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.

Production lot sizing and scheduling with non-triangular sequence-dependent setup times

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Infeasibility handling in genetic algorithm using nested domains for production planning

In this paper we present a genetic algorithm with new components to tackle capacitated lot sizing and scheduling problems with sequence dependent setups that appear in a wide range of industries, from soft drink bottling to food manufacturing. Finding a feasible solution to highly constrained problems is often a very difficult task. Various strategies have been applied to deal with infeasible solutions throughout the search. We propose a new scheme of classifying individuals based on nested domains to determine the solutions according to the level of infeasibility, which in our case represents bands of additional production hours (overtime). Within each band, individuals are just differentiated by their fitness function. As iterations are conducted, the widths of the bands are dynamically adjusted to improve the convergence of the individuals into the feasible domain. The numerical experiments on highly capacitated instances show the effectiveness of this computational tractable approach to guide the search toward the feasible domain. Our approach outperforms other state-of-the-art approaches and commercial solvers. (C) 2009 Elsevier Ltd. All rights reserved.

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: (I 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. (c) 2006 Elsevier Ltd. All rights reserved.

Solution approaches for the soft drink integrated production lot sizing and scheduling problem

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

Heuristics and meta-heuristics for lot sizing and scheduling in the soft drinks industry: A comparison study

This chapter studies a two-level production planning problem where, on each level, a lot sizing and scheduling problem with parallel machines, capacity constraints and sequence-dependent setup costs and times must be solved. The problem can be found in soft drink companies where the production process involves two interdependent levels with decisions concerning raw material storage and soft drink bottling. Models and solution approaches proposed so far are surveyed and conceptually compared. Two different approaches have been selected to perform a series of computational comparisons: an evolutionary technique comprising a genetic algorithm and its memetic version, and a decomposition and relaxation approach. © 2008 Springer-Verlag Berlin Heidelberg.

Reformulação para um problema integrado de dimensionamento e sequenciamento de lotes

In this paper, some new constraints and an extended formulation are presented for a Lot Sizing and Scheduling Model proposed in the literature. In the production process considered a key material is prepared and is transformed into different final items. The sequencing decisions are related to the order in which the materials are processed and the lot sizing decisions are related to the final items production. The mathematical formulation considers sequence-dependent setup costs and times. Results of the computational tests executed using the software Cplex 10.0 showed that the performance of the branch-and-cut method can be improved by the proposed a priori reformulation.

A priori reformulations for joint rolling-horizon scheduling of materials processing and lot-sizing problem

In many production processes, a key material is prepared and then transformed into different final products. The lot sizing decisions concern not only the production of final products, but also that of material preparation in order to take account of their sequence-dependent setup costs and times. The amount of research in recent years indicates the relevance of this problem in various industrial settings. In this paper, facility location reformulation and strengthening constraints are newly applied to a previous lot-sizing model in order to improve solution quality and computing time. Three alternative metaheuristics are used to fix the setup variables, resulting in much improved performance over previous research, especially regarding the use of the metaheuristics for larger instances. © 2013 Elsevier Ltd. All rights reserved.

Solving two production scheduling problems with sequence-dependent set-up times

In today’s competitive markets, the importance of goodscheduling strategies in manufacturing companies lead to theneed of developing efficient methods to solve complexscheduling problems.In this paper, we studied two production scheduling problemswith sequence-dependent setups times. The setup times areone of the most common complications in scheduling problems,and are usually associated with cleaning operations andchanging tools and shapes in machines.The first problem considered is a single-machine schedulingwith release dates, sequence-dependent setup times anddelivery times. The performance measure is the maximumlateness.The second problem is a job-shop scheduling problem withsequence-dependent setup times where the objective is tominimize the makespan.We present several priority dispatching rules for bothproblems, followed by a study of their performance. Finally,conclusions and directions of future research are presented.

Condition-dependent expression of melanin-based coloration in the Eurasian kestrel.

Melanin is the most common pigment in animal integuments and is responsible for some of the most striking ornaments. A central tenet of sexual selection theory states that melanin-based traits can signal absolute individual quality in any environment only if their expression is condition-dependent. Significant costs imposed by an ornament would ensure that only the highest quality individuals display the most exaggerated forms of the signal. Firm evidence that melanin-based traits can be condition-dependent is still rare in birds. In an experimental test of this central assumption, we report condition-dependent expression of a melanin-based trait in the Eurasian kestrel (Falco tinnunculus). We manipulated nestling body condition by reducing or increasing the number of nestlings soon after hatching. A few days before fledging, we measured the width of sub-terminal black bands on the tail feathers. Compared to nestlings from enlarged broods, individuals raised in reduced broods were in better condition and thereby developed larger sub-terminal bands. Furthermore, in 2 years, first-born nestlings also developed larger sub-terminal bands than their younger siblings that are in poorer condition. This demonstrates that expression of melanin-based traits can be condition-dependent.

