Automatic Design of Dispatching Rules for Job Shop Scheduling with Genetic Programming

Scheduling is an important planning activity in manufacturing systems to help optimise the usage of scarce resources and improve the customer satisfaction. In the job shop manufacturing environment, scheduling problems are challenging due to the complexity of production flows and practical requirements such as dynamic changes, uncertainty, multiple objectives, and multiple scheduling decisions. Also, job shop scheduling (JSS) is very common in small manufacturing businesses and JSS is considered one of the most popular research topics in this domain due to its potential to dramatically decrease the costs and increase the throughput. Practitioners and researchers have applied different computational techniques, from different fields such as operations research and computer science, to deal with JSS problems. Although optimisation methods usually show their dominance in the literature, applying optimisation techniques in practical situations is not straightforward because of the practical constraints and conditions in the shop. Dispatching rules are a very useful approach to dealing with these environments because they are easy to implement(by computers and shop floor operators) and can cope with dynamic changes. However, designing an effective dispatching rule is not a trivial task and requires extensive knowledge about the scheduling problem. The overall goal of this thesis is to develop a genetic programming based hyper-heuristic (GPHH) approach for automatic heuristic design of reusable and competitive dispatching rules in job shop scheduling environments. This thesis focuses on incorporating special features of JSS in the representations and evolutionary search mechanisms of genetic programming(GP) to help enhance the quality of dispatching rules obtained. This thesis shows that representations and evaluation schemes are the important factors that significantly influence the performance of GP for evolving dispatching rules. The thesis demonstrates that evolved rules which are trained to adapt their decisions based on the changes in shops are better than conventional rules. Moreover, by applying a new evaluation scheme, the evolved rules can effectively learn from the mistakes made in previous completed schedules to construct better scheduling decisions. The GP method using the newproposed evaluation scheme shows better performance than the GP method using the conventional scheme. This thesis proposes a new multi-objective GPHH to evolve a Pareto front of non-dominated dispatching rules. Instead of evolving a single rule with assumed preferences over different objectives, the advantage of this GPHH method is to allow GP to evolve rules to handle multiple conflicting objectives simultaneously. The Pareto fronts obtained by the GPHH method can be used as an effective tool to help decision makers select appropriate rules based on their knowledge regarding possible trade-offs. The thesis shows that evolved rules can dominate well-known dispatching rules when a single objective and multiple objectives are considered. Also, the obtained Pareto fronts show that many evolved rules can lead to favourable trade-offs, which have not been explored in the literature. This thesis tackles one of themost challenging issues in job shop scheduling, the interactions between different scheduling decisions. New GPHH methods have been proposed to help evolve scheduling policies containing multiple scheduling rules for multiple scheduling decisions. The two decisions examined in this thesis are sequencing and due date assignment. The experimental results show that the evolved scheduling rules are significantly better than scheduling policies in the literature. A cooperative coevolution approach has also been developed to reduce the complexity of evolving sophisticated scheduling policies. A new evolutionary search mechanisms and customised genetic operations are proposed in this approach to improve the diversity of the obtained Pareto fronts

A hyper-heuristic ensemble method for static job-shop scheduling.

We describe a new hyper-heuristic method NELLI-GP for solving job-shop scheduling problems (JSSP) that evolves an ensemble of heuristics. The ensemble adopts a divide-and-conquer approach in which each heuristic solves a unique subset of the instance set considered. NELLI-GP extends an existing ensemble method called NELLI by introducing a novel heuristic generator that evolves heuristics composed of linear sequences of dispatching rules: each rule is represented using a tree structure and is itself evolved. Following a training period, the ensemble is shown to outperform both existing dispatching rules and a standard genetic programming algorithm on a large set of new test instances. In addition, it obtains superior results on a set of 210 benchmark problems from the literature when compared to two state-of-the-art hyperheuristic approaches. Further analysis of the relationship between heuristics in the evolved ensemble and the instances each solves provides new insights into features that might describe similar instances

