4 research outputs found

    Modelling and Optimizing Supply Chain Integrated Production Scheduling Problems

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    Globalization and advanced information technologies (e.g., Internet of Things) have considerably impacted supply chains (SCs) by persistently forcing original equipment manufacturers (OEMs) to switch production strategies from make-to-stock (MTS) to make-to-order (MTO) to survive in competition. Generally, an OEM follows the MTS strategy for products with steady demand. In contrast, the MTO strategy exists under a pull system with irregular demand in which the received customer orders are scheduled and launched into production. In comparison to MTS, MTO has the primary challenges of ensuring timely delivery at the lowest possible cost, satisfying the demands of high customization and guaranteeing the accessibility of raw materials throughout the production process. These challenges are increasing substantially since industrial productions are becoming more flexible, diversified, and customized. Besides, independently making the production scheduling decisions from other stages of these SCs often find sub-optimal results, creating substantial challenges to fulfilling demands timely and cost-effectively. Since adequately managing these challenges asynchronously are difficult, constructing optimization models by integrating SC decisions, such as customer requirements, supply portfolio (supplier selection and order allocation), delivery batching decisions, and inventory portfolio (inventory replenishment, consumption, and availability), with shop floor scheduling under a deterministic and dynamic environment is essential to fulfilling customer expectations at the least possible cost. These optimization models are computationally intractable. Consequently, designing algorithms to schedule or reschedule promptly is also highly challenging for these time-sensitive, operationally integrated optimization models. Thus, this thesis focuses on modelling and optimizing SC-integrated production scheduling problems, named SC scheduling problems (SCSPs). The objective of optimizing job shop scheduling problems (JSSPs) is to ensure that the requisite resources are accessible when required and that their utilization is maximally efficient. Although numerous algorithms have been devised, they can sometimes become computationally exorbitant and yield sub-optimal outcomes, rendering production systems inefficient. These could be due to a variety of causes, such as an imbalance in population quality over generations, recurrent generation and evaluation of identical schedules, and permitting an under-performing method to conduct the evolutionary process. Consequently, this study designs two methods, a sequential approach (Chapter 2) and a multi-method approach (Chapter 3), to address the aforementioned issues and to acquire competitive results in finding optimal or near-optimal solutions for JSSPs in a single objective setting. The devised algorithms for JSSPs optimize workflows for each job by accurate mapping between/among related resources, generating more optimal results than existing algorithms. Production scheduling can not be accomplished precisely without considering supply and delivery decisions and customer requirements simultaneously. Thus, a few recent studies have operationally integrated SCs to accurately predict process insights for executing, monitoring, and controlling the planned production. However, these studies are limited to simple shop-floor configurations and can provide the least flexibility to address the MTO-based SC challenges. Thus, this study formulates a bi-objective optimization model that integrates the supply portfolio into a flexible job shop scheduling environment with a customer-imposed delivery window to cost-effectively meet customized and on-time delivery requirements (Chapter 4). Compared to the job shop that is limited to sequence flexibility only, the flexible job shop has been deemed advantageous due to its capacity to provide increased scheduling flexibility (both process and sequence flexibility). To optimize the model, the performance of the multi-objective particle swarm optimization algorithm has been enhanced, with the results providing decision-makers with an increased degree of flexibility, offering a larger number of Pareto solutions, more varied and consistent frontiers, and a reasonable time for MTO-based SCs. Environmental sustainability is spotlighted for increasing environmental awareness and follow-up regulations. Consequently, the related factors strongly regulate the supply portfolio for sustainable development, which remained unexplored in the SCSP as those criteria are primarily qualitative (e.g., green production, green product design, corporate social responsibility, and waste disposal system). These absences may lead to an unacceptable supply portfolio. Thus, this study overcomes the problem by integrating VIKORSORT into the proposed solution methodology of the extended SCSP. In addition, forming delivery batches of heterogeneous customer orders is challenging, as one order can lead to another being delayed. Therefore, the previous optimization model is extended by integrating supply, manufacturing, and delivery batching decisions and concurrently optimizing them in response to heterogeneous customer requirements with time window constraints, considering both economic and environmental sustainability for the supply portfolio (Chapter 5). Since the proposed optimization model is an extension of the flexible job shop, it can be classified as a non-deterministic polynomial-time (NP)-hard problem, which cannot be solved by conventional optimization techniques, particularly in the case of larger instances. Therefore, a reinforcement learning-based hyper-heuristic (HH) has been designed, where four solution-updating heuristics are intelligently guided to deliver the best possible results compared to existing algorithms. The optimization model furnishes a set of comprehensive schedules that integrate the supply portfolio, production portfolio (work-center/machine assignment and customer orders sequencing), and batching decisions. This provides numerous meaningful managerial insights and operational flexibility prior to the execution phase. Recently, SCs have been experiencing unprecedented and massive disruptions caused by an abrupt outbreak, resulting in difficulties for OEMs to recover from disruptive demand-supply equilibrium. Hence, this study proposes a multi-portfolio (supply, production, and inventory portfolios) approach for a proactive-reactive scheme, which concerns the SCSP with complex multi-level products, simultaneously including unpredictably dynamic supply, demand, and shop floor disruptions (Chapter 6). This study considers fabrication and assembly in a multi-level product structure. To effectively address this time-sensitive model based on real-time data, a Q-learning-based multi-operator differential evolution algorithm in a HH has been designed to address disruptive events and generate a timely rescheduling plan. The numerical results and analyses demonstrate the proposed model's capability to effectively address single and multiple disruptions, thus providing significant managerial insights and ensuring SC resilience

