Combination of statistical process control (SPC) methods and classification strategies for situation assessment of batch processes

Postprint (published version

Optimizing production scheduling of steel plate hot rolling for economic load dispatch under time-of-use electricity pricing

Time-of-Use (TOU) electricity pricing provides an opportunity for industrial users to cut electricity costs. Although many methods for Economic Load Dispatch (ELD) under TOU pricing in continuous industrial processing have been proposed, there are still difficulties in batch-type processing since power load units are not directly adjustable and nonlinearly depend on production planning and scheduling. In this paper, for hot rolling, a typical batch-type and energy intensive process in steel industry, a production scheduling optimization model for ELD is proposed under TOU pricing, in which the objective is to minimize electricity costs while considering penalties caused by jumps between adjacent slabs. A NSGA-II based multi-objective production scheduling algorithm is developed to obtain Pareto-optimal solutions, and then TOPSIS based multi-criteria decision-making is performed to recommend an optimal solution to facilitate filed operation. Experimental results and analyses show that the proposed method cuts electricity costs in production, especially in case of allowance for penalty score increase in a certain range. Further analyses show that the proposed method has effect on peak load regulation of power grid.Comment: 13 pages, 6 figures, 4 table

Decision support for build-to-order supply chain management through multiobjective optimization

This paper aims to identify the gaps in decision-making support based on multiobjective optimization for build-to-order supply chain management (BTOSCM). To this end, it reviews the literature available on modelling build-to-order supply chains (BTO-SC) with the focus on adopting multiobjective optimization (MOO) techniques as a decision support tool. The literature has been classified based on the nature of the decisions in different part of the supply chain, and the key decision areas across a typical BTO-SC are discussed in detail. Available software packages suitable for supporting decision making in BTO supply chains are also identified and their related solutions are outlined. The gap between the modelling and optimization techniques developed in the literature and the decision support needed in practice are highlighted and future research directions to better exploit the decision support capabilities of MOO are proposed

Warehouse design and control: framework and literature review

In this paper we present a reference framework and a classification of warehouse design and control problems. Based on this framework, we review the existing literature on warehousing systems and indicate important gaps. In particular, we emphasize the need for design oriented studies, as opposed to the strong analysis oriented research on isolated subproblems that seems to be dominant in the current literature

Decision support for build-to-order supply chain management through multiobjective optimization

This is the post-print version of the final paper published in International Journal of Production Economics. The published article is available from the link below. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. Copyright @ 2010 Elsevier B.V.This paper aims to identify the gaps in decision-making support based on multiobjective optimization (MOO) for build-to-order supply chain management (BTO-SCM). To this end, it reviews the literature available on modelling build-to-order supply chains (BTO-SC) with the focus on adopting MOO techniques as a decision support tool. The literature has been classified based on the nature of the decisions in different part of the supply chain, and the key decision areas across a typical BTO-SC are discussed in detail. Available software packages suitable for supporting decision making in BTO supply chains are also identified and their related solutions are outlined. The gap between the modelling and optimization techniques developed in the literature and the decision support needed in practice are highlighted. Future research directions to better exploit the decision support capabilities of MOO are proposed. These include: reformulation of the extant optimization models with a MOO perspective, development of decision supports for interfaces not involving manufacturers, development of scenarios around service-based objectives, development of efficient solution tools, considering the interests of each supply chain party as a separate objective to account for fair treatment of their requirements, and applying the existing methodologies on real-life data sets.Brunel Research Initiative and Enterprise Fund (BRIEF

Stochastic make-to-stock inventory deployment problem: an endosymbiotic psychoclonal algorithm based approach

Integrated steel manufacturers (ISMs) have no specific product, they just produce finished product from the ore. This enhances the uncertainty prevailing in the ISM regarding the nature of the finished product and significant demand by customers. At present low cost mini-mills are giving firm competition to ISMs in terms of cost, and this has compelled the ISM industry to target customers who want exotic products and faster reliable deliveries. To meet this objective, ISMs are exploring the option of satisfying part of their demand by converting strategically placed products, this helps in increasing the variability of product produced by the ISM in a short lead time. In this paper the authors have proposed a new hybrid evolutionary algorithm named endosymbiotic-psychoclonal (ESPC) to decide what and how much to stock as a semi-product in inventory. In the proposed theory, the ability of previously proposed psychoclonal algorithms to exploit the search space has been increased by making antibodies and antigen more co-operative interacting species. The efficacy of the proposed algorithm has been tested on randomly generated datasets and the results compared with other evolutionary algorithms such as genetic algorithms (GA) and simulated annealing (SA). The comparison of ESPC with GA and SA proves the superiority of the proposed algorithm both in terms of quality of the solution obtained and convergence time required to reach the optimal/near optimal value of the solution

