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.

Lot sizing and furnace scheduling in small foundries

A lot sizing and scheduling problem prevalent in small market-driven foundries is studied. There are two related decision levels: (1) the furnace scheduling of metal alloy production, and (2) moulding machine planning which specifies the type and size of production lots. A mixed integer programming (MIP) formulation of the problem is proposed, but is impractical to solve in reasonable computing time for non-small instances. As a result, a faster relax-and-fix (RF) approach is developed that can also be used on a rolling horizon basis where only immediate-term schedules are implemented. As well as a MIP method to solve the basic RF approach, three variants of a local search method are also developed and tested using instances based on the literature. Finally, foundry-based tests with a real-order book resulted in a very substantial reduction of delivery delays and finished inventory, better use of capacity, and much faster schedule definition compared to the foundry's own practice. © 2006 Elsevier Ltd. All rights reserved.

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.

Learning for scheduling a portfolio of constraint solvers

Nel lavoro di tesi qui presentato si indaga l'applicazione di tecniche di apprendimento mirate ad una più efficiente esecuzione di un portfolio di risolutore di vincoli (constraint solver). Un constraint solver è un programma che dato in input un problema di vincoli, elabora una soluzione mediante l'utilizzo di svariate tecniche. I problemi di vincoli sono altamente presenti nella vita reale. Esempi come l'organizzazione dei viaggi dei treni oppure la programmazione degli equipaggi di una compagnia aerea, sono tutti problemi di vincoli. Un problema di vincoli è formalizzato da un problema di soddisfacimento di vincoli(CSP). Un CSP è descritto da un insieme di variabili che possono assumere valori appartenenti ad uno specico dominio ed un insieme di vincoli che mettono in relazione variabili e valori assumibili da esse. Una tecnica per ottimizzare la risoluzione di tali problemi è quella suggerita da un approccio a portfolio. Tale tecnica, usata anche in am- biti come quelli economici, prevede la combinazione di più solver i quali assieme possono generare risultati migliori di un approccio a singolo solver. In questo lavoro ci preoccupiamo di creare una nuova tecnica che combina un portfolio di constraint solver con tecniche di machine learning. Il machine learning è un campo di intelligenza articiale che si pone l'obiettivo di immettere nelle macchine una sorta di `intelligenza'. Un esempio applicativo potrebbe essere quello di valutare i casi passati di un problema ed usarli in futuro per fare scelte. Tale processo è riscontrato anche a livello cognitivo umano. Nello specico, vogliamo ragionare in termini di classicazione. Una classicazione corrisponde ad assegnare ad un insieme di caratteristiche in input, un valore discreto in output, come vero o falso se una mail è classicata come spam o meno. La fase di apprendimento sarà svolta utilizzando una parte di CPHydra, un portfolio di constraint solver sviluppato presso la University College of Cork (UCC). Di tale algoritmo a portfolio verranno utilizzate solamente le caratteristiche usate per descrivere determinati aspetti di un CSP rispetto ad un altro; queste caratteristiche vengono altresì dette features. Creeremo quindi una serie di classicatori basati sullo specifico comportamento dei solver. La combinazione di tali classicatori con l'approccio a portfolio sara nalizzata allo scopo di valutare che le feature di CPHydra siano buone e che i classicatori basati su tali feature siano affidabili. Per giusticare il primo risultato, eettueremo un confronto con uno dei migliori portfolio allo stato dell'arte, SATzilla. Una volta stabilita la bontà delle features utilizzate per le classicazioni, andremo a risolvere i problemi simulando uno scheduler. Tali simulazioni testeranno diverse regole costruite con classicatori precedentemente introdotti. Prima agiremo su uno scenario ad un processore e successivamente ci espanderemo ad uno scenario multi processore. In questi esperimenti andremo a vericare che, le prestazioni ottenute tramite l'applicazione delle regole create appositamente sui classicatori, abbiano risultati migliori rispetto ad un'esecuzione limitata all'utilizzo del migliore solver del portfolio. I lavoro di tesi è stato svolto in collaborazione con il centro di ricerca 4C presso University College Cork. Su questo lavoro è stato elaborato e sottomesso un articolo scientico alla International Joint Conference of Articial Intelligence (IJCAI) 2011. Al momento della consegna della tesi non siamo ancora stati informati dell'accettazione di tale articolo. Comunque, le risposte dei revisori hanno indicato che tale metodo presentato risulta interessante.

