A hybrid dynamic programming for solving a mixed-model sequencing problem with production mix restriction and free interruptions

In this article, we propose a hybrid procedure based on bounded dynamic programming assisted by linear programming to solve the mixed-model sequencing problem with workload minimization with serial workstations, free interruption of the operations and with production mix restrictions. We performed a computational experiment with 23 instances related to a case study of the Nissan powertrain plant located in Barcelona. The results of our proposal are compared with those obtained by mixed integer linear programming.Peer ReviewedPostprint (author's final draft

Free and regular mixed-model sequences by a linear program-assisted hybrid algorithm GRASP-LP

A linear program-assisted hybrid algorithm (GRASP-LP) is presented to solve a mixed-model sequencing problem in an assembly line. The issue of the problem is to obtain manufacturing sequences of product models with the minimum work overload, allowing the free interruption of operations at workstations and preserving the production mix. The implemented GRASP-LP is compared with other procedures through a case study linked with the Nissan’ Engine Plant from Barcelona.Peer ReviewedPostprint (author's final draft

Balancing and Sequencing of Mixed Model Assembly Lines

Assembly lines are cost efficient production systems that mass produce identical products. Due to customer demand, manufacturers use mixed model assembly lines to produce customized products that are not identical. To stay efficient, management decisions for the line such as number of workers and assembly task assignment to stations need to be optimized to increase throughput and decrease cost. In each station, the work to be done depends on the exact product configuration, and is not consistent across all products. In this dissertation, a mixed model line balancing integer program (IP) that considers parallel workers, zoning, task assignment, and ergonomic constraints with the objective of minimizing the number of workers is proposed. Upon observing the limitation of the IP, a Constraint Programming (CP) model that is based on CPLEX CP Optimizer is developed to solve larger assembly line balancing problems. Data from an automotive OEM are used to assess the performance of both the MIP and CP models. Using the OEM data, we show that the CP model outperforms the IP model for bigger problems. A sensitivity analysis is done to assess the cost of enforcing some of the constraint on the computation complexity and the amount of violations to these constraints once they are disabled. Results show that some of the constraints are helpful in reducing the computation time. Specifically, the assignment constraints in which decision variables are fixed or bounded result in a smaller search space. Finally, since the line balance for mixed model is based on task duration averages, we propose a mixed model sequencing model that minimize the number of overload situation that might occur due to variability in tasks times by providing an optimal production sequence. We consider the skip-policy to manage overload situations and allow interactions between stations via workers swimming. An IP model formulation is proposed and a GRASP solution heuristic is developed to solve the problem. Data from the literature are used to assess the performance of the developed heuristic and to show the benefit of swimming in reducing work overload situations

Production Scheduling

Generally speaking, scheduling is the procedure of mapping a set of tasks or jobs (studied objects) to a set of target resources efficiently. More specifically, as a part of a larger planning and scheduling process, production scheduling is essential for the proper functioning of a manufacturing enterprise. This book presents ten chapters divided into five sections. Section 1 discusses rescheduling strategies, policies, and methods for production scheduling. Section 2 presents two chapters about flow shop scheduling. Section 3 describes heuristic and metaheuristic methods for treating the scheduling problem in an efficient manner. In addition, two test cases are presented in Section 4. The first uses simulation, while the second shows a real implementation of a production scheduling system. Finally, Section 5 presents some modeling strategies for building production scheduling systems. This book will be of interest to those working in the decision-making branches of production, in various operational research areas, as well as computational methods design. People from a diverse background ranging from academia and research to those working in industry, can take advantage of this volume

Dynamic Resource Allocation For Coordination Of Inpatient Operations In Hospitals

