Lot-Sizing and Scheduling for the Plastic Injection Molding Industry - A Hybrid Optimization Approach

The management of industrial systems is done through different levels, ranging from strategic (designing the system), to tactical (planning the activities and assigning the resources) and operational (scheduling the activities). In this paper, we focus on the latter level by considering a real-world scheduling problem from a plastic injection company, where the production process combines parallel machines and a set of resources. We present a scheduling algorithm that combines a metaheuristic and a list algorithm. Two metaheuristics are tested and compared when used in the proposed scheduling approach: the stochastic descent and the simulated annealing. The method’s performances are analyzed through an experimental study and the obtained results show that its outcomes outperform those of the scheduling policy conducted in a case-study company. Moreover, besides being able to solve large real-world problems in a reasonable amount of time, the proposed approach has a structure that makes it flexible and easily adaptable to several different planning and scheduling problems. Indeed, since it is composed by a reusable generic part, the metaheuristic, it is only required to develop a list algorithm adapted to the objective function and constraints of the new problem to be solved.FEDER Hauts de France and CEA Tec

A Novel MILP Model for the Production, Lot Sizing, and Scheduling of Automotive Plastic Components on Parallel Flexible Injection Machines with Setup Common Operators

[EN] In this article, a mixed integer linear program (MILP) model is proposed for the production, lot sizing, and scheduling of automotive plastic components to minimize the setup, inventory, stockout, and backorder costs, by taking into account injection molds as the main index to schedule on parallel flexible injection machines. The proposed MILP considers the minimum and maximum inventory capacities and penalizes stockout. A relevant characteristic of the modeled problem is the dependence between mold setups to produce plastic components. The lot sizing and scheduling problem solution results in the assignment of molds to machines during a specific time period and in the calculation of the number of components to be produced, which is often called lot size, following a sequence-dependent setup time. Depending on the machine on which the mold is setup, the number of units to be produced will be distinct because machines differ from one another. The stock coverage, defined in demand days, is also included in the MILP to avoid backorders, which is highly penalized in the automotive supply chain. Added to this, the proposed model is extended by considering setup common operators to respond to and fulfill the constraints that appear in automotive plastic enterprises. In this regard, the MILP presented solves a lot-sizing and scheduling problem, emerged in a second-tier supplier of a real automotive supply chain. Finally, this article validates the MILP by performing experiments with different sized instances, including small, medium, and large. The large-sized dataset is characterized by replicating the amount of data used in the real enterprise, which is the object of this study. The goodness of the model is evaluated with the computational time and the deviation of the obtained results as regards to the optimal solution.Thiis work was supported by the Conselleria de Educacion, Investigacion, Cultura y Deporte-Generalitat Valenciana for hiring predoctoral research staff with Grant no. ACIF/2018/170 and European Social Fund with Grant Operational Program of FSE 2014-2020, the Valencian Community, and the authors would like to acknowledge the support of the researchers participating in the collaborative projects 'Cloud Collaborative Manufacturing Networks' (C2NET) (http://c2net-project.eu/), which has received funding from the EU Horizon 2020 Research and Innovation Programme with grant agreement no. 63690, and "Zero Defects Manufacturing Platform" (ZDMP) (http://www.zdmp.eu), which has received funding from the EU Horizon 2020 Research and Innovation Programme with grant agreement no. 825631.Andres, B.; Guzmán-Ortiz, BE.; Poler, R. (2021). A Novel MILP Model for the Production, Lot Sizing, and Scheduling of Automotive Plastic Components on Parallel Flexible Injection Machines with Setup Common Operators. Complexity. 2021:1-16. https://doi.org/10.1155/2021/6667516116202

Relax-and-fix heuristics applied to a real-world lot-sizing and scheduling problem in the personal care consumer goods industry

This paper addresses an integrated lot-sizing and scheduling problem in the industry of consumer goods for personal care, a very competitive market in which the good customer service level and the cost management show up in the competition for the clients. In this research, a complex operational environment composed of unrelated parallel machines with limited production capacity and sequence-dependent setup times and costs is studied. There is also a limited finished-goods storage capacity, a characteristic not found in the literature. Backordering is allowed but it is extremely undesirable. The problem is described through a mixed integer linear programming formulation. Since the problem is NP-hard, relax-and-fix heuristics with hybrid partitioning strategies are investigated. Computational experiments with randomly generated and also with real-world instances are presented. The results show the efficacy and efficiency of the proposed approaches. Compared to current solutions used by the company, the best proposed strategies yield results with substantially lower costs, primarily from the reduction in inventory levels and better allocation of production batches on the machines