Many-Objective Genetic Programming for Job-Shop Scheduling

The Job Shop Scheduling (JSS) problem is considered to be a challenging one due to practical requirements such as multiple objectives and the complexity of production flows. JSS has received great attention because of its broad applicability in real-world situations. One of the prominent solutions approaches to handling JSS problems is to design effective dispatching rules. Dispatching rules are investigated broadly in both academic and industrial environments because they are easy to implement (by computers and shop floor operators) with a low computational cost. However, the manual development of dispatching rules is time-consuming and requires expert knowledge of the scheduling environment. The hyper-heuristic approach that uses genetic programming (GP) to solve JSS problems is known as GP-based hyper-heuristic (GP-HH). GP-HH is a very useful approach for discovering dispatching rules automatically. Although it is technically simple to consider only a single objective optimization for JSS, it is now widely evidenced in the literature that JSS by nature presents several potentially conflicting objectives, including the maximal flowtime, mean flowtime, and mean tardiness. A few studies in the literature attempt to solve many-objective JSS with more than three objectives, but existing studies have some major limitations. First, many-objective JSS problems have been solved by multi-objective evolutionary algorithms (MOEAs). However, recent studies have suggested that the performance of conventional MOEAs is prone to the scalability challenge and degrades dramatically with many-objective optimization problems (MaOPs). Many-objective JSS using MOEAs inherit the same challenge as MaOPs. Thus, using MOEAs for many-objective JSS problems often fails to select quality dispatching rules. Second, although the reference points method is one of the most prominent and efficient methods for diversity maintenance in many-objective problems, it uses a uniform distribution of reference points which is only appropriate for a regular Pareto-front. However, JSS problems often have irregular Pareto-front and uniformly distributed reference points do not match well with the irregular Pareto-front. It results in many useless points during evolution. These useless points can significantly affect the performance of the reference points-based algorithms. They cannot help to enhance the solution diversity of evolved Pareto-front in many-objective JSS problems. Third, Pareto Local Search (PLS) is a prominent and effective local search method for handling multi-objective JSS optimization problems but the literature does not discover any existing studies which use PLS in GP-HH. To address these limitations, this thesis's overall goal is to develop GP-HH approaches to evolving effective rules to handle many conflicting objectives simultaneously in JSS problems. To achieve the first goal, this thesis proposes the first many-objective GP-HH method for JSS problems to find the Pareto-fronts of nondominated dispatching rules. Decision-makers can utilize this GP-HH method for selecting appropriate rules based on their preference over multiple conflicting objectives. This study combines GP with the fitness evaluation scheme of a many-objective reference points-based approach. The experimental results show that the proposed algorithm significantly outperforms MOEAs such as NSGA-II and SPEA2. To achieve the second goal, this thesis proposes two adaptive reference point approaches (model-free and model-driven). In both approaches, the reference points are generated according to the distribution of the evolved dispatching rules. The model-free reference point adaptation approach is inspired by Particle Swarm Optimization (PSO). The model-driven approach constructs the density model and estimates the density of solutions from each defined sub-location in a whole objective space. Furthermore, the model-driven approach provides smoothness to the model by applying a Gaussian Process model and calculating the area under the mean function. The mean function area helps to find the required number of the reference points in each mean function. The experimental results demonstrate that both adaptive approaches are significantly better than several state-of-the-art MOEAs. To achieve the third goal, the thesis proposes the first algorithm that combines GP as a global search with PLS as a local search in many-objective JSS. The proposed algorithm introduces an effective fitness-based selection strategy for selecting initial individuals for neighborhood exploration. It defines the GP's proper neighborhood structure and a new selection mechanism for selecting the effective dispatching rules during the local search. The experimental results on the JSS benchmark problem show that the newly proposed algorithm can significantly outperform its baseline algorithm (GP-NSGA-III)

