Improvement to an existing multi-level capacitated lot sizing problem considering setup carryover, backlogging, and emission control

This paper presents a multi-level, multi-item, multi-period capacitated lot-sizing problem. The lot-sizing problem studies can obtain production quantities, setup decisions and inventory levels in each period fulfilling the demand requirements with limited capacity resources, considering the Bill of Material (BOM) structure while simultaneously minimizing the production, inventory, and machine setup costs. The paper proposes an exact solution to Chowdhury et al. (2018)\u27s[1] developed model, which considers the backlogging cost, setup carryover & greenhouse gas emission control to its model complexity. The problem contemplates the Dantzig-Wolfe (D.W.) decomposition to decompose the multi-level capacitated problem into a single-item uncapacitated lot-sizing sub-problem. To avoid the infeasibilities of the weighted problem (WP), an artificial variable is introduced, and the Big-M method is employed in the D.W. decomposition to produce an always feasible master problem. In addition, Wagner & Whitin\u27s[2] forward recursion algorithm is also incorporated in the solution approach for both end and component items to provide the minimum cost production plan. Introducing artificial variables in the D.W. decomposition method is a novel approach to solving the MLCLSP model. A better performance was achieved regarding reduced computational time (reduced by 50%) and optimality gap (reduced by 97.3%) in comparison to Chowdhury et al. (2018)\u27s[1] developed model

Combining Column Generation and Lagrangian Relaxation

Although the possibility to combine column generation and Lagrangian relaxation has been known for quite some time, it has only recently been exploited in algorithms. In this paper, we discuss ways of combining these techniques. We focus on solving the LP relaxation of the Dantzig-Wolfe master problem. In a first approach we apply Lagrangian relaxation directly to this extended formulation, i.e. no simplex method is used. In a second one, we use Lagrangian relaxation to generate new columns, that is Lagrangian relaxation is applied to the compact for-mulation. We will illustrate the ideas behind these algorithms with an application in Lot-sizing. To show the wide applicability of these techniques, we also discuss applications in integrated vehicle and crew scheduling, plant location and cutting stock problems.column generation;Lagrangean relaxation;cutting stock problem;lotsizing;vehicle and crew scheduling

Combining Column Generation and Lagrangian Relaxation

Although the possibility to combine column generation and Lagrangian relaxation has been known for quite some time, it has only recently been exploited in algorithms. In this paper, we discuss ways of combining these techniques. We focus on solving the LP relaxation of the Dantzig-Wolfe master problem. In a first approach we apply Lagrangian relaxation directly to this extended formulation, i.e. no simplex method is used. In a second one, we use Lagrangian relaxation to generate new columns, that is Lagrangian relaxation is applied to the compact for-mulation. We will illustrate the ideas behind these algorithms with an application in Lot-sizing. To show the wide applicability of these techniques, we also discuss applications in integrated vehicle and crew scheduling, plant location and cutting stock problems

Reformulation and decomposition of integer programs

In this survey we examine ways to reformulate integer and mixed integer programs. Typically, but not exclusively, one reformulates so as to obtain stronger linear programming relaxations, and hence better bounds for use in a branch-and-bound based algorithm. First we cover in detail reformulations based on decomposition, such as Lagrangean relaxation, Dantzig-Wolfe column generation and the resulting branch-and-price algorithms. This is followed by an examination of Benders’ type algorithms based on projection. Finally we discuss in detail extended formulations involving additional variables that are based on problem structure. These can often be used to provide strengthened a priori formulations. Reformulations obtained by adding cutting planes in the original variables are not treated here.Integer program, Lagrangean relaxation, column generation, branch-and-price, extended formulation, Benders' algorithm

Local cuts and two-period convex hull closures for big-bucket lot-sizing problems

Despite the significant attention they have drawn, big bucket lot-sizing problems remain notoriously difficult to solve. Previous work of Akartunali and Miller (2012) presented results (computational and theoretical) indicating that what makes these problems difficult are the embedded single-machine, single-level, multi-period submodels. We therefore consider the simplest such submodel, a multi-item, two-period capacitated relaxation. We propose a methodology that can approximate the convex hulls of all such possible relaxations by generating violated valid inequalities. To generate such inequalities, we separate two-period projections of fractional LP solutions from the convex hulls of the two-period closure we study. The convex hull representation of the two-period closure is generated dynamically using column generation. Contrary to regular column generation, our method is an outer approximation, and therefore can be used efficiently in a regular branch-and-bound procedure. We present computational results that illustrate how these two-period models could be effective in solving complicated problems

