Improvement to an existing multi-level capacitated lot sizing problem considering setup carryover, backlogging, and emission control

This paper presents a multi-level, multi-item, multi-period capacitated lot-sizing problem. The lot-sizing problem studies can obtain production quantities, setup decisions and inventory levels in each period fulfilling the demand requirements with limited capacity resources, considering the Bill of Material (BOM) structure while simultaneously minimizing the production, inventory, and machine setup costs. The paper proposes an exact solution to Chowdhury et al. (2018)\u27s[1] developed model, which considers the backlogging cost, setup carryover & greenhouse gas emission control to its model complexity. The problem contemplates the Dantzig-Wolfe (D.W.) decomposition to decompose the multi-level capacitated problem into a single-item uncapacitated lot-sizing sub-problem. To avoid the infeasibilities of the weighted problem (WP), an artificial variable is introduced, and the Big-M method is employed in the D.W. decomposition to produce an always feasible master problem. In addition, Wagner & Whitin\u27s[2] forward recursion algorithm is also incorporated in the solution approach for both end and component items to provide the minimum cost production plan. Introducing artificial variables in the D.W. decomposition method is a novel approach to solving the MLCLSP model. A better performance was achieved regarding reduced computational time (reduced by 50%) and optimality gap (reduced by 97.3%) in comparison to Chowdhury et al. (2018)\u27s[1] developed model

Meta-Heuristics for Dynamic Lot Sizing: a review and comparison of solution approaches

Proofs from complexity theory as well as computational experiments indicate that most lot sizing problems are hard to solve. Because these problems are so difficult, various solution techniques have been proposed to solve them. In the past decade, meta-heuristics such as tabu search, genetic algorithms and simulated annealing, have become popular and efficient tools for solving hard combinational optimization problems. We review the various meta-heuristics that have been specifically developed to solve lot sizing problems, discussing their main components such as representation, evaluation neighborhood definition and genetic operators. Further, we briefly review other solution approaches, such as dynamic programming, cutting planes, Dantzig-Wolfe decomposition, Lagrange relaxation and dedicated heuristics. This allows us to compare these techniques. Understanding their respective advantages and disadvantages gives insight into how we can integrate elements from several solution approaches into more powerful hybrid algorithms. Finally, we discuss general guidelines for computational experiments and illustrate these with several examples

Local cuts and two-period convex hull closures for big-bucket lot-sizing problems

Despite the significant attention they have drawn, big bucket lot-sizing problems remain notoriously difficult to solve. Previous work of Akartunali and Miller (2012) presented results (computational and theoretical) indicating that what makes these problems difficult are the embedded single-machine, single-level, multi-period submodels. We therefore consider the simplest such submodel, a multi-item, two-period capacitated relaxation. We propose a methodology that can approximate the convex hulls of all such possible relaxations by generating violated valid inequalities. To generate such inequalities, we separate two-period projections of fractional LP solutions from the convex hulls of the two-period closure we study. The convex hull representation of the two-period closure is generated dynamically using column generation. Contrary to regular column generation, our method is an outer approximation, and therefore can be used efficiently in a regular branch-and-bound procedure. We present computational results that illustrate how these two-period models could be effective in solving complicated problems