Incorporating batching decisions and operational constraints into the scheduling problem of multisite manufacturing environments

In multisite production environments, the appropriate management of production resources is an activity of fundamental relevance to optimally respond to market demands. In particular, each production facility can operate with different policies according to its objectives, prioritizing the quality and standardization of the product, customer service, or the overall efficiency of the system; goals which must be taken into account when planning the production of the entire complex. At the operational level, in order to achieve an efficient operation of the production system, the integrated problem of batching and scheduling must be solved over all facilities, instead of doing it for each plant separately, as has been usual so far. Then, this paper proposes a mixed-integer linear programming model for the multisite batching and scheduling problems, where different operational policies are considered for multiple batch plants. Through two examples, the impact of policies on the decision-making process is shown.Fil: Ackermann, Sergio Alfredo. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo y Diseño. Universidad Tecnológica Nacional. Facultad Regional Santa Fe. Instituto de Desarrollo y Diseño; ArgentinaFil: Fumero, Yanina. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo y Diseño. Universidad Tecnológica Nacional. Facultad Regional Santa Fe. Instituto de Desarrollo y Diseño; ArgentinaFil: Montagna, Jorge Marcelo. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo y Diseño. Universidad Tecnológica Nacional. Facultad Regional Santa Fe. Instituto de Desarrollo y Diseño; Argentin

Proactive management of uncertainty to improve scheduling robustness in proces industries

Dinamisme, capacitat de resposta i flexibilitat són característiques essencials en el desenvolupament de la societat actual. Les noves tendències de globalització i els avenços en tecnologies de la informació i comunicació fan que s'evolucioni en un entorn altament dinàmic i incert. La incertesa present en tot procés esdevé un factor crític a l'hora de prendre decisions, així com un repte altament reconegut en l'àrea d'Enginyeria de Sistemes de Procés (PSE). En el context de programació de les operacions, els models de suport a la decisió proposats fins ara, així com també software comercial de planificació i programació d'operacions avançada, es basen generalment en dades estimades, assumint implícitament que el programa d'operacions s'executarà sense desviacions. La reacció davant els efectes de la incertesa en temps d'execució és una pràctica habitual, però no sempre resulta efectiva o factible. L'alternativa és considerar la incertesa de forma proactiva, és a dir, en el moment de prendre decisions, explotant el coneixement disponible en el propi sistema de modelització.Davant aquesta situació es plantegen les següents preguntes: què s'entén per incertesa? Com es pot considerar la incertesa en el problema de programació d'operacions? Què s'entén per robustesa i flexibilitat d'un programa d'operacions? Com es pot millorar aquesta robustesa? Quins beneficis comporta? Aquesta tesi respon a aquestes preguntes en el marc d'anàlisis operacionals en l'àrea de PSE. La incertesa es considera no de la forma reactiva tradicional, sinó amb el desenvolupament de sistemes proactius de suport a la decisió amb l'objectiu d'identificar programes d'operació robustos que serveixin com a referència pel nivell inferior de control de planta, així com també per altres centres en un entorn de cadenes de subministrament. Aquest treball de recerca estableix les bases per formalitzar el concepte de robustesa d'un programa d'operacions de forma sistemàtica. Segons aquest formalisme, els temps d'operació i les ruptures d'equip són considerats inicialment com a principals fonts d'incertesa presents a nivell de programació de la producció. El problema es modelitza mitjançant programació estocàstica, desenvolupant-se finalment un entorn d'optimització basat en simulació que captura les múltiples fonts d'incertesa, així com també estratègies de programació d'operacions reactiva, de forma proactiva. La metodologia desenvolupada en el context de programació de la producció s'estén posteriorment per incloure les operacions de transport en sistemes de múltiples entitats i incertesa en els temps de distribució. Amb aquesta perspectiva més àmplia del nivell d'operació s'estudia la coordinació de les activitats de producció i transport, fins ara centrada en nivells estratègic o tàctic. L'estudi final considera l'efecte de la incertesa en la demanda en les decisions de programació de la producció a curt termini. El problema s'analitza des del punt de vista de gestió del risc, i s'avaluen diferents mesures per controlar l'eficiència del sistema en un entorn incert.En general, la tesi posa de manifest els avantatges en reconèixer i modelitzar la incertesa, amb la identificació de programes d'operació robustos capaços d'adaptar-se a un ampli rang de situacions possibles, enlloc de programes d'operació òptims per un escenari hipotètic. La metodologia proposada a nivell d'operació es pot considerar com un pas inicial per estendre's a nivells de decisió estratègics i tàctics. Alhora, la visió proactiva del problema permet reduir el buit existent entre la teoria i la pràctica industrial, i resulta en un major coneixement del procés, visibilitat per planificar activitats futures, així com també millora l'efectivitat de les tècniques reactives i de tot el sistema en general, característiques altament desitjables per mantenir-se actiu davant la globalitat, competitivitat i dinàmica que envolten un procés.Dynamism, responsiveness, and flexibility are essential features in the development of the current society. Globalization trends and fast advances in communication and information technologies make all evolve in a highly dynamic and uncertain environment. The uncertainty involved in a process system becomes a critical problem in decision making, as well as a recognized challenge in the area of Process Systems Engineering (PSE). In the context of scheduling, decision-support models developed up to this point, as well as commercial advanced planning and scheduling systems, rely generally on estimated input information, implicitly assuming that a schedule will be executed without deviations. The reaction to the effects of the uncertainty at execution time becomes a common practice, but it is not always effective or even possible. The alternative is to address the uncertainty proactively, i.e., at the time of reasoning, exploiting the available knowledge in the modeling procedure itself. In view of this situation, the following questions arise: what do we understand for uncertainty? How can uncertainty be considered within scheduling modeling systems? What is understood for schedule robustness and flexibility? How can schedule robustness be improved? What are the benefits? This thesis answers these questions in the context of operational analysis in PSE. Uncertainty is managed not from the traditional reactive viewpoint, but with the development of proactive decision-support systems aimed at identifying robust schedules that serve as a useful guidance for the lower control level, as well as for dependent entities in a supply chain environment. A basis to formalize the concept of schedule robustness is established. Based on this formalism, variable operation times and equipment breakdowns are first considered as the main uncertainties in short-term production scheduling. The problem is initially modeled using stochastic programming, and a simulation-based stochastic optimization framework is finally developed, which captures the multiple sources of uncertainty, as well as rescheduling strategies, proactively. The procedure-oriented system developed in the context of production scheduling is next extended to involve transport scheduling in multi-site systems with uncertain travel times. With this broader operational perspective, the coordination of production and transport activities, considered so far mainly in strategic and tactical analysis, is assessed. The final research point focuses on the effect of demands uncertainty in short-term scheduling decisions. The problem is analyzed from a risk management viewpoint, and alternative measures are assessed and compared to control the performance of the system in the uncertain environment.Overall, this research work reveals the advantages of recognizing and modeling uncertainty, with the identification of more robust schedules able to adapt to a wide range of possible situations, rather than optimal schedules for a hypothetical scenario. The management of uncertainty proposed from an operational perspective can be considered as a first step towards its extension to tactical and strategic levels of decision. The proactive perspective of the problem results in a more realistic view of the process system, and it is a promising way to reduce the gap between theory and industrial practices. Besides, it provides valuable insight on the process, visibility for future activities, as well as it improves the efficiency of reactive techniques and of the overall system, all highly desirable features to remain alive in the global, competitive, and dynamic process environment

