Scheduling Hybrid Flow Lines of Aerospace Composite Manufacturing Systems

Composite manufacturing is a vital part of aerospace manufacturing systems. Applying effective scheduling within these systems can cut the costs in aerospace companies significantly. These systems can be characterized as two-stage Hybrid Flow Shops (HFS) with identical, non-identical and unrelated parallel discrete-processing machines in the first stage and non-identical parallel batch-processing machines in the second stage. The first stage is normally the lay-up process in which the carbon fiber sheets are stacked on the molds (tools). Then, the parts are batched based on the compatibility of their cure recipe before going to the second stage into the autoclave for curing. Autoclaves require enormous capital investment and maximizing their utilization is of utmost importance. In this thesis, a Mixed Integer Linear Programming (MILP) model is developed to maximize the utilization of the resources in the second stage of this HFS. CPLEX, with an underlying branch and bound algorithm, is used to solve the model. The results show the high level of flexibility and computational efficiency of the proposed model when applied to small and medium-size problems. However, due to the NP-hardness of the problem, the MILP model fails to solve large problems (i.e. problems with more than 120 jobs as input) in reasonable CPU times. To solve the larger instances of the problem, a novel heuristic method along with a Genetic Algorithm (GA) are developed. The heuristic algorithm is designed based on a careful observation of the behavior of the MILP model for different problem sets. Moreover, it is enhanced by adding a number of proper dispatching rules. As its output, this heuristic algorithm generates eight initial feasible solutions which are then used as the initial population of the proposed GA. The GA improves the initial solutions obtained from the aforementioned heuristic through its stochastic iterations until it reaches the satisfactory near-optimal solutions. A novel crossover operator is introduced in this GA which is unique to the HFS of aerospace composite manufacturing systems. The proposed GA is proven to be very efficient when applied to large-size problems with up to 300 jobs. The results show the high quality of the solutions achieved by the GA when compared to the optimal solutions which are obtained from the MILP model. A real case study undertaken at one of the leading companies in the Canadian aerospace industry is used for the purpose of data experiments and analysis

Efficient Heuristic Solution Methodologies for Scheduling Batch Processor with Incompatible Job-Families, Non-identical Job-Sizes and Non-identical Job-Dimensions

Part 3: Production Management Theory and MethodologyInternational audienceEfficient scheduling of heat-treatment furnace (HTF), a batch processor (BP), is very important to meet both throughput benefits as well as the committed due date to the customer, as the heat-treatment operations require very long processing time in the entire steel casting manufacturing process and accounts for large part of the total casting processing time required. In the recent time, there are good number of studies reported in the literature related to scheduling of BP associated with many discrete parts manufacturing. However, still there is very scant treatment has been given in scheduling of HTF problem, which has one of the unique job-characteristic: non-identical job-dimensions. This characteristic differentiates most of the other BP problems reported in the literature. Thus, this study considers a scheduling HTF, close to real-life problem characteristics, and proposes efficient heuristic solution methodologies

Production Scheduling

Generally speaking, scheduling is the procedure of mapping a set of tasks or jobs (studied objects) to a set of target resources efficiently. More specifically, as a part of a larger planning and scheduling process, production scheduling is essential for the proper functioning of a manufacturing enterprise. This book presents ten chapters divided into five sections. Section 1 discusses rescheduling strategies, policies, and methods for production scheduling. Section 2 presents two chapters about flow shop scheduling. Section 3 describes heuristic and metaheuristic methods for treating the scheduling problem in an efficient manner. In addition, two test cases are presented in Section 4. The first uses simulation, while the second shows a real implementation of a production scheduling system. Finally, Section 5 presents some modeling strategies for building production scheduling systems. This book will be of interest to those working in the decision-making branches of production, in various operational research areas, as well as computational methods design. People from a diverse background ranging from academia and research to those working in industry, can take advantage of this volume

