A survey of scheduling problems with setup times or costs

Author name used in this publication: C. T. NgAuthor name used in this publication: T. C. E. Cheng2007-2008 > Academic research: refereed > Publication in refereed journalAccepted ManuscriptPublishe

Algorithms for Scheduling Problems

This edited book presents new results in the area of algorithm development for different types of scheduling problems. In eleven chapters, algorithms for single machine problems, flow-shop and job-shop scheduling problems (including their hybrid (flexible) variants), the resource-constrained project scheduling problem, scheduling problems in complex manufacturing systems and supply chains, and workflow scheduling problems are given. The chapters address such subjects as insertion heuristics for energy-efficient scheduling, the re-scheduling of train traffic in real time, control algorithms for short-term scheduling in manufacturing systems, bi-objective optimization of tortilla production, scheduling problems with uncertain (interval) processing times, workflow scheduling for digital signal processor (DSP) clusters, and many more

Dynamic Facility Layout for Cellular and Reconfigurable Manufacturing using Dynamic Programming and Multi-Objective Metaheuristics

The facility layout problem is one of the most classical yet influential problems in the planning of production systems. A well-designed layout minimizes the material handling costs (MHC), personnel flow distances, work in process, and improves the performance of these systems in terms of operating costs and time. Because of this importance, facility layout has a rich literature in industrial engineering and operations research. Facility layout problems (FLPs) are generally concerned with positioning a set of facilities to satisfy some criteria or objectives under certain constraints. Traditional FLPs try to put facilities with the high material flow as close as possible to minimize the MHC. In static facility layout problems (SFLP), the product demands and mixes are considered deterministic parameters with constant values. The material flow between facilities is fixed over the planning horizon. However, in today’s market, manufacturing systems are constantly facing changes in product demands and mixes. These changes make it necessary to change the layout from one period to the other to be adapted to the changes. Consequently, there is a need for dynamic approaches of FLP that aim to generate layouts with high adaptation concerning changes in product demand and mix. This thesis focuses on studying the layout problems, with an emphasis on the changing environment of manufacturing systems. Despite the fact that designing layouts within the dynamic environment context is more realistic, the SFLP is observed to have been remained worthy to be analyzed. Hence, a math-heuristic approach is developed to solve an SFLP. To this aim, first, the facilities are grouped into many possible vertical clusters, second, the best combination of the generated clusters to be in the final layout are selected by solving a linear programming model, and finally, the selected clusters are sequenced within the shop floor. Although the presented math-heuristic approach is effective in solving SFLP, applying approaches to cope with the changing manufacturing environment is required. One of the most well-known approaches to deal with the changing manufacturing environment is the dynamic facility layout problem (DFLP). DFLP suits reconfigurable manufacturing systems since their machinery and material handling devices are reconfigurable to encounter the new necessities for the variations of product mix and demand. In DFLP, the planning horizon is divided into some periods. The goal is to find a layout for each period to minimize the total MHC for all periods and the total rearrangement costs between the periods. Dynamic programming (DP) has been known as one of the effective methods to optimize DFLP. In the DP method, all the possible layouts for every single period are generated and given to DP as its state-space. However, by increasing the number of facilities, it is impossible to give all the possible layouts to DP and only a restricted number of layouts should be fed to DP. This leads to ignoring some layouts and losing the optimality; to deal with this difficulty, an improved DP approach is proposed. It uses a hybrid metaheuristic algorithm to select the initial layouts for DP that lead to the best solution of DP for DFLP. The proposed approach includes two phases. In the first phase, a large set of layouts are generated through a heuristic method. In the second phase, a genetic algorithm (GA) is applied to search for the best subset of layouts to be given to DP. DP, improved by starting with the most promising initial layouts, is applied to find the multi-period layout. Finally, a tabu search algorithm is utilized for further improvement of the solution obtained by improved DP. Computational experiments show that improved DP provides more efficient solutions than DP approaches in the literature. The improved DP can efficiently solve DFLP and find the best layout for each period considering both material handling and layout rearrangement costs. However, rearrangement costs may include some unpredictable costs concerning interruption in production or moving of facilities. Therefore, in some cases, managerial decisions tend to avoid any rearrangements. To this aim, a semi-robust approach is developed to optimize an FLP in a cellular manufacturing system (CMS). In this approach, the pick-up/drop-off (P/D) points of the cells are changed to adapt the layout with changes in product demand and mix. This approach suits more a cellular flexible manufacturing system or a conventional system. A multi-objective nonlinear mixed-integer programming model is proposed to simultaneously search for the optimum number of cells, optimum allocation of facilities to cells, optimum intra- and inter-cellular layout design, and the optimum locations of the P/D points of the cells in each period. A modified non-dominated sorting genetic algorithm (MNSGA-II) enhanced by an improved non-dominated sorting strategy and a modified dynamic crowding distance procedure is used to find Pareto-optimal solutions. The computational experiments are carried out to show the effectiveness of the proposed MNSGA-II against other popular metaheuristic algorithms