An abstract machine based execution model for computer architecture design and efficient implementation of logic programs in parallel.

The term "Logic Programming" refers to a variety of computer languages and execution models which are based on the traditional concept of Symbolic Logic. The expressive power of these languages offers promise to be of great assistance in facing the programming challenges of present and future symbolic processing applications in Artificial Intelligence, Knowledge-based systems, and many other areas of computing. The sequential execution speed of logic programs has been greatly improved since the advent of the first interpreters. However, higher inference speeds are still required in order to meet the demands of applications such as those contemplated for next generation computer systems. The execution of logic programs in parallel is currently considered a promising strategy for attaining such inference speeds. Logic Programming in turn appears as a suitable programming paradigm for parallel architectures because of the many opportunities for parallel execution present in the implementation of logic programs. This dissertation presents an efficient parallel execution model for logic programs. The model is described from the source language level down to an "Abstract Machine" level suitable for direct implementation on existing parallel systems or for the design of special purpose parallel architectures. Few assumptions are made at the source language level and therefore the techniques developed and the general Abstract Machine design are applicable to a variety of logic (and also functional) languages. These techniques offer efficient solutions to several areas of parallel Logic Programming implementation previously considered problematic or a source of considerable overhead, such as the detection and handling of variable binding conflicts in AND-Parallelism, the specification of control and management of the execution tree, the treatment of distributed backtracking, and goal scheduling and memory management issues, etc. A parallel Abstract Machine design is offered, specifying data areas, operation, and a suitable instruction set. This design is based on extending to a parallel environment the techniques introduced by the Warren Abstract Machine, which have already made very fast and space efficient sequential systems a reality. Therefore, the model herein presented is capable of retaining sequential execution speed similar to that of high performance sequential systems, while extracting additional gains in speed by efficiently implementing parallel execution. These claims are supported by simulations of the Abstract Machine on sample programs.

An integrated scheduling problem of PCB components on sequential pick-and-place machines:mathematical models and heuristic solutions

This paper formulates several mathematical models for determining the optimal sequence of component placements and assignment of component types to feeders simultaneously or the integrated scheduling problem for a type of surface mount technology placement machines, called the sequential pick-andplace (PAP) machine. A PAP machine has multiple stationary feeders storing components, a stationary working table holding a printed circuit board (PCB), and a movable placement head to pick up components from feeders and place them to a board. The objective of integrated problem is to minimize the total distance traveled by the placement head. Two integer nonlinear programming models are formulated first. Then, each of them is equivalently converted into an integer linear type. The models for the integrated problem are verified by two commercial packages. In addition, a hybrid genetic algorithm previously developed by the authors is adopted to solve the models. The algorithm not only generates the optimal solutions quickly for small-sized problems, but also outperforms the genetic algorithms developed by other researchers in terms of total traveling distance.

Integrated component scheduling models for chip shooter machines

This paper focuses on minimizing printed circuit board (PCB) assembly time for a chipshootermachine, which has a movable feeder carrier holding components, a movable X–Y table carrying a PCB, and a rotary turret with multiple assembly heads. The assembly time of the machine depends on two inter-related optimization problems: the component sequencing problem and the feeder arrangement problem. Nevertheless, they were often regarded as two individual problems and solved separately. This paper proposes two complete mathematical models for the integrated problem of the machine. The models are verified by two commercial packages. Finally, a hybrid genetic algorithm previously developed by the authors is presented to solve the model. The algorithm not only generates the optimal solutions quickly for small-sized problems, but also outperforms the genetic algorithms developed by other researchers in terms of total assembly time.