Integrated Models and Algorithms for Automotive Supply Chain Optimization

The automotive industry is one of the most important economic sectors, and the efficiency of its supply chain is crucial for ensuring its profitability. Developing and applying techniques to optimize automotive supply chains can lead to favorable economic outcomes and customer satisfaction. In this dissertation, we develop integrated models and algorithms for automotive supply chain optimization. Our objective is to explore methods that can increase the competitiveness of the automotive supply chain via maximizing efficiency and service levels. Based on interactions with an automotive industry supplier, we define an automotive supply chain planning problem at a detailed operational level while taking into account realistic assumptions such as sequence-dependent setups on parallel machines, auxiliary resource assignments, and multiple types of costs. We model the research problem of interest using mixed-integer linear programming. Given the problem’s NP-hard complexity, we develop a hybrid metaheuristic approach, including a constructive heuristic and an effective encoding-decoding strategy, to minimize the total integrated cost of production setups, inventory holding, transportation, and production outsourcing. Furthermore, since there are often conflicting objectives of interest in automotive supply chains, we investigate simultaneously optimizing total cost and customer service level via a multiobjective optimization methodology. Finally, we analyze the impact of adding an additional transportation mode, which offers a cost vs. delivery time option to the manufacturer, on total integrated cost. Our results demonstrate the promising performance of the proposed solution approaches to analyze the integrated cost minimization problem to near optimality in a timely manner, lowering the cost of the automotive supply chain. The proposed bicriteria, hybrid metaheuristic offers decision makers several options to trade-off cost with service level via identified Pareto-optimal solutions. The effect of the available additional transportation mode’s lead time is found to be bigger than its cost on the total integrated cost measure under study

Comparison of heuristics for an economic lot scheduling problem with deliberated coproduction

We built on the Economic Lot Scheduling Problem Scheduling (ELSP) literature by making some modifications in order to introduce new constraints which had not been thoroughly studied with a view to simulating specific real situations. Specifically, our aim is to propose and simulate different scheduling policies for a new ELSP variant: Deliberated Coproduction. This problem comprises a product system in an ELSP environment in which we may choose if more than one product can be produced on the machine at a given time. We expressly consider the option of coproducing two products whose demand is not substitutable. In order to draw conclusions, a simulation model and its results were developed in the article by employing modified Bomberger data which include two items that could be produced simultaneouslyPeer Reviewe

Planning and Scheduling Optimization

Although planning and scheduling optimization have been explored in the literature for many years now, it still remains a hot topic in the current scientific research. The changing market trends, globalization, technical and technological progress, and sustainability considerations make it necessary to deal with new optimization challenges in modern manufacturing, engineering, and healthcare systems. This book provides an overview of the recent advances in different areas connected with operations research models and other applications of intelligent computing techniques used for planning and scheduling optimization. The wide range of theoretical and practical research findings reported in this book confirms that the planning and scheduling problem is a complex issue that is present in different industrial sectors and organizations and opens promising and dynamic perspectives of research and development

Models and Algorithms for the Optimisation of Replenishment, Production and Distribution Plans in Industrial Enterprises