An intelligent manufacturing system for heat treatment scheduling

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.This research is focused on the integration problem of process planning and scheduling in steel heat treatment operations environment using artificial intelligent techniques that are capable of dealing with such problems. This work addresses the issues involved in developing a suitable methodology for scheduling heat treatment operations of steel. Several intelligent algorithms have been developed for these propose namely, Genetic Algorithm (GA), Sexual Genetic Algorithm (SGA), Genetic Algorithm with Chromosome differentiation (GACD), Age Genetic Algorithm (AGA), and Mimetic Genetic Algorithm (MGA). These algorithms have been employed to develop an efficient intelligent algorithm using Algorithm Portfolio methodology. After that all the algorithms have been tested on two types of scheduling benchmarks. To apply these algorithms on heat treatment scheduling, a furnace model is developed for optimisation proposes. Furthermore, a system that is capable of selecting the optimal heat treatment regime is developed so the required metal properties can be achieved with the least energy consumption and the shortest time using Neuro-Fuzzy (NF) and Particle Swarm Optimisation (PSO) methodologies. Based on this system, PSO is used to optimise the heat treatment process by selecting different heat treatment conditions. The selected conditions are evaluated so the best selection can be identified. This work addresses the issues involved in developing a suitable methodology for developing an NF system and PSO for mechanical properties of the steel. Using the optimisers, furnace model and heat treatment system model, the intelligent system model is developed and implemented successfully. The results of this system were exciting and the optimisers were working correctly

An intelligent manufacturing system for heat treatment scheduling

This research is focused on the integration problem of process planning and scheduling in steel heat treatment operations environment using artificial intelligent techniques that are capable of dealing with such problems. This work addresses the issues involved in developing a suitable methodology for scheduling heat treatment operations of steel. Several intelligent algorithms have been developed for these propose namely, Genetic Algorithm (GA), Sexual Genetic Algorithm (SGA), Genetic Algorithm with Chromosome differentiation (GACD), Age Genetic Algorithm (AGA), and Mimetic Genetic Algorithm (MGA). These algorithms have been employed to develop an efficient intelligent algorithm using Algorithm Portfolio methodology. After that all the algorithms have been tested on two types of scheduling benchmarks. To apply these algorithms on heat treatment scheduling, a furnace model is developed for optimisation proposes. Furthermore, a system that is capable of selecting the optimal heat treatment regime is developed so the required metal properties can be achieved with the least energy consumption and the shortest time using Neuro-Fuzzy (NF) and Particle Swarm Optimisation (PSO) methodologies. Based on this system, PSO is used to optimise the heat treatment process by selecting different heat treatment conditions. The selected conditions are evaluated so the best selection can be identified. This work addresses the issues involved in developing a suitable methodology for developing an NF system and PSO for mechanical properties of the steel. Using the optimisers, furnace model and heat treatment system model, the intelligent system model is developed and implemented successfully. The results of this system were exciting and the optimisers were working correctly.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Optimizing and Reoptimizing: tackling static and dynamic combinatorial problems

As suggested by the title, in this thesis both static and dynamic problems of Operations Research will be addressed by either designing new procedures or adapting well-known algorithmic schemes. Specifically, the first part of the thesis is devoted to the discussion of three variants of the widely studied Shortest Path Problem, one of which is defined on dynamic graphs. Namely, first the Reoptimization of Shortest Paths in case of multiple and generic cost changes is dealt with an exact algorithm whose performance is compared with Dijkstra's label setting procedure in order to detect which approach has to be preferred. Secondly, the k-Color Shortest Path Problem is tackled. It is a recent problem, defined on an edge-constrained graph, for which a Dynamic Programming algorithm is proposed here; its performance is compared with the state of the art solution approach, namely a Branch & Bound procedure. Finally, the Resource Constrained Clustered Shortest Path Tree Problem is presented. It is a newly defined problem for which both a mathematical model and a Branch & Price procedure are detailed here. Moreover, the performance of this solution approach is compared with that of CPLEX solver. Furthermore, in the first part of the thesis, also the Path Planning in Urban Air Mobility, is discussed by considering both the definition of the Free-Space Maps and the computation of the trajectories. For the former purpose, three different but correlated discretization methods are described; as for the latter, a two steps resolution, offline and online, of the resulting shortest path problems is performed. In addition, it is checked whether the reoptimization algorithm can be used in the online step. In the second part of this thesis, the recently studied Additive Manufacturing Machine Scheduling Problem with not identical machines is presented. Specifically, a Reinforcement Learning Iterated Local Search meta-heuristic featuring a Q-learning Variable Neighbourhood Search is described to solve this problem and its performance is compared with the one of CPLEX solver. It is worthwhile mentioning that, for each of the proposed approaches, a thorough experimentation is performed and each Chapter is equipped with a detailed analysis of the results in order to appraise the performance of the method and to detect its limits

