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.

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.

Planification de la récolte et allocation des produits aux usines

L’industrie forestière est un secteur qui, même s’il est en déclin, se trouve au cœur du débat sur la mondialisation et le développement durable. Pour de nombreux pays tels que le Canada, la Suède et le Chili, les objectifs sont de maintenir un secteur florissant sans nuire à l’environnement et en réalisant le caractère fini des ressources. Il devient important d’être compétitif et d’exploiter de manière efficace les territoires forestiers, de la récolte jusqu’à la fabrication des produits aux usines, en passant par le transport, dont les coûts augmentent rapidement. L’objectif de ce mémoire est de développer un modèle de planification tactique/opérationnelle qui permet d’ordonnancer les activités pour une année de récolte de façon à satisfaire les demandes des usines, sans perdre de vue le transport des quantités récoltées et la gestion des inventaires en usine. L’année se divise en 26 périodes de deux semaines. Nous cherchons à obtenir les horaires et l’affectation des équipes de récolte aux blocs de coupe pour une année. Le modèle mathématique développé est un problème linéaire mixte en nombres entiers dont la structure est basée sur chaque étape de la chaine d’approvisionnement forestière. Nous choisissons de le résoudre par une méthode exacte, le branch-and-bound. Nous avons pu évaluer combien la résolution directe de notre problème de planification était difficile pour les instances avec un grand nombre de périodes. Cependant l’approche des horizons roulants s’est avérée fructueuse. Grâce à elle en une journée, il est possible de planifier les activités de récolte des blocs pour l’année entière (26 périodes).

Modèles et méthodes pour la planification de la récolte forestière

Ce projet de recherche a été réalisé avec la collaboration de FPInnovations. Une part des travaux concernant le problème de récolte chilien a été effectuée à l'Instituto Sistemas Complejos de Ingeniería (ISCI) à Santiago (Chili).

The Benefits of Re-Evaluating Real-Time Fulfillment Decisions

At the time of a customer order, the e-tailer assigns the order to one or more of its order fulfillment centers, and/or to drop shippers, so as to minimize procurement and transportation costs, based on the available current information. However this assignment is necessarily myopic as it cannot account for all future events, such as subsequent customer orders or inventory replenishments. We examine the potential benefits from periodically re-evaluating these real-time order-assignment decisions. We construct near-optimal heuristics for the re-assignment for a large set of customer orders with the objective to minimize the total number of shipments. We investigate how best to implement these heuristics for a rolling horizon, and discuss the effect of demand correlation, customer order size, and the number of customer orders on the nature of the heuristics. Finally, we present potential saving opportunities by testing the heuristics on sets of order data from a major e-tailer.

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.

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.

Modelagem do problema integrado de dimensionamento de lotes e corte de estoque em indústria moveleira

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Hierarchical Forest Management Planning: A Bilevel Wood Supply Modelling Approach

Le processus de planification forestière hiérarchique présentement en place sur les terres publiques risque d’échouer à deux niveaux. Au niveau supérieur, le processus en place ne fournit pas une preuve suffisante de la durabilité du niveau de récolte actuel. À un niveau inférieur, le processus en place n’appuie pas la réalisation du plein potentiel de création de valeur de la ressource forestière, contraignant parfois inutilement la planification à court terme de la récolte. Ces échecs sont attribuables à certaines hypothèses implicites au modèle d’optimisation de la possibilité forestière, ce qui pourrait expliquer pourquoi ce problème n’est pas bien documenté dans la littérature. Nous utilisons la théorie de l’agence pour modéliser le processus de planification forestière hiérarchique sur les terres publiques. Nous développons un cadre de simulation itératif en deux étapes pour estimer l’effet à long terme de l’interaction entre l’État et le consommateur de fibre, nous permettant ainsi d’établir certaines conditions pouvant mener à des ruptures de stock. Nous proposons ensuite une formulation améliorée du modèle d’optimisation de la possibilité forestière. La formulation classique du modèle d’optimisation de la possibilité forestière (c.-à-d., maximisation du rendement soutenu en fibre) ne considère pas que le consommateur de fibre industriel souhaite maximiser son profit, mais suppose plutôt la consommation totale de l’offre de fibre à chaque période, peu importe le potentiel de création de valeur de celle-ci. Nous étendons la formulation classique du modèle d’optimisation de la possibilité forestière afin de permettre l’anticipation du comportement du consommateur de fibre, augmentant ainsi la probabilité que l’offre de fibre soit entièrement consommée, rétablissant ainsi la validité de l’hypothèse de consommation totale de l’offre de fibre implicite au modèle d’optimisation. Nous modélisons la relation principal-agent entre le gouvernement et l’industrie à l’aide d’une formulation biniveau du modèle optimisation, où le niveau supérieur représente le processus de détermination de la possibilité forestière (responsabilité du gouvernement), et le niveau inférieur représente le processus de consommation de la fibre (responsabilité de l’industrie). Nous montrons que la formulation biniveau peux atténuer le risque de ruptures de stock, améliorant ainsi la crédibilité du processus de planification forestière hiérarchique. Ensemble, le modèle biniveau d’optimisation de la possibilité forestière et la méthodologie que nous avons développée pour résoudre celui-ci à l’optimalité, représentent une alternative aux méthodes actuellement utilisées. Notre modèle biniveau et le cadre de simulation itérative représentent un pas vers l’avant en matière de technologie de planification forestière axée sur la création de valeur. L’intégration explicite d’objectifs et de contraintes industrielles au processus de planification forestière, dès la détermination de la possibilité forestière, devrait favoriser une collaboration accrue entre les instances gouvernementales et industrielles, permettant ainsi d’exploiter le plein potentiel de création de valeur de la ressource forestière.