Tesis por compendio[ES] La optimización en las empresas manufactureras es especialmente importante, debido a las grandes inversiones que realizan, ya que a veces estas inversiones no obtienen el rendimiento esperado porque los márgenes de beneficio de los productos son muy ajustados. Por ello, las empresas tratan de maximizar el uso de los recursos productivos y financieros minimizando el tiempo perdido y, al mismo tiempo, mejorando los flujos de los procesos y satisfaciendo las necesidades del mercado. El proceso de planificación es una actividad crítica para las empresas. Esta tarea implica grandes retos debido a los cambios del mercado, las alteraciones en los procesos de producción dentro de la empresa y en la cadena de suministro, y los cambios en la legislación, entre otros. La planificación del aprovisionamiento, la producción y la distribución desempeña un papel fundamental en el rendimiento de las empresas manufactureras, ya que una planificación ineficaz de los proveedores, los procesos de producción y los sistemas de distribución contribuye a aumentar los costes de los productos, a alargar los plazos de entrega y a reducir los beneficios. La planificación eficaz es un proceso complejo que abarca una amplia gama de actividades para garantizar que los equipos, los materiales y los recursos humanos estén disponibles en el momento y el lugar adecuados. Motivados por la complejidad de la planificación en las empresas manufactureras, esta tesis estudia y desarrolla herramientas cuantitativas para ayudar a los planificadores en los procesos de la planificación del aprovisionamiento, producción y distribución. Desde esta perspectiva, se proponen modelos realistas y métodos eficientes para apoyar la toma de decisiones en las empresas industriales, principalmente en las pequeñas y medianas empresas (PYMES). Las aportaciones de esta tesis suponen un avance científico basado en una exhaustiva revisión bibliográfica sobre la planificación del aprovisionamiento, la producción y la distribución que ayuda a comprender los principales modelos y algoritmos utilizados para resolver estos planes, y pone en relieve las tendencias y las futuras direcciones de investigación. También proporciona un marco holístico para caracterizar los modelos y algoritmos centrándose en la planificación de la producción, la programación y la secuenciación. Esta tesis también propone una herramienta de apoyo a la decisión para seleccionar un algoritmo o método de solución para resolver problemas concretos de la planificación del aprovisionamiento, producción y distribución en función de su complejidad, lo que permite a los planificadores no duplicar esfuerzos de modelización o programación de técnicas de solución. Por último, se desarrollan nuevos modelos matemáticos y enfoques de solución de última generación, como los algoritmos matheurísticos, que combinan la programación matemática y las técnicas metaheurísticas. Los nuevos modelos y algoritmos comprenden mejoras en términos de rendimiento computacional, e incluyen características realistas de los problemas del mundo real a los que se enfrentan las empresas de fabricación. Los modelos matemáticos han sido validados con un caso de una importante empresa del sector de la automoción en España, lo que ha permitido evaluar la relevancia práctica de estos novedosos modelos utilizando instancias de gran tamaño, similares a las existentes en la empresa objeto de estudio. Además, los algoritmos matheurísticos han sido probados utilizando herramientas libres y de código abierto. Esto también contribuye a la práctica de la investigación operativa, y proporciona una visión de cómo desplegar estos métodos de solución y el tiempo de cálculo y rendimiento de la brecha que se puede obtener mediante el uso de software libre o de código abierto.[CA] L'optimització a les empreses manufactureres és especialment important, a causa de les grans inversions que realitzen, ja que de vegades aquestes inversions no obtenen el rendiment esperat perquè els marges de benefici dels productes són molt ajustats. Per això, les empreses intenten maximitzar l'ús dels recursos productius i financers minimitzant el temps perdut i, alhora, millorant els fluxos dels processos i satisfent les necessitats del mercat. El procés de planificació és una activitat crítica per a les empreses. Aquesta tasca implica grans reptes a causa dels canvis del mercat, les alteracions en els processos de producció dins de l'empresa i la cadena de subministrament, i els canvis en la legislació, entre altres. La planificació de l'aprovisionament, la producció i la distribució té un paper fonamental en el rendiment de les empreses manufactureres, ja que una planificació ineficaç dels proveïdors, els processos de producció i els sistemes de distribució contribueix a augmentar els costos dels productes, allargar els terminis de lliurament i reduir els beneficis. La planificació eficaç és un procés complex que abasta una àmplia gamma d'activitats per garantir que els equips, els materials i els recursos humans estiguen disponibles al moment i al lloc adequats. Motivats per la complexitat de la planificació a les empreses manufactureres, aquesta tesi estudia i desenvolupa eines quantitatives per ajudar als planificadors en els processos de la planificació de l'aprovisionament, producció i distribució. Des d'aquesta perspectiva, es proposen models realistes i mètodes eficients per donar suport a la presa de decisions a les empreses industrials, principalment a les petites i mitjanes empreses (PIMES). Les aportacions d'aquesta tesi suposen un avenç científic basat en una exhaustiva revisió bibliogràfica sobre la planificació de l'aprovisionament, la producció i la distribució que ajuda a comprendre els principals models i algorismes utilitzats per resoldre aquests plans, i posa de relleu les tendències i les futures direccions de recerca. També proporciona un marc holístic per caracteritzar els models i algorismes centrant-se en la planificació de la producció, la programació i la seqüenciació. Aquesta tesi també proposa una eina de suport a la decisió per seleccionar un algorisme o mètode de solució per resoldre problemes concrets de la planificació de l'aprovisionament, producció i distribució en funció de la seua complexitat, cosa que permet als planificadors no duplicar esforços de modelització o programació de tècniques de solució. Finalment, es desenvolupen nous models matemàtics i enfocaments de solució d'última generació, com ara els algoritmes matheurístics, que combinen la programació matemàtica i les tècniques metaheurístiques. Els nous models i algoritmes comprenen millores en termes de rendiment computacional, i inclouen característiques realistes dels problemes del món real a què s'enfronten les empreses de fabricació. Els models matemàtics han estat validats amb un cas d'una important empresa del sector de l'automoció a Espanya, cosa que ha permés avaluar la rellevància pràctica d'aquests nous models utilitzant instàncies grans, similars a les existents a l'empresa objecte d'estudi. A més, els algorismes matheurístics han estat provats utilitzant eines lliures i de codi obert. Això també contribueix a la pràctica de la investigació operativa, i proporciona una visió de com desplegar aquests mètodes de solució i el temps de càlcul i rendiment de la bretxa que es pot obtindre mitjançant l'ús de programari lliure o de codi obert.[EN] Optimisation in manufacturing companies is especially important, due to the large investments they make, as sometimes these investments do not obtain the expected return because the profit margins of products are very tight. Therefore, companies seek to maximise the use of productive and financial resources by minimising lost time and, at the same time, improving process flows while meeting market needs. The planning process is a critical activity for companies. This task involves great challenges due to market changes, alterations in production processes within the company and in the supply chain, and changes in legislation, among others. Planning of replenishment, production and distribution plays a critical role in the performance of manufacturing companies because ineffective planning of suppliers, production processes and distribution systems contributes to higher product costs, longer lead times and less profits. Effective planning is a complex process that encompasses a wide range of activities to ensure that equipment, materials and human resources are available in the right time and the right place. Motivated by the complexity of planning in manufacturing companies, this thesis studies and develops quantitative tools to help planners in the replenishment, production and delivery planning processes. From this perspective, realistic models and efficient methods are proposed to support decision making in industrial companies, mainly in small- and medium-sized enterprises (SMEs). The contributions of this thesis represent a scientific breakthrough based on a comprehensive literature review about replenishment, production and distribution planning that helps to understand the main models and algorithms used to solve these plans, and highlights trends and future research directions. It also provides a holistic framework to characterise models and algorithms by focusing on production planning, scheduling and sequencing. This thesis also proposes a decision support tool for selecting an algorithm or solution method to solve concrete replenishment, production and distribution planning problems according to their complexity, which allows planners to not duplicate efforts modelling or programming solution techniques. Finally, new state-of-the-art mathematical models and solution approaches are developed, such as matheuristic algorithms, which combine mathematical programming and metaheuristic techniques. The new models and algorithms comprise improvements in computational performance terms, and include realistic features of real-world problems faced by manufacturing companies. The mathematical models have been validated with a case of an important company in the automotive sector in Spain, which allowed to evaluate the practical relevance of these novel models using large instances, similarly to those existing in the company under study. In addition, the matheuristic algorithms have been tested using free and open-source tools. This also helps to contribute to the practice of operations research, and provides insight into how to deploy these solution methods and the computational time and gap performance that can be obtained by using free or open-source software.This work would not have been possible without the following funding sources: Conselleria de Educación, Investigación, Cultura y Deporte, Generalitat Valenciana for hiring predoctoral research staff with Grant (ACIF/2018/170) and the European Social Fund with the Grant Operational Programme of FSE 2014-2020. Conselleria de Educación, Investigación, Cultura y Deporte, Generalitat Valenciana for predoctoral contract students to stay in research centers outside the research centers outside the Valencian Community (BEFPI/2021/040) and the European Social Fund.Guzmán Ortiz, BE. (2022). Models and Algorithms for the Optimisation of Replenishment, Production and Distribution Plans in Industrial Enterprises [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/187461Compendi