Modeling and Analysis of Scheduling Problems Containing Renewable Energy Decisions

With globally increasing energy demands, world citizens are facing one of society\u27s most critical issues: protecting the environment. To reduce the emission of greenhouse gases (GHG), which are by-products of conventional energy resources, people are reducing the consumption of oil, gas, and coal collectively. In the meanwhile, interest in renewable energy resources has grown in recent years. Renewable generators can be installed both on the power grid side and end-use customer side of power systems. Energy management in power systems with multiple microgrids containing renewable energy resources has been a focus of industry and researchers as of late. Further, on-site renewable energy provides great opportunities for manufacturing plants to reduce energy costs when faced with time-varying electricity prices. To efficiently utilize on-site renewable energy generation, production schedules and energy supply decisions need to be coordinated. As renewable energy resources like solar and wind energy typically fluctuate with weather variations, the inherent stochastic nature of renewable energy resources makes the decision making of utilizing renewable generation complex. In this dissertation, we study a power system with one main grid (arbiter) and multiple microgrids (agents). The microgrids (MGs) are equipped to control their local generation and demand in the presence of uncertain renewable generation and heterogeneous energy management settings. We propose an extension to the classical two-stage stochastic programming model to capture these interactions by modeling the arbiter\u27s problem as the first-stage master problem and the agent decision problems as second-stage subproblems. To tackle this problem formulation, we propose a sequential sampling-based optimization algorithm that does not require a priori knowledge of probability distribution functions or selection of samples for renewable generation. The subproblems capture the details of different energy management settings employed at the agent MGs to control heating, ventilation and air conditioning systems; home appliances; industrial production; plug-in electrical vehicles; and storage devices. Computational experiments conducted on the US western interconnect (WECC-240) data set illustrate that the proposed algorithm is scalable and our solutions are statistically verifiable. Our results also show that the proposed framework can be used as a systematic tool to gauge (a) the impact of energy management settings in efficiently utilizing renewable generation and (b) the role of flexible demands in reducing system costs. Next, we present a two-stage, multi-objective stochastic program for flow shops with sequence-dependent setups in order to meet production schedules while managing energy costs. The first stage provides optimal schedules to minimize the total completion time, while the second stage makes energy supply decisions to minimize energy costs under a time-of-use electricity pricing scheme. Power demand for production is met by on-site renewable generation, supply from the main grid, and an energy storage system. An ε-constraint algorithm integrated with an L-shaped method is proposed to analyze the problem. Sets of Pareto optimal solutions are provided for decision-makers and our results show that the energy cost of setup operations is relatively high such that it cannot be ignored. Further, using solar or wind energy can save significant energy costs with solar energy being the more viable option of the two for reducing costs. Finally, we extend the flow shop scheduling problem to a job shop environment under hour-ahead real-time electricity pricing schemes. The objectives of interest are to minimize total weighted completion time and energy costs simultaneously. Besides renewable generation, hour-ahead real-time electricity pricing is another source of uncertainty in this study as electricity prices are released to customers only hours in advance of consumption. A mathematical model is presented and an ε-constraint algorithm is used to tackle the bi-objective problem. Further, to improve computational efficiency and generate solutions in a practically acceptable amount of time, a hybrid multi-objective evolutionary algorithm based on the Non-dominated Sorting Genetic Algorithm II (NSGA-II) is developed. Five methods are developed to calculate chromosome fitness values. Computational tests show that both mathematical modeling and our proposed algorithm are comparable, while our algorithm produces solutions much quicker. Using a single method (rather than five) to generate schedules can further reduce computational time without significantly degrading solution quality

Energy aware hybrid flow shop scheduling

Only if humanity acts quickly and resolutely can we limit global warming' conclude more than 25,000 academics with the statement of SCIENTISTS FOR FUTURE. The concern about global warming and the extinction of species has steadily increased in recent years

Energy Efficient Policies, Scheduling, and Design for Sustainable Manufacturing Systems