Histopathology laboratory operations analysis and improvement

Histopathology laboratories aim to deliver high quality diagnoses based on patient tissue samples. Indicators for quality are the accuracy of the diagnoses and the diagnostic turnaround times. However, challenges exist regarding employee workload and turnaround times in the histopathology laboratory. This paper proposes a decomposed planning and scheduling method for the histopathology laboratory using (mixed) integer linear programming ((M)ILP) to improve the spread of workload and reduce the diagnostic turnaround times. First, the batching problem is considered, in which batch completion times are equally divided over the day to spread the workload. This reduces the peaks of physical work available in the laboratory. Thereafter, the remaining processes are scheduled to minimize the tardiness of orders. Preliminary results show that using this decomposition method, the peaks in histopathology workload in UMC Utrecht, a large university medical center in the Netherlands, are potentially reduced with up to 50% by better spreading the workload over the day. Furthermore, turnaround times are potentially reduced with up to 20% compared to current practices

Assembly Line

An assembly line is a manufacturing process in which parts are added to a product in a sequential manner using optimally planned logistics to create a finished product in the fastest possible way. It is a flow-oriented production system where the productive units performing the operations, referred to as stations, are aligned in a serial manner. The present edited book is a collection of 12 chapters written by experts and well-known professionals of the field. The volume is organized in three parts according to the last research works in assembly line subject. The first part of the book is devoted to the assembly line balancing problem. It includes chapters dealing with different problems of ALBP. In the second part of the book some optimization problems in assembly line structure are considered. In many situations there are several contradictory goals that have to be satisfied simultaneously. The third part of the book deals with testing problems in assembly line. This section gives an overview on new trends, techniques and methodologies for testing the quality of a product at the end of the assembling line