A genetic algorithm/mathematical programming approach to solve a two-level soft drink production problem

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

A Study of Different Subsequence Elimination Strategies for the Soft Drink Production Planning

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

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.

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.

Recent research trend of economic-lot scheduling problems

Purpose - This research note aims to present a summary of research concerning economic-lot scheduling problem (ELSP). Design/methodology/approach - The paper's approach is to review over 100 selected studies published in the last 15 years (1997-2012), which are then grouped under different research themes. Findings - Five research themes are identified and insights for future studies are reported at the end of this paper. Research limitations/implications - The motivation of preparing this research note is to summarize key research studies in this field since 1997, when the ELSP problems have been verified as NP-hard. Originality/value - ELSP is an important scheduling problem that has been studied since the 1950s. Because of its complexity in delivering a feasible analytical closed form solution, many studies in the last two decades employed heuristic algorithms in order to come up with good and acceptable solutions. As a consequence, the solution approaches are quite diversified. The major contribution of this paper is to provide researchers who are interested in this area with a quick reference guide on the reviewed studies. © Emerald Group Publishing Limited.

Models and methods for supporting lot sizing decisions in product recovery systems

Magdeburg, Univ., Fak. für Wirtschaftswiss., Diss., 2011

On Certain Greedoid Polyhedra, Partially Indexable Scheduling Problems, and Extended Restless Bandit Allocation Indices

We present a polyhedral framework for establishing general structural properties on optimal solutions of stochastic scheduling problems, where multiple job classes vie for service resources: the existence of an optimal priority policy in a given family, characterized by a greedoid (whose feasible class subsets may receive higher priority), where optimal priorities are determined by class-ranking indices, under restricted linear performance objectives (partial indexability). This framework extends that of Bertsimas and Niño-Mora (1996), which explained the optimality of priority-index policies under all linear objectives (general indexability). We show that, if performance measures satisfy partial conservation laws (with respect to the greedoid), which extend previous generalized conservation laws, then the problem admits a strong LP relaxation over a so-called extended greedoid polytope, which has strong structural and algorithmic properties. We present an adaptive-greedy algorithm (which extends Klimov's) taking as input the linear objective coefficients, which (1) determines whether the optimal LP solution is achievable by a policy in the given family; and (2) if so, computes a set of class-ranking indices that characterize optimal priority policies in the family. In the special case of project scheduling, we show that, under additional conditions, the optimal indices can be computed separately for each project (index decomposition). We further apply the framework to the important restless bandit model (two-action Markov decision chains), obtaining new index policies, that extend Whittle's (1988), and simple sufficient conditions for their validity. These results highlight the power of polyhedral methods (the so-called achievable region approach) in dynamic and stochastic optimization.

On certain greedoid polyhedra, partially indexable scheduling problems and extended restless bandit allocation indices

We present a polyhedral framework for establishing general structural properties on optimal solutions of stochastic scheduling problems, where multiple job classes vie for service resources: the existence of an optimal priority policy in a given family, characterized by a greedoid(whose feasible class subsets may receive higher priority), where optimal priorities are determined by class-ranking indices, under restricted linear performance objectives (partial indexability). This framework extends that of Bertsimas and Niño-Mora (1996), which explained the optimality of priority-index policies under all linear objectives (general indexability). We show that, if performance measures satisfy partial conservation laws (with respect to the greedoid), which extend previous generalized conservation laws, then theproblem admits a strong LP relaxation over a so-called extended greedoid polytope, which has strong structural and algorithmic properties. We present an adaptive-greedy algorithm (which extends Klimov's) taking as input the linear objective coefficients, which (1) determines whether the optimal LP solution is achievable by a policy in the given family; and (2) if so, computes a set of class-ranking indices that characterize optimal priority policies in the family. In the special case of project scheduling, we show that, under additional conditions, the optimal indices can be computed separately for each project (index decomposition). We further apply the framework to the important restless bandit model (two-action Markov decision chains), obtaining new index policies, that extend Whittle's (1988), and simple sufficient conditions for their validity. These results highlight the power of polyhedral methods (the so-called achievable region approach) in dynamic and stochastic optimization.

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

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.

Integrating Crew Scheduling and Rostering Problems

Crew scheduling and crew rostering are similar and related problems which can be solved by similar procedures. So far, the existing solution methods usually create a model for each one of these problems (scheduling and rostering), and when they are solved together in some cases an interaction between models is considered in order to obtain a better solution. A single set covering model to solve simultaneously both problems is presented here, where the total quantity of drivers needed is directly considered and optimized. This integration allows to optimize all of the depots at the same time, while traditional approaches needed to work depot by depot, and also it allows to see and manage the relationship between scheduling and rostering, which was known in some degree but usually not easy to quantify as this model permits. Recent research in the area of crew scheduling and rostering has stated that one of the current challenges to be achieved is to determine a schedule where crew fatigue, which depends mainly on the quality of the rosters created, is reduced. In this approach rosters are constructed in such way that stable working hours are used in every week of work, and a change to a different shift is done only using free days in between to make easier the adaptation to the new working hours. Computational results for real-world-based instances are presented. Instances are geographically diverse to test the performance of the procedures and the model in different scenarios.

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.

A hybrid heuristic for the multi-plant capacitated lot sizing problem with setup carry-over

This paper addresses the capacitated lot sizing problem (CLSP) with a single stage composed of multiple plants, items and periods with setup carry-over among the periods. The CLSP is well studied and many heuristics have been proposed to solve it. Nevertheless, few researches explored the multi-plant capacitated lot sizing problem (MPCLSP), which means that few solution methods were proposed to solve it. Furthermore, to our knowledge, no study of the MPCLSP with setup carry-over was found in the literature. This paper presents a mathematical model and a GRASP (Greedy Randomized Adaptive Search Procedure) with path relinking to the MPCLSP with setup carry-over. This solution method is an extension and adaptation of a previously adopted methodology without the setup carry-over. Computational tests showed that the improvement of the setup carry-over is significant in terms of the solution value with a low increase in computational time.

Ant colony system based approach to single machine scheduling problems: weighted tardiness scheduling problem

The paper introduces an approach to solve the problem of generating a sequence of jobs that minimizes the total weighted tardiness for a set of jobs to be processed in a single machine. An Ant Colony System based algorithm is validated with benchmark problems available in the OR library. The obtained results were compared with the best available results and were found to be nearer to the optimal. The obtained computational results allowed concluding on their efficiency and effectiveness.