The adoption of advanced feed-in tariffs in Ontario : a case of institutional layering

En mai 2009, l’Ontario a adopté la Loi sur l’énergie verte et devint ainsi la première juridiction en Amérique du Nord à promouvoir l’énergie renouvelable par le biais de tarifs de rachat garantis. En novembre 2010, dans son Plan énergétique à long terme, la province s’est engagée à déployer 10,700 MW en capacité de production d’énergie renouvelable non-hydroélectrique par 2018. Il s’agit de la cible de déploiement la plus élevée dans ce secteur au Canada. Les infrastructures de production et de distribution d’électricité comprennent des coûts d’installation élevés, une faible rotation des investissements et de longs cycles de vie, facteurs qui servent habituellement à ancrer les politiques énergétiques dans une dynamique de dépendance au sentier. Depuis le début des années 2000, cependant, l’Ontario a commencé à diverger de sa traditionnelle dépendance aux grandes centrales hydroélectriques, aux centrales à charbon et aux centrales nucléaires par une série de petits changements graduels qui feront grimper la part d’énergie renouvelable dans le mix énergétique provincial à 15% par 2018. Le but de ce mémoire est d’élucider le mécanisme de causalité qui a sous-tendu l’évolution graduelle de l’Ontario vers la promotion de l’énergie renouvelable par le biais de tarifs de rachat garantis et d’une cible de déploiement élevée. Ce mémoire applique la théorie du changement institutionnel graduel de Mahoney et Thelen au cas du développement de politiques d’énergie renouvelable en Ontario afin de mieux comprendre les causes, les modes et les effets du changement institutionnel. Nous découvrons que le contexte canadien de la politique énergétique favorise la sédimentation institutionnelle, c’est-à-dire un mode changement caractérisé par de petits gains favorisant l’énergie renouvelable. Ces gains s’accumulent pourtant en transformation politique importante. En Ontario, la mise sur pied d’une vaste coalition pour l’énergie renouvelable fut à l’origine du changement. Les premiers revendicateurs de politiques favorisant l’énergie renouvelable – les environnementalistes et les premières entreprises d’approvisionnement et de service en technologies d’énergie renouvelable – ont dû mettre sur pied un vaste réseau d’appui, représentant la quasi-totalité de la société ontarienne, pour faire avancer leur cause. Ce réseau a fait pression sur le gouvernement provincial et, en tant que front commun, a revendiqué l’énergie renouvelable non seulement comme solution aux changements climatiques, mais aussi comme solution à maints autres défis pressants de santé publique et de développement économique. La convergence favorable d’un nombre de facteurs contextuels a certes contribué à la réussite du réseau ontarien pour l’énergie renouvelable. Cependant, le fait que ce réseau ait trouvé des alliés au sein de l’exécutif du gouvernement provincial s’est révélé d’importance cruciale quant à l’obtention de politiques favorisant l’énergie renouvelable. Au Canada, les gouvernements provinciaux détiennent l’ultime droit de veto sur la politique énergétique. Ce n’est qu’en trouvant des alliés aux plus hauts échelons du gouvernement que le réseau ontarien pour l’énergie renouvelable a pu réussir.

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.

Relax and fix heuristics to solve one-stage one-machine lot-scheduling models for small-scale soft drink plants

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

Sequenciamento de lotes em prensas de alta capacidade com tempo de setup dependente da sequência

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Optimizing PCB assembly for family setup strategy

Purpose – The purpose of this paper is to investigate the optimization for a placement machine in printed circuit board (PCB) assembly when family setup strategy is adopted. Design/methodology/approach – A complete mathematical model is developed for the integrated problem to optimize feeder arrangement and component placement sequences so as to minimize the makespan for a set of PCB batches. Owing to the complexity of the problem, a specific genetic algorithm (GA) is proposed. Findings – The established model is able to find the minimal makespan for a set of PCB batches through determining the feeder arrangement and placement sequences. However, exact solutions to the problem are not practical due to the complexity. Experimental tests show that the proposed GA can solve the problem both effectively and efficiently. Research limitations/implications – When a placement machine is set up for production of a set of PCB batches, the feeder arrangement of the machine together with the component placement sequencing for each PCB type should be solved simultaneously so as to minimize the overall makespan. Practical implications – The paper investigates the optimization for PCB assembly with family setup strategy, which is adopted by many PCB manufacturers for reducing both setup costs and human errors. Originality/value – The paper investigates the feeder arrangement and placement sequencing problems when family setup strategy is adopted, which has not been studied in the literature.