Advances and Novel Approaches in Discrete Optimization

Discrete optimization is an important area of Applied Mathematics with a broad spectrum of applications in many fields. This book results from a Special Issue in the journal Mathematics entitled ‘Advances and Novel Approaches in Discrete Optimization’. It contains 17 articles covering a broad spectrum of subjects which have been selected from 43 submitted papers after a thorough refereeing process. Among other topics, it includes seven articles dealing with scheduling problems, e.g., online scheduling, batching, dual and inverse scheduling problems, or uncertain scheduling problems. Other subjects are graphs and applications, evacuation planning, the max-cut problem, capacitated lot-sizing, and packing algorithms

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

Scheduling, Characterization and Prediction of HPC Workloads for Distributed Computing Environments

As High Performance Computing (HPC) has grown considerably and is expected to grow even more, effective resource management for distributed computing sys- tems is motivated more than ever. As the computational workloads grow in quantity, it is becoming more crucial to apply efficient resource management and workload scheduling to use resources efficiently while keeping the computational performance reasonably good. The problem of efficiently scheduling workloads on resources while meeting performance standards is hard. Additionally, non-clairvoyance of job dimen- sions makes resource management even harder in real-world scenarios. Our research methodology investigates the scheduling problem compliant for HPC and researches the challenges for deploying the scheduling in real world-scenarios using state of the art machine learning and data science techniques.To this end, this Ph.D. dissertation makes the following core contributions: a) We perform a theoretical analysis of space-sharing, non-preemptive scheduling: we studied this scheduling problem and proposed scheduling algorithms with polyno- mial computation time. We also proved constant upper-bounds for the performance of these algorithms. b) We studied the sensitivity of scheduling algorithms to the accuracy of runtime and devised a meta-learning approach to estimate prediction accuracy for newly submitted jobs to the HPC system. c) We studied the runtime prediction problem for HPC applications. For this purpose, we studied the distri- bution of available public workloads and proposed two different solutions that can predict multi-modal distributions: switching state-space models and Mixture Density Networks. d) We studied the effectiveness of recent recurrent neural network models for CPU usage trace prediction for individual VM traces as well as aggregate CPU usage traces. In this dissertation, we explore solutions to improve the performance of scheduling workloads on distributed systems.We begin by looking at the problem from the theoretical perspective. Modeling the problem mathematically, we first propose a scheduling algorithm that finds a constant approximation of the optimal solution for the problem in polynomial time. We prove that the performance of the algorithm (average completion time is the constant approximation of the performance of the optimal scheduling. We next look at the problem in real-world scenarios. Considering High-Performance Computing (HPC) workload computing environments as the most similar real-world equivalent of our mathematical model, we explore the problem of predicting application runtime. We propose an algorithm to handle the existing uncertainties in the real world and show-case our algorithm with demonstrative effectiveness in terms of response time and resource utilization. After looking at the uncertainty problem, we focus on trying to improve the accuracy of existing prediction approaches for HPC application runtime. We propose two solutions, one based on Kalman filters and one based on deep density mixture networks. We showcase the effectiveness of our prediction approaches by comparing with previous prediction approaches in terms of prediction accuracy and impact on improving scheduling performance. In the end, we focus on predicting resource usage for individual applications during their execution. We explore the application of recurrent neural networks for predicting resource usage of applications deployed on individual virtual machines. To validate our proposed models and solutions, we performed extensive trace-driven simulation and measured the effectiveness of our approaches