Component scheduling for chip shooter machines: a hybrid genetic algorithm approach

A chip shooter machine for electronic component assembly has a movable feeder carrier, a movable X–Y table carrying a printed circuit board (PCB), and a rotary turret with multiple assembly heads. This paper presents a hybrid genetic algorithm (HGA) to optimize the sequence of component placements and the arrangement of component types to feeders simultaneously for a chip shooter machine, that is, the component scheduling problem. The objective of the problem is to minimize the total assembly time. The GA developed in the paper hybridizes different search heuristics including the nearest-neighbor heuristic, the 2-opt heuristic, and an iterated swap procedure, which is a new improved heuristic. Compared with the results obtained by other researchers, the performance of the HGA is superior in terms of the assembly time. Scope and purpose When assembling the surface mount components on a PCB, it is necessary to obtain the optimal sequence of component placements and the best arrangement of component types to feeders simultaneously in order to minimize the total assembly time. Since it is very difficult to obtain the optimality, a GA hybridized with several search heuristics is developed. The type of machines being studied is the chip shooter machine. This paper compares the algorithm with a simple GA. It shows that the performance of the algorithm is superior to that of the simple GA in terms of the total assembly time.

Improving scheduling techniques in heterogeneous systems with dynamic, on-line optimisations

Computational performance increasingly depends on parallelism, and many systems rely on heterogeneous resources such as GPUs and FPGAs to accelerate computationally intensive applications. However, implementations for such heterogeneous systems are often hand-crafted and optimised to one computation scenario, and it can be challenging to maintain high performance when application parameters change. In this paper, we demonstrate that machine learning can help to dynamically choose parameters for task scheduling and load-balancing based on changing characteristics of the incoming workload. We use a financial option pricing application as a case study. We propose a simulation of processing financial tasks on a heterogeneous system with GPUs and FPGAs, and show how dynamic, on-line optimisations could improve such a system. We compare on-line and batch processing algorithms, and we also consider cases with no dynamic optimisations.

Realization of an Optimal Schedule for the Two-machine Flow-Shop with Interval Job Processing Times

Non-preemptive two-machine flow-shop scheduling problem with uncertain processing times of n jobs is studied. In an uncertain version of a scheduling problem, there may not exist a unique schedule that remains optimal for all possible realizations of the job processing times. We find necessary and sufficient conditions (Theorem 1) when there exists a dominant permutation that is optimal for all possible realizations of the job processing times. Our computational studies show the percentage of the problems solvable under these conditions for the cases of randomly generated instances with n ≤ 100 . We also show how to use additional information about the processing times of the completed jobs during optimal realization of a schedule (Theorems 2 – 4). Computational studies for randomly generated instances with n ≤ 50 show the percentage of the two- machine flow-shop scheduling problems solvable under the sufficient conditions given in Theorems 2 – 4.

Makespan minimization in a job shop with a batch processing machine

A job shop with one batch processing and several discrete machines is analyzed. Given a set of jobs, their process routes, processing requirements, and size, the objective is to schedule the jobs such that the makespan is minimized. The batch processing machine can process a batch of jobs as long as the machine capacity is not violated. The batch processing time is equal to the longest processing job in the batch. The problem under study can be represented as Jm:batch:Cmax. If no batches were formed, the scheduling problem under study reduces to the classical job shop scheduling problem (i.e. Jm:: Cmax), which is known to be NP-hard. This research extends the scheduling literature by combining Jm::Cmax with batch processing. The primary contributions are the mathematical formulation, a new network representation and several solution approaches. The problem under study is observed widely in metal working and other industries, but received limited or no attention due to its complexity. A novel network representation of the problem using disjunctive and conjunctive arcs, and a mathematical formulation are proposed to minimize the makespan. Besides that, several algorithms, like batch forming heuristics, dispatching rules, Modified Shifting Bottleneck, Tabu Search (TS) and Simulated Annealing (SA), were developed and implemented. An experimental study was conducted to evaluate the proposed heuristics, and the results were compared to those from a commercial solver (i.e., CPLEX). TS and SA, with the combination of MWKR-FF as the initial solution, gave the best solutions among all the heuristics proposed. Their results were close to CPLEX; and for some larger instances, with total operations greater than 225, they were competitive in terms of solution quality and runtime. For some larger problem instances, CPLEX was unable to report a feasible solution even after running for several hours. Between SA and the experimental study indicated that SA produced a better average Cmax for all instances. The solution approaches proposed will benefit practitioners to schedule a job shop (with both discrete and batch processing machines) more efficiently. The proposed solution approaches are easier to implement and requires short run times to solve large problem instances.