Large-Scale Optimisation in Operations Management: Algorithms and Applications

The main contributions of this dissertation are the design, development and application of optimisation methodology, models and algorithms for large-scale problems arising in Operations Management. The first chapter introduces constraint transformations and valid inequalities that enhance the performance of column generation and Lagrange relaxation. I establish theoretical connections with dual-space reduction techniques and develop a novel algorithm that combines Lagrange relaxation and column generation. This algorithm is embedded in a branch-and-price scheme, which combines large neighbourhood and local search to generate upper bounds. Computational experiments on capacitated lot sizing show significant improvements over existing methodologies. The second chapter introduces a Horizon-Decomposition approach that partitions the problem horizon in contiguous intervals. In this way, subproblems identical to the original problem but of smaller size are created. The size of the master problem and the subproblems are regulated via two scalar parameters, giving rise to a family of reformulations. I investigate the efficiency of alternative parameter configurations empirically. Computational experiments on capacitated lot sizing demonstrate superior performance against commercial solvers. Finally, extensions to generic mathematical programs are presented. The final chapter shows how large-scale optimisation methods can be applied to complex operational problems, and presents a modelling framework for scheduling the transhipment operations of the Noble Group, a global supply chain manager of energy products. I focus on coal operations, where coal is transported from mines to vessels using barges and floating cranes. Noble pay millions of dollars in penalties for delays, and for additional resources hired to minimize the impact of delays. A combination of column generation and dedicated heuristics reduces the cost of penalties and additional resources, and improves the efficiency of the operations. Noble currently use the developed framework, and report significant savings attributed to it

Avoiding redundant columns by adding classical Benders cuts to column generation subproblems

This is the author accepted manuscript. The final version is available fro,m Elsevier via the DOI in this recordWhen solving the linear programming (LP) relaxation of a mixed-integer program (MIP) with column generation, columns might be generated that are not needed to express any integer optimal solution. Such columns are called strongly redundant and the dual bound obtained by solving the LP relaxation is potentially stronger if these columns are not generated. We introduce a sufficient condition for strong redundancy that can be checked by solving a compact LP. Using a dual solution of this compact LP we generate classical Benders cuts for the subproblem so that the generation of strongly redundant columns can be avoided. The potential of these cuts to improve the dual bound of the column generation master problem is evaluated computationally using an implementation in the branch-price-and-cut solver GCG. While their efficacy is limited on classical problems, the benefit of applying the cuts is demonstrated on structured models to which a temporal decomposition can be applied.Engineering and Physical Sciences Research Council (EPSRC

Lot-Sizing Problem for a Multi-Item Multi-level Capacitated Batch Production System with Setup Carryover, Emission Control and Backlogging using a Dynamic Program and Decomposition Heuristic

Wagner and Whitin (1958) develop an algorithm to solve the dynamic Economic Lot-Sizing Problem (ELSP), which is widely applied in inventory control, production planning, and capacity planning. The original algorithm runs in O(T^2) time, where T is the number of periods of the problem instance. Afterward few linear-time algorithms have been developed to solve the Wagner-Whitin (WW) lot-sizing problem; examples include the ELSP and equivalent Single Machine Batch-Sizing Problem (SMBSP). This dissertation revisits the algorithms for ELSPs and SMBSPs under WW cost structure, presents a new efficient linear-time algorithm, and compares the developed algorithm against comparable ones in the literature. The developed algorithm employs both lists and stacks data structure, which is completely a different approach than the rest of the algorithms for ELSPs and SMBSPs. Analysis of the developed algorithm shows that it executes fewer number of basic actions throughout the algorithm and hence it improves the CPU time by a maximum of 51.40% for ELSPs and 29.03% for SMBSPs. It can be concluded that the new algorithm is faster than existing algorithms for both ELSPs and SMBSPs. Lot-sizing decisions are crucial because these decisions help the manufacturer determine the quantity and time to produce an item with a minimum cost. The efficiency and productivity of a system is completely dependent upon the right choice of lot-sizes. Therefore, developing and improving solution procedures for lot-sizing problems is key. This dissertation addresses the classical Multi-Level Capacitated Lot-Sizing Problem (MLCLSP) and an extension of the MLCLSP with a Setup Carryover, Backlogging and Emission control. An item Dantzig Wolfe (DW) decomposition technique with an embedded Column Generation (CG) procedure is used to solve the problem. The original problem is decomposed into a master problem and a number of subproblems, which are solved using dynamic programming approach. Since the subproblems are solved independently, the solution of the subproblems often becomes infeasible for the master problem. A multi-step iterative Capacity Allocation (CA) heuristic is used to tackle this infeasibility. A Linear Programming (LP) based improvement procedure is used to refine the solutions obtained from the heuristic method. A comparative study of the proposed heuristic for the first problem (MLCLSP) is conducted and the results demonstrate that the proposed heuristic provide less optimality gap in comparison with that obtained in the literature. The Setup Carryover Assignment Problem (SCAP), which consists of determining the setup carryover plan of multiple items for a given lot-size over a finite planning horizon is modelled as a problem of finding Maximum Weighted Independent Set (MWIS) in a chain of cliques. The SCAP is formulated using a clique constraint and it is proved that the incidence matrix of the SCAP has totally unimodular structure and the LP relaxation of the proposed SCAP formulation always provides integer optimum solution. Moreover, an alternative proof that the relaxed ILP guarantees integer solution is presented in this dissertation. Thus, the SCAP and the special case of the MWIS in a chain of cliques are solvable in polynomial time