    Numerical and Evolutionary Optimization 2020

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    This book was established after the 8th International Workshop on Numerical and Evolutionary Optimization (NEO), representing a collection of papers on the intersection of the two research areas covered at this workshop: numerical optimization and evolutionary search techniques. While focusing on the design of fast and reliable methods lying across these two paradigms, the resulting techniques are strongly applicable to a broad class of real-world problems, such as pattern recognition, routing, energy, lines of production, prediction, and modeling, among others. This volume is intended to serve as a useful reference for mathematicians, engineers, and computer scientists to explore current issues and solutions emerging from these mathematical and computational methods and their applications

    Metodología multiobjetivo basada en un comportamiento evolutivo para programar sistemas de producción flexible job shop. Aplicaciones en la industria metalmecánica

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    El objeto de estudio de la presente tesis es el taller de trabajo flexible en el sector metalmecánico. El problema de investigación se derivó a partir de la búsqueda sistemática de metodologías y algoritmos para programar sistemas productivos; se identificaron configuraciones de variables de proceso no abordadas en la literatura, lo que se considera un vacío en el conocimiento. Consecuente con lo anterior, se diseñó una metodología basada en un algoritmo evolutivo para programar los pedidos en un taller de trabajo flexible, con restricciones de tiempo, secuencia, mantenimiento, liberación de pedidos, disponibilidad, consumo y costo de recurso que varía en el tiempo, con el fin de minimizar tiempo de proceso y costo de producción; incluyó un proceso de ponderación para escoger la mejor secuencia de programación. Como aporte principal se propone una metodología novedosa que al compararla con otras metodologías encontradas en la bibliografía, demostró mejoras mayores al 10% en makespan y costo total del recurso consumidoAbstract: The study object of the present thesis is the flexible job shop in the metal mechanic sector. The research problem was derived from the systematic search of methodologies and algorithms to schedule production systems; configurations of process variables not addressed in the literature were identified, which is considered an empty in knowledge. Consequent with previous, a methodology was designed based on an evolutionary algorithm to schedule orders in a flexible job shop, with time restrictions, sequence, maintenance, liberation of orders, availability, consumption and cost of resource that varies in time, in order to minimize processing time and cost of production; it includes a weighting process to choose the best programming sequence. As main contribution a novel methodology was proposed which, compared with other methodologies found in the literature, it demonstrated greater improvements to 10% in Makespan and total cost of consumed resourceDoctorad
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