A review of discrete-time optimization models for tactical production planning

This is an Accepted Manuscript of an article published in International Journal of Production Research on 27 Mar 2014, available online: http://doi.org/10.1080/00207543.2014.899721[EN] This study presents a review of optimization models for tactical production planning. The objective of this research is to identify streams and future research directions in this field based on the different classification criteria proposed. The major findings indicate that: (1) the most popular production-planning area is master production scheduling with a big-bucket time-type period; (2) most of the considered limited resources correspond to productive resources and, to a lesser extent, to inventory capacities; (3) the consideration of backlogs, set-up times, parallel machines, overtime capacities and network-type multisite configuration stand out in terms of extensions; (4) the most widely used modelling approach is linear/integer/mixed integer linear programming solved with exact algorithms, such as branch-and-bound, in commercial MIP solvers; (5) CPLEX, C and its variants and Lindo/Lingo are the most popular development tools among solvers, programming languages and modelling languages, respectively; (6) most works perform numerical experiments with random created instances, while a small number of works were validated by real-world data from industrial firms, of which the most popular are sawmills, wood and furniture, automobile and semiconductors and electronic devices.This study has been funded by the Universitat Politècnica de València projects: ‘Material Requirement Planning Fourth Generation (MRPIV)’ (Ref. PAID-05-12) and ‘Quantitative Models for the Design of Socially Responsible Supply Chains under Uncertainty Conditions. Application of Solution Strategies based on Hybrid Metaheuristics’ (PAID-06-12).Díaz-Madroñero Boluda, FM.; Mula, J.; Peidro Payá, D. (2014). A review of discrete-time optimization models for tactical production planning. International Journal of Production Research. 52(17):5171-5205. doi:10.1080/00207543.2014.899721S51715205521

Integrated Production and Distribution planning of perishable goods

Tese de doutoramento. Programa Doutoral em Engenharia Industrial e Gestão. Faculdade de Engenharia. Universidade do Porto. 201

Incorporating Memory and Learning Mechanisms Into Meta-RaPS

Due to the rapid increase of dimensions and complexity of real life problems, it has become more difficult to find optimal solutions using only exact mathematical methods. The need to find near-optimal solutions in an acceptable amount of time is a challenge when developing more sophisticated approaches. A proper answer to this challenge can be through the implementation of metaheuristic approaches. However, a more powerful answer might be reached by incorporating intelligence into metaheuristics. Meta-RaPS (Metaheuristic for Randomized Priority Search) is a metaheuristic that creates high quality solutions for discrete optimization problems. It is proposed that incorporating memory and learning mechanisms into Meta-RaPS, which is currently classified as a memoryless metaheuristic, can help the algorithm produce higher quality results. The proposed Meta-RaPS versions were created by taking different perspectives of learning. The first approach taken is Estimation of Distribution Algorithms (EDA), a stochastic learning technique that creates a probability distribution for each decision variable to generate new solutions. The second Meta-RaPS version was developed by utilizing a machine learning algorithm, Q Learning, which has been successfully applied to optimization problems whose output is a sequence of actions. In the third Meta-RaPS version, Path Relinking (PR) was implemented as a post-optimization method in which the new algorithm learns the good attributes by memorizing best solutions, and follows them to reach better solutions. The fourth proposed version of Meta-RaPS presented another form of learning with its ability to adaptively tune parameters. The efficiency of these approaches motivated us to redesign Meta-RaPS by removing the improvement phase and adding a more sophisticated Path Relinking method. The new Meta-RaPS could solve even the largest problems in much less time while keeping up the quality of its solutions. To evaluate their performance, all introduced versions were tested using the 0-1 Multidimensional Knapsack Problem (MKP). After comparing the proposed algorithms, Meta-RaPS PR and Meta-RaPS Q Learning appeared to be the algorithms with the best and worst performance, respectively. On the other hand, they could all show superior performance than other approaches to the 0-1 MKP in the literature

Design and analysis of algorithms for solving a class of routing shop scheduling problems

Ph.DDOCTOR OF PHILOSOPH

Balancing and scheduling tasks in assembly lines with sequence-dependent setup times

The classical Simple Assembly Line Balancing Problem (SALBP) has been widely enriched over the past few years with many realistic approaches and much effort has been made to reduce the distance between the academic theory and the industrial reality. Despite this effort, the scheduling of the execution of tasks assigned to every workstation following the balancing of the assembly line has been scarcely reported in the scientific literature. This is supposed to be an operational concern that the worker should solve himself, but in several real environments, setups between tasks exist and optimal or near-optimal tasks schedules should be provided inside each workstation. The problem presented in this paper adds sequence-dependent setup time considerations to the classical SALBP in the following way: whenever a task is assigned next to another at the same workstation, a setup time must be added to compute the global workstation time. After formulating a mathematical model for this innovative problem and showing the high combinatorial nature of the problem, eight different heuristic rules and a GRASP algorithm are designed and tested for solving the problem in reasonable computational time.Peer Reviewe