Multi-level, Multi-stage and Stochastic Optimization Models for Energy Conservation in Buildings for Federal, State and Local Agencies

Energy Conservation Measure (ECM) project selection is made difficult given real-world constraints, limited resources to implement savings retrofits, various suppliers in the market and project financing alternatives. Many of these energy efficient retrofit projects should be viewed as a series of investments with annual returns for these traditionally risk-averse agencies. Given a list of ECMs available, federal, state and local agencies must determine how to implement projects at lowest costs. The most common methods of implementation planning are suboptimal relative to cost. Federal, state and local agencies can obtain greater returns on their energy conservation investment over traditional methods, regardless of the implementing organization. This dissertation outlines several approaches to improve the traditional energy conservations models. Any public buildings in regions with similar energy conservation goals in the United States or internationally can also benefit greatly from this research. Additionally, many private owners of buildings are under mandates to conserve energy e.g., Local Law 85 of the New York City Energy Conservation Code requires any building, public or private, to meet the most current energy code for any alteration or renovation. Thus, both public and private stakeholders can benefit from this research. The research in this dissertation advances and presents models that decision-makers can use to optimize the selection of ECM projects with respect to the total cost of implementation. A practical application of a two-level mathematical program with equilibrium constraints (MPEC) improves the current best practice for agencies concerned with making the most cost-effective selection leveraging energy services companies or utilities. The two-level model maximizes savings to the agency and profit to the energy services companies (Chapter 2). An additional model presented leverages a single congressional appropriation to implement ECM projects (Chapter 3). Returns from implemented ECM projects are used to fund additional ECM projects. In these cases, fluctuations in energy costs and uncertainty in the estimated savings severely influence ECM project selection and the amount of the appropriation requested. A risk aversion method proposed imposes a minimum on the number of “of projects completed in each stage. A comparative method using Conditional Value at Risk is analyzed. Time consistency was addressed in this chapter. This work demonstrates how a risk-based, stochastic, multi-stage model with binary decision variables at each stage provides a much more accurate estimate for planning than the agency’s traditional approach and deterministic models. Finally, in Chapter 4, a rolling-horizon model allows for subadditivity and superadditivity of the energy savings to simulate interactive effects between ECM projects. The approach makes use of inequalities (McCormick, 1976) to re-express constraints that involve the product of binary variables with an exact linearization (related to the convex hull of those constraints). This model additionally shows the benefits of learning between stages while remaining consistent with the single congressional appropriations framework.

Texture and mechanical properties evolution of a deep drawing medium carbon steel during cold rolling and subsequent recrystallization

Medium carbon steels are mostly used for simple applications; however, new applications have been developed for which good sheet metal formability is required. These types of steels have an inherent low formability. A medium-carbon hot-rolled SAE 1050 steel was selected for this study. It has been cold rolled with thickness reductions varying between 7 and 80%. The samples obtained were used to evaluate the strain hardening curve. For samples with a 50 and 80% thickness reduction, an annealing heat treatment was performed to achieve recrystallization. The material was characterized in the ""as-received"", cold rolled and annealed conditions using several methods: optical metallography, X-ray diffraction (texture), Vickers hardness, and tensile testing. For large thickness reductions, the SAE 1050 steel presented low elongation, less than 2%, and yield strength (YS) and tensile strength (TS) around 1400 MPa. Texture in the ""as-received"" condition showed strong components on the {001} plane, in the < 100 >, < 210 > and (110) directions. After cold rolling, the texture did not present any significant changes for small thickness reductions, however. It changed completely for large ones, where gamma, < 111 >//ND, alpha, < 110 > HRD, and gamma prime, < 223 >//ND, fibres were strengthened. After annealing, the microstructure of the SAE 1050 steel was characterized by recrystallized ferrite and globular cementite. There was little change in the alpha fibre for the 50% reduction, whereas for the 80% reduction, its intensity increased. Both gamma and gamma prime fibres vanished upon annealing for 50 and 80% reductions alike. (c) 2008 Elsevier B.V. All rights reserved.