Branch-and-price and multicommodity flows

Tese de doutoramento em Engenharia de Produção e Sistemas, área de Investigação OperacionalIn this Thesis, we address column generation based methods for linear and integer programming and apply them to three multicommodity flow problems. For (mixed) integer programming problems, the approach taken consists in reformulating an original model, using the Dantzig-Wolfe decomposition principle, and then combining column generation with branch-and-bound (branch-and-price) in order to obtain optimal solutions. The main issue when developing a branch-and-price algorithm is the branching scheme. The approach explored in this work is to branch on the variables of the original model, keeping the structure of the subproblems of the column generation method unchanged. The incorporation of cuts (branch-and-price-and-cut), again without changing the structure of the subproblem, is also explored. Based on that general methodology, we developed a set of C++ classes (ADDing - Automatic Dantzig-Wolfe Decomposition for INteger column Generation), which implements abranch-and-price algorithm. Its main distinctive feature is that it can be used as a “black-box”: all the user is required to do is to provide the original model. ADDing can also be customised to meet a specific problem, if the user is willing to provide a subproblem solver and/or specific branching schemes. We developed column generation based algorithms for three multicommodity flow problems. In this type of problems, it is desired to route a set of commodities through a capacitated network at a minimum cost. In the linear problem, each unit of each commodity is divisible. By using a model with variables associated with paths and circuits, we obtained significant improvements on the solution times over the standard column generation approach, for instances defined in planar networks (in several instances the relative improvement was greater than 60%). In the integer problem, each unit of each commodity is indivisible; the flow of a commodity can be split between different paths, but the flow on each of those paths must be integer. In general, the proposed branch-and-price algorithm was more efficient than Cplex 6.6 in the sets of instances where each commodity is defined by an origin-destination pair; for some of the other sets of instances, Cplex 6.6 gave better time results. In the binary problem, all the flow of each commodity must be routed along a single path. We developed a branch-and-price algorithm based on a knapsack decomposition and modified (by using a different branching scheme) a previously described branch-and-price-and-cut algorithm based on a path decomposition. The outcome of the computational tests was surprising, given that it is usually assumed that specific methods are more efficient than general ones. For the instances tested, a state-of-the-art general-purpose (Cplex 8.1) gave, in general, much better results than both decomposition approaches.Nesta Tese, abordam-se métodos de geração de colunas para programação linear e inteira. A sua aplicação é feita em três problemas de fluxo multicomodidade. Para problemas de programação inteira (mista), a abordagem seguida é a de reformular um modelo original, utilizando o princípio de decomposição de Dantzig-Wolfe, e combinar geração de colunas com o método de partição e avaliação (partição e geração de colunas) para a obtenção de soluções óptimas. A questão essencial no desenvolvimento de um algoritmo deste tipo é a estratégia de partição. A abordagem seguida neste trabalho é a de realizar a partição nas variáveis do modelo original, mantendo a estrutura do subproblema do método de geração de colunas. A incorporação de cortes, ainda sem alteração da estrutura do subproblema, é também explorada. Com base nesta metodologia geral, foi desenvolvido um conjunto de classes em C++ (ADDing - Automatic Dantzig-Wolfe Decomposition for INteger column Generation), que implementa um algorithmo de partição e geração de colunas. A sua característica fundamental é apenas ser requerido ao utilizador a definição de um modelo original. Num modo mais avançado, o utilizador pode implementar algoritmos para resolver o subproblema e/ou esquemas de partição. Foram desenvolvidos algoritmos baseados em geração de colunas para três problemas de fluxo multicomodidade. Neste tipo de problemas, pretende-se encaminhar um conjunto de comodidades através de uma rede capacitada, minimizando o custo. No problema linear, cada unidade de cada comodidade é divisível. Utilizando um modelo com variáveis associadas a caminhos e a circuitos, obtiveram-se melhorias significativas nos tempos de resolução em relação ao método de geração de colunas usual, para instâncias definidas em redes planares (em várias instâncias a melhoria relativa foi superior a 60%). No problema inteiro, cada unidade de cada comodidade é indivisível; o fluxo de uma comodidade pode ser dividido por diferentes caminhos, mas o fluxo em cada um deles tem de ser inteiro. Em geral, o algoritmo de partição e geração de colunas foi mais eficiente do que o software Cplex 6.6 nos conjuntos de instâncias em que cada comodidade é definida por um par origem-destino; para alguns dos outros conjuntos de instâncias, o software Cplex 6.6 obteve melhores resultados. No problema binário, todo o fluxo de cada comodidade apenas pode utilizar um caminho. Foi desenvolvido um algoritmo de partição e geração de colunas baseado numa decomposição de mochila e modificado (através de um esquema de partição diferente) um algoritmo de partição e geração de colunas com cortes, previamente descrito, baseado numa decomposição por caminhos. Os resultados dos testes computacionais foram surpreendentes, dado que é usualmente assumido que métodos específicos são mais eficientes do que métodos gerais. Para as instâncias testadas, o software Cplex 8.1 obteve, em geral, resultados muito melhores do que as duas decomposições