Evaluación de funciones de utilidad de GRASP en la programación de producción para minimizar la tardanza total ponderada en una máquina

This paper considers the total weighted tardiness minimization in a single machineenvironment (1|| wj Tj ) a scheduling problem which has been proved to be NP-Hard. The solution approach uses the Greedy Randomized Adaptive Search Procedure (GRASP) meta-heuristic known for the quality of the solutions it can generate and the selective ability of its utility function during the construction phase. This work proposes and analyses three different utility functions for the problem in question. A statistical study showed significant differences between the mean values obtained from the proposed utility functions. The computational experiments were carried out using problems instances found in the OR-LIBRARY, and the outcome of these experiments were competitive solutions compared to the best known values of the instances involved. This work also shows the ease of developing GRASP methods for solving scheduling problems in a simple spreadsheet software such as MS Excel.Este artículo aborda la minimización de la tardanza total ponderada en un entorno de producción (1|| wj Tj ) que es conocido en complejidad como de tipo NP-hard. El enfoque de solución propuesto utiliza la metaheurística Greedy Randomized Adaptive Search Procedure (GRASP), la cual es reconocida por la correlación existente entre la calidad de las soluciones y la capacidad discriminante de la función de utilidad empleada en su fase constructiva. Este trabajo propone y analiza tres diferentes funciones de utilidad para este problema en particular. El desempeño de estas funciones se evaluó mediante un estudio estadístico que evidenció diferencias significativas en los valores medios de tardanza total ponderada, explicadas por el factor función de utilidad. La fase experimental se desarrolló usando instancias de la librería OR-LIBRARY y permitió obtener soluciones competitivas en calidad con respecto a los mejores valores conocidos para las instancias de este problema. Este trabajo ilustra la potencialidad de uso de métodos GRASP implementados en una hoja de cálculo normal para hallar soluciones a problemas de programación de la producción

MRP IV: Planificación de requerimientos de materiales cuarta generación. Integración de la planificación de la producción y del transporte de aprovisionamiento

Tesis por compendioEl sistema de planificación de requerimientos de materiales o MRP (Material Requirement Planning), desarrollado por Orlicky en 1975, sigue siendo en nuestros días y, a pesar de sus deficiencias identificadas, el sistema de planificación de la producción más utilizado por las empresas industriales. Las evoluciones del MRP se vieron reflejadas en el sistema MRPII (Manufacturing Resource Planning), que considera restricciones de capacidad productiva, MRPIII (Money Resource Planning), que introduce la función de finanzas; y la evolución comercial del mismo en el ERP (Enterprise Resource Planning), que incorpora modularmente todas las funciones de la empresa en un único sistema de decisión, cuyo núcleo central es el MRP. Los desarrollos posteriores de los sistemas ERP han incorporado las nuevas tecnologías de la información y comunicaciones. Asimismo, éstos se han adaptado al contexto económico actual caracterizado por la globalización de los negocios y la deslocalización de los proveedores desarrollando otras funciones como la gestión de la cadena de suministro o del transporte, entre otros. Por otro lado, existen muchos trabajos en la literatura académica que han intentado resolver algunas de las debilidades del MRP tales como la optimización de los resultados, la consideración de la incertidumbre en determinados parámetros, el inflado de los tiempos de entrega, etc. Sin embargo, tanto en el ámbito comercial como en el científico, el MRP y sus variantes se centran en el requerimiento de los materiales y en la planificación de las capacidades de producción, lo que es su desventaja principal en aquellas cadenas de suministro donde existe una gran deslocalización de los proveedores de materias primas y componentes. En estos entornos, la planificación del transporte adquiere un protagonismo fundamental, puesto que los elevados costes y las restricciones logísticas suelen hacer subóptimos e incluso infactibles los planes de producción propuestos, siendo la re-planificación manual una práctica habitual en las empresas. Esta tesis doctoral propone un modelo denominado MRPIV, que considera de forma integrada las decisiones de la planificación de materiales, capacidades de recursos de producción y el transporte, con las restricciones propias de este último, tales como diferentes modos de recogida (milk-run, camión completo, rutas) en la cadena de suministro con el objetivo de evitar la suboptimización de estos planes que en la actualidad se generan usualmente de forma secuencial e independiente. El modelo propuesto se ha validado en una cadena de suministro del sector del automóvil confirmando la reducción de costes totales y una planificación más eficiente del transporte de los camiones necesarios para efectuar el aprovisionamiento.Díaz-Madroñero Boluda, FM. (2015). MRP IV: Planificación de requerimientos de materiales cuarta generación. Integración de la planificación de la producción y del transporte de aprovisionamiento [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/48524TESISCompendi