A hybrid method for large-scale short-term scheduling of make-and-pack production processes

Due to the ongoing trend towards increased product variety, fast-moving consumer goods such as food and beverages, pharmaceuticals, and chemicals are typically manufactured through so-called make-and-pack processes. These processes consist of a make stage, a pack stage, and intermediate storage facilities that decouple these two stages. In operations scheduling, complex technological constraints must be considered, e.g., non-identical parallel processing units, sequence-dependent changeovers, batch splitting, no-wait restrictions, material transfer times, minimum storage times, and finite storage capacity. The short-term scheduling problem is to compute a production schedule such that a given demand for products is fulfilled, all technological constraints are met, and the production makespan is minimised. A production schedule typically comprises 500–1500 operations. Due to the problem size and complexity of the technological constraints, the performance of known mixed-integer linear programming (MILP) formulations and heuristic approaches is often insufficient. We present a hybrid method consisting of three phases. First, the set of operations is divided into several subsets. Second, these subsets are iteratively scheduled using a generic and flexible MILP formulation. Third, a novel critical path-based improvement procedure is applied to the resulting schedule. We develop several strategies for the integration of the MILP model into this heuristic framework. Using these strategies, high-quality feasible solutions to large-scale instances can be obtained within reasonable CPU times using standard optimisation software. We have applied the proposed hybrid method to a set of industrial problem instances and found that the method outperforms state-of-the-art methods.

Modelo de gestión de un embalse en tiempo real durante avenidas basado en redes bayesianas entrenadas con el método de optimización PLEM

En la actualidad, la gestión de embalses para el control de avenidas se realiza, comúnmente, utilizando modelos de simulación. Esto se debe, principalmente, a su facilidad de uso en tiempo real por parte del operador de la presa. Se han desarrollado modelos de optimización de la gestión del embalse que, aunque mejoran los resultados de los modelos de simulación, su aplicación en tiempo real se hace muy difícil o simplemente inviable, pues está limitada al conocimiento de la avenida futura que entra al embalse antes de tomar la decisión de vertido. Por esta razón, se ha planteado el objetivo de desarrollar un modelo de gestión de embalses en avenidas que incorpore las ventajas de un modelo de optimización y que sea de fácil uso en tiempo real por parte del gestor de la presa. Para ello, se construyó un modelo de red Bayesiana que representa los procesos de la cuenca vertiente y del embalse y, que aprende de casos generados sintéticamente mediante un modelo hidrológico agregado y un modelo de optimización de la gestión del embalse. En una primera etapa, se generó un gran número de episodios sintéticos de avenida utilizando el método de Monte Carlo, para obtener las lluvias, y un modelo agregado compuesto de transformación lluvia- escorrentía, para obtener los hidrogramas de avenida. Posteriormente, se utilizaron las series obtenidas como señales de entrada al modelo de gestión de embalses PLEM, que optimiza una función objetivo de costes mediante programación lineal entera mixta, generando igual número de eventos óptimos de caudal vertido y de evolución de niveles en el embalse. Los episodios simulados fueron usados para entrenar y evaluar dos modelos de red Bayesiana, uno que pronostica el caudal de entrada al embalse, y otro que predice el caudal vertido, ambos en un horizonte de tiempo que va desde una a cinco horas, en intervalos de una hora. En el caso de la red Bayesiana hidrológica, el caudal de entrada que se elige es el promedio de la distribución de probabilidad de pronóstico. En el caso de la red Bayesiana hidráulica, debido al comportamiento marcadamente no lineal de este proceso y a que la red Bayesiana devuelve un rango de posibles valores de caudal vertido, se ha desarrollado una metodología para seleccionar un único valor, que facilite el trabajo del operador de la presa. Esta metodología consiste en probar diversas estrategias propuestas, que incluyen zonificaciones y alternativas de selección de un único valor de caudal vertido en cada zonificación, a un conjunto suficiente de episodios sintéticos. Los resultados de cada estrategia se compararon con el método MEV, seleccionándose las estrategias que mejoran los resultados del MEV, en cuanto al caudal máximo vertido y el nivel máximo alcanzado por el embalse, cualquiera de las cuales puede usarse por el operador de la presa en tiempo real para el embalse de estudio (Talave). La metodología propuesta podría aplicarse a cualquier embalse aislado y, de esta manera, obtener, para ese embalse particular, diversas estrategias que mejoran los resultados del MEV. Finalmente, a modo de ejemplo, se ha aplicado la metodología a una avenida sintética, obteniendo el caudal vertido y el nivel del embalse en cada intervalo de tiempo, y se ha aplicado el modelo MIGEL para obtener en cada instante la configuración de apertura de los órganos de desagüe que evacuarán el caudal. Currently, the dam operator for the management of dams uses simulation models during flood events, mainly due to its ease of use in real time. Some models have been developed to optimize the management of the reservoir to improve the results of simulation models. However, real-time application becomes very difficult or simply unworkable, because the decision to discharge depends on the unknown future avenue entering the reservoir. For this reason, the main goal is to develop a model of reservoir management at avenues that incorporates the advantages of an optimization model. At the same time, it should be easy to use in real-time by the dam manager. For this purpose, a Bayesian network model has been developed to represent the processes of the watershed and reservoir. This model learns from cases generated synthetically by a hydrological model and an optimization model for managing the reservoir. In a first stage, a large number of synthetic flood events was generated using the Monte Carlo method, for rain, and rain-added processing model composed of runoff for the flood hydrographs. Subsequently, the series obtained were used as input signals to the reservoir management model PLEM that optimizes a target cost function using mixed integer linear programming. As a result, many optimal discharge rate events and water levels in the reservoir levels were generated. The simulated events were used to train and test two models of Bayesian network. The first one predicts the flow into the reservoir, and the second predicts the discharge flow. They work in a time horizon ranging from one to five hours, in intervals of an hour. In the case of hydrological Bayesian network, the chosen inflow is the average of the probability distribution forecast. In the case of hydraulic Bayesian network the highly non-linear behavior of this process results on a range of possible values of discharge flow. A methodology to select a single value has been developed to facilitate the dam operator work. This methodology tests various strategies proposed. They include zoning and alternative selection of a single value in each discharge rate zoning from a sufficient set of synthetic episodes. The results of each strategy are compared with the MEV method. The strategies that improve the outcomes of MEV are selected and can be used by the dam operator in real time applied to the reservoir study case (Talave). The methodology could be applied to any single reservoir and, thus, obtain, for the particular reservoir, various strategies that improve results from MEV. Finally, the methodology has been applied to a synthetic flood, obtaining the discharge flow and the reservoir level in each time interval. The open configuration floodgates to evacuate the flow at each interval have been obtained applying the MIGEL model.