Large-Scale Optimisation in Operations Management: Algorithms and Applications

The main contributions of this dissertation are the design, development and application of optimisation methodology, models and algorithms for large-scale problems arising in Operations Management. The first chapter introduces constraint transformations and valid inequalities that enhance the performance of column generation and Lagrange relaxation. I establish theoretical connections with dual-space reduction techniques and develop a novel algorithm that combines Lagrange relaxation and column generation. This algorithm is embedded in a branch-and-price scheme, which combines large neighbourhood and local search to generate upper bounds. Computational experiments on capacitated lot sizing show significant improvements over existing methodologies. The second chapter introduces a Horizon-Decomposition approach that partitions the problem horizon in contiguous intervals. In this way, subproblems identical to the original problem but of smaller size are created. The size of the master problem and the subproblems are regulated via two scalar parameters, giving rise to a family of reformulations. I investigate the efficiency of alternative parameter configurations empirically. Computational experiments on capacitated lot sizing demonstrate superior performance against commercial solvers. Finally, extensions to generic mathematical programs are presented. The final chapter shows how large-scale optimisation methods can be applied to complex operational problems, and presents a modelling framework for scheduling the transhipment operations of the Noble Group, a global supply chain manager of energy products. I focus on coal operations, where coal is transported from mines to vessels using barges and floating cranes. Noble pay millions of dollars in penalties for delays, and for additional resources hired to minimize the impact of delays. A combination of column generation and dedicated heuristics reduces the cost of penalties and additional resources, and improves the efficiency of the operations. Noble currently use the developed framework, and report significant savings attributed to it

Lot-Sizing Problem for a Multi-Item Multi-level Capacitated Batch Production System with Setup Carryover, Emission Control and Backlogging using a Dynamic Program and Decomposition Heuristic

Wagner and Whitin (1958) develop an algorithm to solve the dynamic Economic Lot-Sizing Problem (ELSP), which is widely applied in inventory control, production planning, and capacity planning. The original algorithm runs in O(T^2) time, where T is the number of periods of the problem instance. Afterward few linear-time algorithms have been developed to solve the Wagner-Whitin (WW) lot-sizing problem; examples include the ELSP and equivalent Single Machine Batch-Sizing Problem (SMBSP). This dissertation revisits the algorithms for ELSPs and SMBSPs under WW cost structure, presents a new efficient linear-time algorithm, and compares the developed algorithm against comparable ones in the literature. The developed algorithm employs both lists and stacks data structure, which is completely a different approach than the rest of the algorithms for ELSPs and SMBSPs. Analysis of the developed algorithm shows that it executes fewer number of basic actions throughout the algorithm and hence it improves the CPU time by a maximum of 51.40% for ELSPs and 29.03% for SMBSPs. It can be concluded that the new algorithm is faster than existing algorithms for both ELSPs and SMBSPs. Lot-sizing decisions are crucial because these decisions help the manufacturer determine the quantity and time to produce an item with a minimum cost. The efficiency and productivity of a system is completely dependent upon the right choice of lot-sizes. Therefore, developing and improving solution procedures for lot-sizing problems is key. This dissertation addresses the classical Multi-Level Capacitated Lot-Sizing Problem (MLCLSP) and an extension of the MLCLSP with a Setup Carryover, Backlogging and Emission control. An item Dantzig Wolfe (DW) decomposition technique with an embedded Column Generation (CG) procedure is used to solve the problem. The original problem is decomposed into a master problem and a number of subproblems, which are solved using dynamic programming approach. Since the subproblems are solved independently, the solution of the subproblems often becomes infeasible for the master problem. A multi-step iterative Capacity Allocation (CA) heuristic is used to tackle this infeasibility. A Linear Programming (LP) based improvement procedure is used to refine the solutions obtained from the heuristic method. A comparative study of the proposed heuristic for the first problem (MLCLSP) is conducted and the results demonstrate that the proposed heuristic provide less optimality gap in comparison with that obtained in the literature. The Setup Carryover Assignment Problem (SCAP), which consists of determining the setup carryover plan of multiple items for a given lot-size over a finite planning horizon is modelled as a problem of finding Maximum Weighted Independent Set (MWIS) in a chain of cliques. The SCAP is formulated using a clique constraint and it is proved that the incidence matrix of the SCAP has totally unimodular structure and the LP relaxation of the proposed SCAP formulation always provides integer optimum solution. Moreover, an alternative proof that the relaxed ILP guarantees integer solution is presented in this dissertation. Thus, the SCAP and the special case of the MWIS in a chain of cliques are solvable in polynomial time

A column generation approach to the discrete lot sizing and scheduling problem on parallel machines

In this work, we study the discrete lot sizing and scheduling problem (DSLP) in identical parallel resources with (sequence-independent) setup costs and inventory holding costs. We propose a Dantzig-Wolfe decomposition of a known formulation and describe a branch-and-price and column generation procedure to solve the problem to optimality. The results show that the lower bounds provided by the reformulated model are stronger than the lower bounds provided by the linear programming (LP) relaxation of the original model.info:eu-repo/semantics/publishedVersio

Matheuristics:survey and synthesis

In integer programming and combinatorial optimisation, people use the term matheuristics to refer to methods that are heuristic in nature, but draw on concepts from the literature on exact methods. We survey the literature on this topic, with a particular emphasis on matheuristics that yield both primal and dual bounds (i.e., upper and lower bounds in the case of a minimisation problem). We also make some comments about possible future developments

A computational analysis of lower bounds for big bucket production planning problems

In this paper, we analyze a variety of approaches to obtain lower bounds for multi-level production planning problems with big bucket capacities, i.e., problems in which multiple items compete for the same resources. We give an extensive survey of both known and new methods, and also establish relationships between some of these methods that, to our knowledge, have not been presented before. As will be highlighted, understanding the substructures of difficult problems provide crucial insights on why these problems are hard to solve, and this is addressed by a thorough analysis in the paper. We conclude with computational results on a variety of widely used test sets, and a discussion of future research