An apprenticeship learning hyper-heuristic for vehicle routing in HyFlex

Apprenticeship learning occurs via observations while an expert is in action. A hyper-heuristic is a search method or a learning mechanism that controls a set of low level heuristics or combines different heuristic components to generate heuristics for solving a given computationally hard problem. In this study, we investigate into a novel apprenticeship learning-based approach which is used to automatically generate a hyper-heuristic for vehicle routing. This approach itself can be considered as a hyper-heuristic which operates in a train and test fashion. A state-of-the-art hyper-heuristic is chosen as an expert which is the winner of a previous hyper-heuristic competition. Trained on small vehicle routing instances, the learning approach yields various classifiers, each capturing different actions that the expert hyper-heuristic performs during the search process. Those classifiers are then used to produce a hyper-heuristic which is potentially capable of generalizing the actions of the expert hyperheuristic while solving the unseen instances. The experimental results on vehicle routing using the Hyper-heuristic Flexible (HyFlex) framework shows that the apprenticeship-learning based hyper-heuristic delivers an outstanding performance when compared to the expert and some other previously proposed hyper-heuristics

Evolutionary methods for the design of dispatching rules for complex and dynamic scheduling problems

Three methods, based on Evolutionary Algorithms (EAs), to support and automate the design of dispatching rules for complex and dynamic scheduling problems are proposed in this thesis. The first method employs an EA to search for problem instances on which a given dispatching rule performs badly. These instances can then be analysed to reveal weaknesses of the tested rule, thereby providing guidelines for the design of a better rule. The other two methods are hyper-heuristics, which employ an EA directly to generate effective dispatching rules. In particular, one hyper-heuristic is based on a specific type of EA, called Genetic Programming (GP), and generates a single rule from basic job and machine attributes, while the other generates a set of work centre-specific rules by selecting a (potentially) different rule for each work centre from a number of existing rules. Each of the three methods is applied to some complex and dynamic scheduling problem(s), and the resulting dispatching rules are tested against benchmark rules from the literature. In each case, the benchmark rules are shown to be outperformed by a rule (set) that results from the application of the respective method, which demonstrates the effectiveness of the proposed methods

Entwicklung und Einführung von Produktionssteuerungsverbesserungen für die kundenorientierte Halbleiterfertigung