Progressive selection method for the coupled lot-sizing and cutting-stock problem

The coupled lot-sizing and cutting-stock problem has been a challenging and significant problem for industry, and has therefore received sustained research attention. The quality of the solution is a major determinant of cost performance in related production and inventory management systems, and therefore there is intense pressure to develop effective practical solutions. In the literature, a number of heuristics have been proposed for solving the problem. However, the heuristics are limited in obtaining high solution qualities. This paper proposes a new progressive selection algorithm that hybridizes heuristic search and extended reformulation into a single framework. The method has the advantage of generating a strong bound using the extended reformulation, which can provide good guidelines on partitioning and sampling in the heuristic search procedure so as to ensure an efficient solution process. We also analyze per-item and per-period Dantzig-Wolfe decompositions of the problem and present theoretical comparisons. The master problem of the per-period Dantzig-Wolfe decomposition is often degenerate, which results in a tailing-off effect for column generation. We apply a hybridization of Lagrangian relaxation and stabilization techniques to improve the convergence. The discussion is followed by extensive computational tests, where we also perform detailed statistical analyses on various parameters. Comparisons with other methods indicate that our approach is computationally tractable and is able to obtain improved results

Arc flow formulations based on dynamic programming: Theoretical foundations and applications

Network flow formulations are among the most successful tools to solve optimization problems. Such formulations correspond to determining an optimal flow in a network. One particular class of network flow formulations is the arc flow, where variables represent flows on individual arcs of the network. For NP-hard problems, polynomial-sized arc flow models typically provide weak linear relaxations and may have too much symmetry to be efficient in practice. Instead, arc flow models with a pseudo-polynomial size usually provide strong relaxations and are efficient in practice. The interest in pseudo-polynomial arc flow formulations has grown considerably in the last twenty years, in which they have been used to solve many open instances of hard problems. A remarkable advantage of pseudo-polynomial arc flow models is the possibility to solve practical-sized instances directly by a Mixed Integer Linear Programming solver, avoiding the implementation of complex methods based on column generation. In this survey, we present theoretical foundations of pseudo-polynomial arc flow formulations, by showing a relation between their network and Dynamic Programming (DP). This relation allows a better understanding of the strength of these formulations, through a link with models obtained by Dantzig-Wolfe decomposition. The relation with DP also allows a new perspective to relate state-space relaxation methods for DP with arc flow models. We also present a dual point of view to contrast the linear relaxation of arc flow models with that of models based on paths and cycles. To conclude, we review the main solution methods and applications of arc flow models based on DP in several domains such as cutting, packing, scheduling, and routing

Integrated machine learning and optimization approaches

