may be used by more than one task and may be needed at different points of time. In addition, we must consider Quality-of-Service issues, such as execution time and running costs. Existing approaches to resource allocation and scheduling in public clouds and grid computing are not applicable to this new problem. This paper presents a random-key genetic algorithm that solves new resource allocation and scheduling problem. Experimental results demonstrate the effectiveness and scalability of the algorithm.