Climate mitigation, more stringent regulations, rising energy costs, and sustainable manufacturing are pushing researchers to focus on energy efficiency, energy flexibility, and implementation of renewable energy sources in manufacturing systems. This thesis aims to analyze the main works proposed regarding these hot topics, and to fill the gaps in the literature. First, a detailed literature review is proposed. Works regarding energy efficiency in different manufacturing levels, in the assembly line, energy saving policies, and the implementation of renewable energy sources are analyzed. Then, trying to fill the gaps in the literature, different topics are analyzed more in depth. In the single machine context, a mathematical model aiming to align the manufacturing power required to a renewable energy supply in order to obtain the maximum profit is developed. The model is applied to a single work center powered by the electric grid and by a photovoltaic system; afterwards, energy storage is also added to the power system. Analyzing the job shop context, switch off policies implementing workload approach and scheduling considering variable speed of the machines and power constraints are proposed. The direct and indirect workloads of the machines are considered to support the switch on/off decisions. A simulation model is developed to test the proposed policies compared to others presented in the literature. Regarding the job shop scheduling, a fixed and variable power constraints are considered, assuming the minimization of the makespan as the objective function. Studying the factory level, a mathematical model to design a flow line considering the possibility of using switch-off policies is developed. The design model for production lines includes a targeted imbalance among the workstations to allow for defined idle time. Finally, the main findings, results, and the future directions and challenges are presented

Organizing timely treatment in multi-disciplinary care

Healthcare providers experience an increased pressure to organize their processes more efficiently and to provide coordinated care over multiple disciplines. Organizing multi-disciplinary care is typically highly constrained, since multiple appointments per patient have to be scheduled with possible restrictions between them. Furthermore, schedules of professionals from various facilities or with different skills must be aligned. Since it is important that patients are treated on time, access time targets are set on the time between referral to the facility and the actual start of the treatment. These targets may vary per patient type: e.g., urgent patients have shorter access time targets than regular patients. In this thesis, we use operations research methods to support multi-disciplinary care settings in providing timely treatments with an excellent quality of care, against affordable costs, while taking patient and employee satisfaction into account. We consider settings in rehabilitation care and radiotherapy, but the underlying planning problems are applicable to many other multi-disciplinary care settings, such as cancer care or specialty clinics. The developed models are applied to case studies in the Sint Maartenskliniek Nijmegen, the AMC Amsterdam and a BCCA cancer clinic in Vancouver, Canada. The results of the thesis demonstrate that adequate admission policies and capacity allocation to different activities and stages in complex treatment processes can improve compliance with access time targets for multi-disciplinary care systems considerably, while using the available resource capacities and taking patient and employee satisfaction into account

Mathematics in the Supply Chain

[no abstract available

Variant-oriented Planning Models for Parts/Products Grouping, Sequencing and Operations

This research aims at developing novel methods for utilizing the commonality between part/product variants to make modern manufacturing systems more flexible, adaptable, and agile for dealing with less volume per variant and minimizing total changes in the setup between variants. Four models are developed for use in four important domains of manufacturing systems: production sequencing, product family formation, production flow, and products operations sequences retrieval. In all these domains, capitalizing on commonality between the part/product variants has a pivotal role. For production sequencing; a new policy based on setup similarity between product variants is proposed and its results are compared with a developed mathematical model in a permutation flow shop. The results show the proposed algorithm is capable of finding solutions in less than 0.02 seconds with an average error of 1.2%. For product family formation; a novel operation flow based similarity coefficient is developed for variants having networked structures and integrated with two other similarity coefficients, operation and volume similarity, to provide a more comprehensive similarity coefficient. Grouping variants based on the proposed integrated similarity coefficient improves changeover time and utilization of the system. A sequencing method, as a secondary application of this approach, is also developed. For production flow; a new mixed integer programing (MIP) model is developed to assign operations of a family of product variants to candidate machines and also to select the best place for each machine among the candidate locations. The final sequence of performing operations for each variant having networked structures is also determined. The objective is to minimize the total backtracking distance leading to an improvement in total throughput of the system (7.79% in the case study of three engine blocks). For operations sequences retrieval; two mathematical models and an algorithm are developed to construct a master operation sequence from the information of the existing variants belonging to a family of parts/products. This master operation sequence is used to develop the operation sequences for new variants which are sufficiently similar to existing variants. Using the proposed algorithm decreases time of developing the operations sequences of new variants to the seconds