MINLP Optimization Algorithm for the Synthesis of Heat and Work Exchange Networks

This paper introduces a new optimization model for the simultaneous synthesis of heat and work exchange networks. The work integration is performed in the work exchange network (WEN), while the heat integration is carried out in the heat exchanger network (HEN). In the WEN synthesis, streams at high-pressure (HP) and low-pressure (LP) are subjected to pressure manipulation stages, via turbines and compressors running on common shafts and stand-alone equipment. The model allows the use of several units of single-shaft-turbine-compressor (SSTC), as well as helper motors and generators to respond to any shortage and/or excess of energy, respectively, in the SSTC axes. The heat integration of the streams occurs in the HEN between each WEN stage. Thus, as the inlet and outlet streams temperatures in the HEN are dependent of the WEN design, they must be considered as optimization variables. The proposed multi-stage superstructure is formulated in mixed-integer nonlinear programming (MINLP), in order to minimize the total annualized cost composed by capital and operational expenses. A case study is conducted to verify the accuracy of the proposed approach. The results indicate that the heat integration between the WEN stages is essential to enhance the work integration, and to reduce the total cost of process due the need of a smaller amount of hot and cold utilities.

MINLP Model for the Synthesis of Heat Exchanger Networks with Handling Pressure of Process Streams

This paper introduces a new mathematical model for the simultaneous synthesis of heat exchanger networks (HENs), wherein the handling pressure of process streams is used to enhance the heat integration. The proposed approach combines generalized disjunctive programming (GDP) and mixed-integer nonlinear programming (MINLP) formulation, in order to minimize the total annualized cost composed by operational and capital expenses. A multi-stage superstructure is developed for the HEN synthesis, assuming constant heat capacity flow rates and isothermal mixing, and allowing for streams splits. In this model, the pressure and temperature of streams must be treated as optimization variables, increasing further the complexity and difficulty to solve the problem. In addition, the model allows for coupling of compressors and turbines to save energy. A case study is performed to verify the accuracy of the proposed model. In this example, the optimal integration between the heat and work decreases the need for thermal utilities in the HEN design. As a result, the total annualized cost is also reduced due to the decrease in the operational expenses related to the heating and cooling of the streams.