Healthcare systems face difficult challenges such as increasing complexity of processes, inefficient utilization of resources, high pressure to enhance the quality of care and services, and the need to balance and coordinate the staff workload. Therefore, the need for effective and efficient processes of delivering healthcare services increases. Data-driven approaches, including operations research and predictive modeling, can help overcome these challenges and improve the performance of health systems in terms of quality, cost, patient health outcomes and satisfaction. Hospitals are a key component of healthcare systems with many scarce resources such as caregivers (nurses, physicians) and expensive facilities/equipment. Most hospital systems in the developed world have employed some form of an Electronic Health Record (EHR) system in recent years to improve information flow, health outcomes, and reduce costs. While EHR systems form a critical data backbone, there is a need for platforms that can allow coordinated orchestration of the relatively complex healthcare operations. Information available in EHR systems can play a significant role in providing better operational coordination between different departments/services in the hospital through optimized task/resource allocation. In this research, we propose a dynamic real-time coordination framework for resource and task assignment to improve patient flow and resource utilization across the emergency department (ED) and inpatient unit (IU) network within hospitals. The scope of patient flow coordination includes ED, IUs, environmental services responsible for room/bed cleaning/turnaround, and patient transport services. EDs across the U.S. routinely suffer from extended patient waiting times during admission from the ED to the hospital\u27s inpatient units, also known as ED patient `boarding\u27. This ED patient boarding not only compromises patient health outcomes but also blocks access to ED care for new patients from increased bed occupancy. There are also significant cost implications as well as increased stress and hazards to staff. We carry out this research with the goal of enabling two different modes of coordination implementation across the ED-to-IU network to reduce ED patient boarding: Reactive and Proactive. The proposed `reactive\u27 coordination approach is relatively easy to implement in the presence of modern EHR and hospital IT management systems for it relies only on real-time information readily available in most hospitals. This approach focuses on managing the flow of patients at the end of their ED care and being admitted to specific inpatient units. We developed a deterministic dynamic real-time coordination model for resource and task assignment across the ED-to-IU network using mixed-integer programming. The proposed \u27proactive\u27 coordination approach relies on the power of predictive analytics that anticipate ED patient admissions into the hospital as they are still undergoing ED care. The proactive approach potentially allows additional lead-time for coordinating downstream resources, however, it requires the ability to accurately predict ED patient admissions, target IU for admission, as well as the remaining length-of-stay (care) within the ED. Numerous other studies have demonstrated that modern EHR systems combined with advances in data mining and machine learning methods can indeed facilitate such predictions, with reasonable accuracy. The proposed proactive coordination optimization model extends the reactive deterministic MIP model to account for uncertainties associated with ED patient admission predictions, leading to an effective and efficient proactive stochastic MIP model. Both the reactive and proactive coordination methods have been developed to account for numerous real-world operational requirements (e.g., rolling planning horizon, event-based optimization and task assignments, schedule stability management, patient overflow management, gender matching requirements for IU rooms with double occupancy, patient isolation requirements, equity in staff utilization and equity in reducing ED patient waiting times) and computational efficiency (e.g., through model decomposition and efficient construction of scenarios for proactive coordination). We demonstrate the effectiveness of the proposed models using data from a leading healthcare facility in SE-Michigan, U.S. Results suggest that even the highly practical optimization enabled reactive coordination can lead to dramatic reduction in ED patient boarding times. Results also suggest that signification additional reductions in patient boarding are possible through the proposed proactive approach in the presence of reliable analytics models for prediction ED patient admissions and remaining ED length-of-stay. Future research can focus on further extending the scope of coordination to include admissions management (including any necessary approvals from insurance), coordination needs for admissions that stem from outside the ED (e.g., elective surgeries), as well as ambulance diversions to manage patient flows across the region and hospital networks

Discrete Event Simulation and Optimization Approaches for the Predictive Maintenance of Railway Infrastructure

This thesis is carried out within the PhD Course in Logistics and Transport at CIELI - Italian Centre of Excellence on Logistics, Transport and Infrastructures, University of Genoa. In this work, a discrete event simulation and optimization model is created to schedule the predictive maintenance activities. Nowadays, after a severe decrease of transport demand during the pandemic period, rail public transport is resuming a central role for both freight and passenger transport. To cope with this increase in demand, to maintain high safety standards and to avoid unnecessary costs, the idea is to switch to predictive maintenance strategy, intervening before an asset failure and when it has reached a certain state of degradation. The degradation and asset future conditions are predicted according to probabilistic models and maintenance deadlines are defined by applying a risk based approach. The problem is first formulated as a MILP (Mixed Integer Linear Programming) optimization problem and then transformed into a simulation-based optimization problem using the ExtendSim software. Different simulative models are created to take into account the stochastic nature of some variables in real processes. After the formal description of the models, some real-world applications are presented. Finally, considerations on the proposed approach are reported highlighting limits and challenges in predictive maintenance planning, such as lack of data and the stochastic and complex environment

Modeling water resources management at the basin level: review and future directions

Water quality / Water resources development / Agricultural production / River basin development / Mathematical models / Simulation models / Water allocation / Policy / Economic aspects / Hydrology / Reservoir operation / Groundwater management / Drainage / Conjunctive use / Surface water / GIS / Decision support systems / Optimization methods / Water supply

A Digital Twin Framework for Production Planning Optimization: Applications for Make-To-Order Manufacturers

In this dissertation, we develop a Digital Twin framework for manufacturing systems and apply it to various production planning and scheduling problems faced by Make-To-Order (MTO) firms. While this framework can be used to digitally represent a particular manufacturing environment with high fidelity, our focus is in using it to generate realistic settings to test production planning and scheduling algorithms in practice. These algorithms have traditionally been tested by either translating a practical situation into the necessary modeling constructs, without discussion of the assumptions and inaccuracies underlying this translation, or by generating random instances of the modeling constructs, without assessing the limitations in accurately representing production environments. The consequence has been a serious gap between theory advancement and industry practice. The major goal of this dissertation is to develop a framework that allows for practical testing, evaluation, and implementation of new approaches for seamless industry adoption. We develop this framework as a modular software package and emphasize the practicality and configurability of the framework, such that minimal modelling effort is required to apply the framework to a multitude of optimization problems and manufacturing systems. Throughout this dissertation, we emphasize the importance of the underlying scheduling problems which provide the basis for additional operational decision making. We focus on the computational evaluation and comparisons of various modeling choices within the developed frameworks, with the objective of identifying models which are both effective and computationally efficient. In Part 1 of this dissertation, we consider a class of Production Planning and Execution problems faced by job shop manufacturing systems. In Part 2 of this dissertation, we consider a class of scheduling problems faced by manufacturers whose production system is dominated by a single operation