Medium carbon steel deep drawing: A study on the evolution of mechanical properties, texture and simulations, from cold rolling to the end product

Medium carbon steels are mostly used for simple applications; nevertheless new applications have been developed for which good sheet formability is required. This class of steels has an inherent low formability. A medium carbon hot rolled SAE 1050 steel has been selected for this study. It has been cold rolled with reductions in the 7-80% range. Samples have been used to assess the cold work hardening curve. For samples with a 50 and 80% thickness reduction, an annealing heat treatment has been performed to obtain recrystallization. The material has been characterized in the ""as received"", cold rolled and annealed conditions, using several methods: optical microscopy, X-ray diffraction (texture), Vickers hardness and tensile testing. The 50% cold rolled and recrystallized material has been further studied in terms of sheet metal formability and texture evolution during the actual stamping of a steel toecap that has been used to validate the finite element simulations. (C) 2008 Elsevier B.V. All rights reserved.

Effect of rolling on the residual stresses and magnetic properties of a 0.5% Si electrical steel

Cold-rolled (0-19% of reduction) 0.5% Si electrical steel sheets were studied in detail, including macro and micro residual stress measurements, crystallographic texture, dc-hysteresis curves and iron losses. Even for the smallest deformation, losses increase significantly, with large increase of the hysteresis losses, whereas the anomalous losses reduce slightly. The residual microstresses are similar to 150-350 MPa, whereas residual macrostresses are compressive, similar to 50 MPa. The large increase of the hysteresis losses is attributed to the residual microstresses. The dislocation density estimated by X-ray diffraction is in reasonable agreement with that predicted from the Sablik et al. model for effect of plastic deformation on hysteresis. The intensity of the texture fibers {1 1 1}< u v w > and < 110 >//RD (RD = rolling direction) increases with the reduction. (C) 2008 Elsevier B.V. All rights reserved.

Infinite horizon MPC with non-minimal state space feedback

In the MPC literature, stability is usually assured under the assumption that the state is measured. Since the closed-loop system may be nonlinear because of the constraints, it is not possible to apply the separation principle to prove global stability for the Output feedback case. It is well known that, a nonlinear closed-loop system with the state estimated via an exponentially converging observer combined with a state feedback controller can be unstable even when the controller is stable. One alternative to overcome the state estimation problem is to adopt a non-minimal state space model, in which the states are represented by measured past inputs and outputs [P.C. Young, M.A. Behzadi, C.L. Wang, A. Chotai, Direct digital and adaptative control by input-output, state variable feedback pole assignment, International journal of Control 46 (1987) 1867-1881; C. Wang, P.C. Young, Direct digital control by input-output, state variable feedback: theoretical background, International journal of Control 47 (1988) 97-109]. In this case, no observer is needed since the state variables can be directly measured. However, an important disadvantage of this approach is that the realigned model is not of minimal order, which makes the infinite horizon approach to obtain nominal stability difficult to apply. Here, we propose a method to properly formulate an infinite horizon MPC based on the output-realigned model, which avoids the use of an observer and guarantees the closed loop stability. The simulation results show that, besides providing closed-loop stability for systems with integrating and stable modes, the proposed controller may have a better performance than those MPC controllers that make use of an observer to estimate the current states. (C) 2008 Elsevier Ltd. All rights reserved.

Adequacy of Cold Rolling Models to Upgrade Set-up Generation Systems

This paper presents two strategies for the upgrade of set-up generation systems for tandem cold mills. Even though these mills have been modernized mainly due to quality requests, their upgrades may be made intending to replace pre-calculated reference tables. In this case, Bryant and Osborn mill model without adaptive technique is proposed. As a more demanding modernization, Bland and Ford model including adaptation is recommended, although it requires a more complex computational hardware. Advantages and disadvantages of these two systems are compared and discussed and experimental results obtained from an industrial cold mill are shown.