Optimization and Machine Learning Frameworks for Complex Network Analysis

Thesis (Ph.D.)--University of Washington, 2016-06

Zero weights and non-zero slacks:different solution to the same problem

This paper re-assesses three independently developed approaches that are aimed at solving the problem of zero-weights or non-zero slacks in Data Envelopment Analysis (DEA). The methods are weights restricted, non-radial and extended facet DEA models. Weights restricted DEA models are dual to envelopment DEA models with restrictions on the dual variables (DEA weights) aimed at avoiding zero values for those weights; non-radial DEA models are envelopment models which avoid non-zero slacks in the input-output constraints. Finally, extended facet DEA models recognize that only projections on facets of full dimension correspond to well defined rates of substitution/transformation between all inputs/outputs which in turn correspond to non-zero weights in the multiplier version of the DEA model. We demonstrate how these methods are equivalent, not only in their aim but also in the solutions they yield. In addition, we show that the aforementioned methods modify the production frontier by extending existing facets or creating unobserved facets. Further we propose a new approach that uses weight restrictions to extend existing facets. This approach has some advantages in computational terms, because extended facet models normally make use of mixed integer programming models, which are computationally demanding.

An integer-valued data envelopment analysis model with bounded outputs

Integer-valued data envelopment analysis (DEA) with alternative returns to scale technology has been introduced and developed recently by Kuosmanen and Kazemi Matin. The proportionality assumption of their introduced "natural augmentability" axiom in constant and nondecreasing returns to scale technologies makes it possible to achieve feasible decision-making units (DMUs) of arbitrary large size. In many real world applications it is not possible to achieve such production plans since some of the input and output variables are bounded above. In this paper, we extend the axiomatic foundation of integer-valuedDEAmodels for including bounded output variables. Some model variants are achieved by introducing a new axiom of "boundedness" over the selected output variables. A mixed integer linear programming (MILP) formulation is also introduced for computing efficiency scores in the associated production set. © 2011 The Authors. International Transactions in Operational Research © 2011 International Federation of Operational Research Societies.

Integer Programming Approach to HP Folding

One of the most widely studied protein structure prediction models is the hydrophobic-hydrophilic (HP) model, which explains the hydrophobic interaction and tries to maximize the number of contacts among hydrophobic amino-acids. In order to find a lower bound for the number of contacts, a number of heuristics have been proposed, but finding the optimal solution is still a challenge. In this research, we focus on creating a new integer programming model which is capable to provide tractable input for mixed-integer programming solvers, is general enough and allows relaxation with provable good upper bounds. Computational experiments using benchmark problems show that our formulation achieves these goals.

Algorithms for scheduling parallel batch processing machines with non-identical job ready times

This research is motivated by a practical application observed at a printed circuit board (PCB) manufacturing facility. After assembly, the PCBs (or jobs) are tested in environmental stress screening (ESS) chambers (or batch processing machines) to detect early failures. Several PCBs can be simultaneously tested as long as the total size of all the PCBs in the batch does not violate the chamber capacity. PCBs from different production lines arrive dynamically to a queue in front of a set of identical ESS chambers, where they are grouped into batches for testing. Each line delivers PCBs that vary in size and require different testing (or processing) times. Once a batch is formed, its processing time is the longest processing time among the PCBs in the batch, and its ready time is given by the PCB arriving last to the batch. ESS chambers are expensive and a bottleneck. Consequently, its makespan has to be minimized. ^ A mixed-integer formulation is proposed for the problem under study and compared to a formulation recently published. The proposed formulation is better in terms of the number of decision variables, linear constraints and run time. A procedure to compute the lower bound is proposed. For sparse problems (i.e. when job ready times are dispersed widely), the lower bounds are close to optimum. ^ The problem under study is NP-hard. Consequently, five heuristics, two metaheuristics (i.e. simulated annealing (SA) and greedy randomized adaptive search procedure (GRASP)), and a decomposition approach (i.e. column generation) are proposed—especially to solve problem instances which require prohibitively long run times when a commercial solver is used. Extensive experimental study was conducted to evaluate the different solution approaches based on the solution quality and run time. ^ The decomposition approach improved the lower bounds (or linear relaxation solution) of the mixed-integer formulation. At least one of the proposed heuristic outperforms the Modified Delay heuristic from the literature. For sparse problems, almost all the heuristics report a solution close to optimum. GRASP outperforms SA at a higher computational cost. The proposed approaches are viable to implement as the run time is very short. ^

Schedulazione delle rotte marittime nel settore ortofrutticolo. Modelli e Metodi

Il trasporto marittimo è una delle modalità più utilizzate soprattutto per la movimentazione di grandi volumi di prodotti tra i continenti in quanto è a basso costo, sicuro e meno inquinante rispetto ad altri mezzi di movimentazione. Ai giorni nostri è responsabile di circa l’80% del commercio globale (in volume di carichi trasportati). Il settore del trasporto marittimo ha avuto una lunga tradizione di pianificazione manuale effettuata da progettisti esperti.
 L’obiettivo principale di questa trattazione è stato quello di implementare un modello matematico lineare (MILP, Mixed-Integer Linear Programming Model) per l’ottimizzazione delle rotte marittime nell’ambito del mercato orto-frutticolo che si sviluppa nel bacino del Mediterraneo (problema di Ship-Scheduling). Il modello fornito in questa trattazione è un valido strumento di supporto alle decisioni che può utilizzare uno spedizioniere nell’ambito della pianificazione delle rotte marittime della flotta di navi in suo possesso. Consente di determinare l’insieme delle rotte ottimali che devono essere svolte da un insieme di vettori al fine di massimizzare il profitto complessivo dello spedizioniere, generato nell’arco di tempo considerato. Inoltre, permette di ottenere, per ogni nave considerata, la ripartizione ottimale della merce (carico ottimale).