Data-Aware Scheduling in Datacenters

Datacenters have emerged as the dominant form of computing infrastructure over the last two decades. The tremendous increase in the requirements of data analysis has led to a proportional increase in power consumption and datacenters are now one of the fastest growing electricity consumers in the United States. Another rising concern is the loss of throughput due to network congestion. Scheduling models that do not explicitly account for data placement may lead to a transfer of large amounts of data over the network causing unacceptable delays. In this dissertation, we study different scheduling models that are inspired by the dual objectives of minimizing energy costs and network congestion in a datacenter. As datacenters are equipped to handle peak workloads, the average server utilization in most datacenters is very low. As a result, one can achieve huge energy savings by selectively shutting down machines when demand is low. In this dissertation, we introduce the network-aware machine activation problem to find a schedule that simultaneously minimizes the number of machines necessary and the congestion incurred in the network. Our model significantly generalizes well-studied combinatorial optimization problems such as hard-capacitated hypergraph covering and is thus strongly NP-hard. As a result, we focus on finding good approximation algorithms. Data-parallel computation frameworks such as MapReduce have popularized the design of applications that require a large amount of communication between different machines. Efficient scheduling of these communication demands is essential to guarantee efficient execution of the different applications. In the second part of the thesis, we study the approximability of the co-flow scheduling problem that has been recently introduced to capture these application-level demands. Finally, we also study the question, "In what order should one process jobs?'' Often, precedence constraints specify a partial order over the set of jobs and the objective is to find suitable schedules that satisfy the partial order. However, in the presence of hard deadline constraints, it may be impossible to find a schedule that satisfies all precedence constraints. In this thesis we formalize different variants of job scheduling with soft precedence constraints and conduct the first systematic study of these problems.

A Hybrid Genetic Algorithm to Solve a Logt-Sizing and Scheduling Problem

Abstract: This paper reports a lot-sizing and scheduling problem, which minimizes inventory and backlog costs on m parallel machines with sequence-dependent set-up times over t periods. Problem solutions are represented as product subsets ordered and/or unordered for each machine m at each period t. The optimal lot sizes are determined applying a linear program. A genetic algorithm searches either over ordered or over unordered subsets (which are implicitly ordered using a fast ATSP-type heuristic) to identify an overall optimal solution. Initial computational results are presented, comparing the speed and solution quality of the ordered and unordered genetic algorithm approaches.

Methods for integrating machine learning and constrained optimization

In the framework of industrial problems, the application of Constrained Optimization is known to have overall very good modeling capability and performance and stands as one of the most powerful, explored, and exploited tool to address prescriptive tasks. The number of applications is huge, ranging from logistics to transportation, packing, production, telecommunication, scheduling, and much more. The main reason behind this success is to be found in the remarkable effort put in the last decades by the OR community to develop realistic models and devise exact or approximate methods to solve the largest variety of constrained or combinatorial optimization problems, together with the spread of computational power and easily accessible OR software and resources. On the other hand, the technological advancements lead to a data wealth never seen before and increasingly push towards methods able to extract useful knowledge from them; among the data-driven methods, Machine Learning techniques appear to be one of the most promising, thanks to its successes in domains like Image Recognition, Natural Language Processes and playing games, but also the amount of research involved. The purpose of the present research is to study how Machine Learning and Constrained Optimization can be used together to achieve systems able to leverage the strengths of both methods: this would open the way to exploiting decades of research on resolution techniques for COPs and constructing models able to adapt and learn from available data. In the first part of this work, we survey the existing techniques and classify them according to the type, method, or scope of the integration; subsequently, we introduce a novel and general algorithm devised to inject knowledge into learning models through constraints, Moving Target. In the last part of the thesis, two applications stemming from real-world projects and done in collaboration with Optit will be presented.