This dissertation focuses on the integration of machine learning and optimization. Specifically, novel machine learning-based frameworks are proposed to help solve a broad range of well-known operations research problems to reduce the solution times. The first study presents a bidirectional Long Short-Term Memory framework to learn optimal solutions to sequential decision-making problems. Computational results show that the framework significantly reduces the solution time of benchmark capacitated lot-sizing problems without much loss in feasibility and optimality. Also, models trained using shorter planning horizons can successfully predict the optimal solution of the instances with longer planning horizons. For the hardest data set, the predictions at the 25% level reduce the solution time of 70 CPU hours to less than 2 CPU minutes with an optimality gap of 0.8% and without infeasibility. In the second study, an extendable prediction-optimization framework is presented for multi-stage decision-making problems to address the key issues of sequential dependence, infeasibility, and generalization. Specifically, an attention-based encoder-decoder neural network architecture is integrated with an infeasibility-elimination and generalization framework to learn high-quality feasible solutions. The proposed framework is demonstrated to tackle the two well-known dynamic NP-Hard optimization problems: multi-item capacitated lot-sizing and multi-dimensional knapsack. The results show that models trained on shorter and smaller-dimension instances can be successfully used to predict longer and larger-dimension problems with the presented item-wise expansion algorithm. The solution time can be reduced by three orders of magnitude with an average optimality gap below 0.1%. The proposed framework can be advantageous for solving dynamic mixed-integer programming problems that need to be solved instantly and repetitively. In the third study, a deep reinforcement learning-based framework is presented for solving scenario-based two-stage stochastic programming problems, which are computationally challenging to solve. A general two-stage deep reinforcement learning framework is proposed where two learning agents sequentially learn to solve each stage of a general two-stage stochastic multi-dimensional knapsack problem. The results show that solution time can be reduced significantly with a relatively small gap. Additionally, decision-making agents can be trained with a few scenarios and solve problems with a large number of scenarios. In the fourth study, a learning-based prediction-optimization framework is proposed for solving scenario-based multi-stage stochastic programs. The issue of non-anticipativity is addressed with a novel neural network architecture that is based on a neural machine translation system. Furthermore, training the models on deterministic problems is suggested instead of solving hard and time-consuming stochastic programs. In this framework, the level of variables used for the solution is iteratively reduced to eliminate infeasibility, and a heuristic based on a linear relaxation is performed to reduce the solution time. An improved item-wise expansion strategy is introduced to generalize the algorithm to tackle instances with different sizes. The results are presented in solving stochastic multi-item capacitated lot-sizing and stochastic multi-stage multi-dimensional knapsack problems. The results show that the solution time can be reduced by a factor of 599 with an optimality gap of only 0.08%. Moreover, results demonstrate that the models can be used to predict similarly structured stochastic programming problems with a varying number of periods, items, and scenarios. The frameworks presented in this dissertation can be utilized to achieve high-quality and fast solutions to repeatedly-solved problems in various industrial and business settings, such as production and inventory management, capacity planning, scheduling, airline logistics, dynamic pricing, and emergency management