Interrupted searches in the BBMCSFilter context for MINLP problems

The BBMCSFilter method was developed to solve mixed integer nonlinear programming problems. This kind of problems have integer and continuous variables and they appear very frequently in process engineering problems. The objective of this work is to analyze the performance of the method when the coordinate searches are interrupted in the context of the multistart strategy. From the numerical experiments, we observed a reduction on the number of function evaluations and on the CPU time.

Design and management of a supply chain: a joint location-inventory problem under uncertainty (Part A)

In this paper, a joint location-inventory model is proposed that simultaneously optimises strategic supply chain design decisions such as facility location and customer allocation to facilities, and tactical-operational inventory management and production scheduling decisions. All this is analysed in a context of demand uncertainty and supply uncertainty. While demand uncertainty stems from potential fluctuations in customer demands over time, supply-side uncertainty is associated with the risk of “disruption” to which facilities may be subject. The latter is caused by external factors such as natural disasters, strikes, changes of ownership and information technology security incidents. The proposed model is formulated as a non-linear mixed integer programming problem to minimise the expected total cost, which includes four basic cost items: the fixed cost of locating facilities at candidate sites, the cost of transport from facilities to customers, the cost of working inventory, and the cost of safety stock. Next, since the optimisation problem is very complex and the number of evaluable instances is very low, a "matheuristic" solution is presented. This approach has a twofold objective: on the one hand, it considers a larger number of facilities and customers within the network in order to reproduce a supply chain configuration that more closely reflects a real-world context; on the other hand, it serves to generate a starting solution and perform a series of iterations to try to improve it. Thanks to this algorithm, it was possible to obtain a solution characterised by a lower total system cost than that observed for the initial solution. The study concludes with some reflections and the description of possible future insights.

Biased Random-key Genetic Algorithms For The Winner Determination Problem In Combinatorial Auctions.

Abstract In this paper, we address the problem of picking a subset of bids in a general combinatorial auction so as to maximize the overall profit using the first-price model. This winner determination problem assumes that a single bidding round is held to determine both the winners and prices to be paid. We introduce six variants of biased random-key genetic algorithms for this problem. Three of them use a novel initialization technique that makes use of solutions of intermediate linear programming relaxations of an exact mixed integer-linear programming model as initial chromosomes of the population. An experimental evaluation compares the effectiveness of the proposed algorithms with the standard mixed linear integer programming formulation, a specialized exact algorithm, and the best-performing heuristics proposed for this problem. The proposed algorithms are competitive and offer strong results, mainly for large-scale auctions.

Model for facilities or vendors location in a global scale considering several echelons in the Chain

The facilities location problem for companies with global operations is very complex and not well explored in the literature. This work proposes a MILP model that solves the problem through minimization of the total logistic cost. Main contributions of the model are the pioneer carrying cost calculation, the treatment given to the take-or-pay costs and to the international tax benefits such as drawback and added value taxes in Brazil. The model was successfully applied to a real case of a chemical industry with industrial plants and sales all over the world. The model application recommended a totally new sourcing model for the company.

Non-Markovian homodyne-mediated feedback on a two-level atom: a quantum trajectory treatment

Quantum feedback can stabilize a two-level atom against decoherence (spontaneous emission), putting it into an arbitrary (specified) pure state. This requires perfect homodyne detection of the atomic emission, and instantaneous feedback. Inefficient detection was considered previously by two of us. Here we allow for a non-zero delay time tau in the feedback circuit. Because a two-level atom is a non-linear optical system, an analytical solution is not possible. However, quantum trajectories allow a simple numerical simulation of the resulting non-Markovian process. We find the effect of the time delay to be qualitatively similar to chat of inefficient detection. The solution of the non-Markovian quantum trajectory will not remain fixed, so that the time-averaged state will be mixed, not pure. In the case where one tries to stabilize the atom in the excited state, an approximate analytical solution to the quantum trajectory is possible. The result, that the purity (P = 2Tr[rho (2)] - 1) of the average state is given by P = 1 - 4y tau (where gamma is the spontaneous emission rate) is found to agree very well with the numerical results. (C) 2001 Elsevier Science B.V. All rights reserved.