Applications of biased-randomized algorithms and simheuristics in integrated logistics

Transportation and logistics (T&L) activities play a vital role in the development of many businesses from different industries. With the increasing number of people living in urban areas, the expansion of on-demand economy and e-commerce activities, the number of services from transportation and delivery has considerably increased. Consequently, several urban problems have been potentialized, such as traffic congestion and pollution. Several related problems can be formulated as a combinatorial optimization problem (COP). Since most of them are NP-Hard, the finding of optimal solutions through exact solution methods is often impractical in a reasonable amount of time. In realistic settings, the increasing need for 'instant' decision-making further refutes their use in real life. Under these circumstances, this thesis aims at: (i) identifying realistic COPs from different industries; (ii) developing different classes of approximate solution approaches to solve the identified T&L problems; (iii) conducting a series of computational experiments to validate and measure the performance of the developed approaches. The novel concept of 'agile optimization' is introduced, which refers to the combination of biased-randomized heuristics with parallel computing to deal with real-time decision-making.Las actividades de transporte y logística (T&L) juegan un papel vital en el desarrollo de muchas empresas de diferentes industrias. Con el creciente número de personas que viven en áreas urbanas, la expansión de la economía a lacarta y las actividades de comercio electrónico, el número de servicios de transporte y entrega ha aumentado considerablemente. En consecuencia, se han potencializado varios problemas urbanos, como la congestión del tráfico y la contaminación. Varios problemas relacionados pueden formularse como un problema de optimización combinatoria (COP). Dado que la mayoría de ellos son NP-Hard, la búsqueda de soluciones óptimas a través de métodos de solución exactos a menudo no es práctico en un período de tiempo razonable. En entornos realistas, la creciente necesidad de una toma de decisiones "instantánea" refuta aún más su uso en la vida real. En estas circunstancias, esta tesis tiene como objetivo: (i) identificar COP realistas de diferentes industrias; (ii) desarrollar diferentes clases de enfoques de solución aproximada para resolver los problemas de T&L identificados; (iii) realizar una serie de experimentos computacionales para validar y medir el desempeño de los enfoques desarrollados. Se introduce el nuevo concepto de optimización ágil, que se refiere a la combinación de heurísticas aleatorias sesgadas con computación paralela para hacer frente a la toma de decisiones en tiempo real.Les activitats de transport i logística (T&L) tenen un paper vital en el desenvolupament de moltes empreses de diferents indústries. Amb l'augment del nombre de persones que viuen a les zones urbanes, l'expansió de l'economia a la carta i les activitats de comerç electrònic, el nombre de serveis del transport i el lliurament ha augmentat considerablement. En conseqüència, s'han potencialitzat diversos problemes urbans, com ara la congestió del trànsit i la contaminació. Es poden formular diversos problemes relacionats com a problema d'optimització combinatòria (COP). Com que la majoria són NP-Hard, la recerca de solucions òptimes mitjançant mètodes de solució exactes sovint no és pràctica en un temps raonable. En entorns realistes, la creixent necessitat de prendre decisions "instantànies" refuta encara més el seu ús a la vida real. En aquestes circumstàncies, aquesta tesi té com a objectiu: (i) identificar COP realistes de diferents indústries; (ii) desenvolupar diferents classes d'aproximacions aproximades a la solució per resoldre els problemes identificats de T&L; (iii) la realització d'una sèrie d'experiments computacionals per validar i mesurar el rendiment dels enfocaments desenvolupats. S'introdueix el nou concepte d'optimització àgil, que fa referència a la combinació d'heurístiques esbiaixades i aleatòries amb informàtica paral·lela per fer front a la presa de decisions en temps real.Tecnologies de la informació i de xarxe