A hybrid multi-objective evolutionary algorithm-based semantic foundation for sustainable distributed manufacturing systems

Rising energy prices, increasing maintenance costs, and strict environmental regimes have augmented the already existing pressure on the contemporary manufacturing environment. Although the decentralization of supply chain has led to rapid advancements in manufacturing systems, finding an efficient supplier simultaneously from the pool of available ones as per customer requirement and enhancing the process planning and scheduling functions are the predominant approaches still needed to be addressed. Therefore, this paper aims to address this issue by considering a set of gear manufacturing industries located across India as a case study. An integrated classifier-assisted evolutionary multi-objective evolutionary approach is proposed for solving the objectives of makespan, energy consumption, and increased service utilization rate, interoperability, and reliability. To execute the approach initially, text-mining-based supervised machine-learning models, namely Decision Tree, Naïve Bayes, Random Forest, and Support Vector Machines (SVM) were adopted for the classification of suppliers into task-specific suppliers. Following this, with the identified suppliers as input, the problem was formulated as a multi-objective Mixed-Integer Linear Programming (MILP) model. We then proposed a Hybrid Multi-Objective Moth Flame Optimization algorithm (HMFO) to optimize process planning and scheduling functions. Numerical experiments have been carried out with the formulated problem for 10 different instances, along with a comparison of the results with a Non-Dominated Sorting Genetic Algorithm (NSGA-II) to illustrate the feasibility of the approach.The project is funded by Department of Science and Technology, Science and Engineering Research Board (DST-SERB), Statutory Body Established through an Act of Parliament: SERB Act 2008, Government of India with Sanction Order No ECR/2016/001808, and also by FCT–Portuguese Foundation for Science and Technology within the R&D Units Projects Scopes: UIDB/00319/2020, UIDP/04077/2020, and UIDB/04077/2020