Production control in a semiconductor production facility is a very complex and timeconsuming task. Different demands regarding facility performance parameters are defined by customer and facility management. These requirements are usually opponents, and an efficient strategy is not simple to define. In semiconductor manufacturing, the available production control systems often use priorities to define the importance of each production lot. The production lots are ranked according to the defined priorities. This process is called dispatching. The priority allocation is carried out by special algorithms. In literature, a huge variety of different strategies and rules is available. For the semiconductor foundry business, there is a need for a very flexible and adaptable policy taking the facility state and the defined requirements into account. At our case the production processes are characterized by a low-volume high-mix product portfolio. This portfolio causes additional stability problems and performance lags. The unstable characteristic increases the influence of reasonable production control logic. This thesis offers a very flexible and adaptable production control policy. This policy is based on a detailed facility model with real-life production data. The data is extracted from a real high-mix low-volume semiconductor facility. The dispatching strategy combines several dispatching rules. Different requirements like line balance, throughput optimization and on-time delivery targets can be taken into account. An automated detailed facility model calculates a semi-optimal combination of the different dispatching rules under a defined objective function. The objective function includes different demands from the management and the customer. The optimization is realized by a genetic heuristic for a fast and efficient finding of a close-to-optimal solution. The strategy is evaluated with real-life production data. The analysis with the detailed facility model of this fab shows an average improvement of 5% to 8% for several facility performance parameters like cycle time per mask layer. Finally the approach is realized and applied at a typical high-mix low-volume semiconductor facility. The system realization bases on a JAVA implementation. This implementation includes common state-of-the-art technologies such as web services. The system replaces the older production control solution. Besides the dispatching algorithm, the production policy includes the possibility to skip several metrology operations under defined boundary conditions. In a real-life production process, not all metrology operations are necessary for each lot. The thesis evaluates the influence of the sampling mechanism to the production process. The solution is included into the system implementation as a framework to assign different sampling rules to different metrology operations. Evaluations show greater improvements at bottleneck situations. After the productive introduction and usage of both systems, the practical results are evaluated. The staff survey offers good acceptance and response to the system. Furthermore positive effects on the performance measures are visible. The implemented system became part of the daily tools of a real semiconductor facility.Produktionssteuerung im Bereich der kundenorientierten Halbleiterfertigung ist heutzutage eine sehr komplexe und zeitintensive Aufgabe. Verschiedene Anforderungen bezüglich der Fabrikperformance werden seitens der Kunden als auch des Fabrikmanagements definiert. Diese Anforderungen stehen oftmals in Konkurrenz. Dadurch ist eine effiziente Strategie zur Kompromissfindung nicht einfach zu definieren. Heutige Halbleiterfabriken mit ihren verfügbaren Produktionssteuerungssystemen nutzen oft prioritätsbasierte Lösungen zur Definition der Wichtigkeit eines jeden Produktionsloses. Anhand dieser Prioritäten werden die Produktionslose sortiert und bearbeitet. In der Literatur existiert eine große Bandbreite verschiedener Algorithmen. Im Bereich der kundenorientierten Halbleiterfertigung wird eine sehr flexible und anpassbare Strategie benötigt, die auch den aktuellen Fabrikzustand als auch die wechselnden Kundenanforderungen berücksichtigt. Dies gilt insbesondere für den hochvariablen geringvolumigen Produktionsfall. Diese Arbeit behandelt eine flexible Strategie für den hochvariablen Produktionsfall einer solchen Produktionsstätte. Der Algorithmus basiert auf einem detaillierten Fabriksimulationsmodell mit Rückgriff auf Realdaten. Neben synthetischen Testdaten wurde der Algorithmus auch anhand einer realen Fertigungsumgebung geprüft. Verschiedene Steuerungsregeln werden hierbei sinnvoll kombiniert und gewichtet. Wechselnde Anforderungen wie Linienbalance, Durchsatz oder Liefertermintreue können adressiert und optimiert werden. Mittels einer definierten Zielfunktion erlaubt die automatische Modellgenerierung eine Optimierung anhand des aktuellen Fabrikzustandes. Die Optimierung basiert auf einen genetischen Algorithmus für eine flexible und effiziente Lösungssuche. Die Strategie wurde mit Realdaten aus der Fertigung einer typischen hochvariablen geringvolumigen Halbleiterfertigung geprüft und analysiert. Die Analyse zeigt ein Verbesserungspotential von 5% bis 8% für die bekannten Performancekriterien wie Cycletime im Vergleich zu gewöhnlichen statischen Steuerungspolitiken. Eine prototypische Implementierung realisiert diesen Ansatz zur Nutzung in der realen Fabrikumgebung. Die Implementierung basiert auf der JAVA-Programmiersprache. Aktuelle Implementierungsmethoden erlauben den flexiblen Einsatz in der Produktionsumgebung. Neben der Fabriksteuerung wurde die Möglichkeit der Reduktion von Messoperationszeit (auch bekannt unter Sampling) unter gegebenen Randbedingungen einer hochvariablen geringvolumigen Fertigung untersucht und geprüft. Oftmals ist aufgrund stabiler Prozesse in der Fertigung die Messung aller Lose an einem bestimmten Produktionsschritt nicht notwendig. Diese Arbeit untersucht den Einfluss dieses gängigen Verfahrens aus der Massenfertigung für die spezielle geringvolumige Produktionsumgebung. Die Analysen zeigen insbesondere in Ausnahmesituationen wie Anlagenausfällen und Kapazitätsengpässe einen positiven Effekt, während der Einfluss unter normalen Produktionsbedingungen aufgrund der hohen Produktvariabilität als gering angesehen werden kann. Nach produktiver Einführung in einem typischen Vertreter dieser Halbleiterfabriken zeigten sich schnell positive Effekte auf die Fabrikperformance als auch eine breite Nutzerakzeptanz. Das implementierte System wurde Bestandteil der täglichen genutzten Werkzeuglandschaft an diesem Standort

Genetic Programming Hyper-heuristics for Job Shop Scheduling

Scheduling problems arise whenever there is a choice of order in which a number of tasks should be performed; they arise commonly, daily and everywhere. A job shop is a common manufacturing environment in which a schedule for processing a set of jobs through a set of machines needs to be constructed. Job shop scheduling (JSS) has been called a fascinating challenge as it is computationally hard and prevalent in the real-world. Developing more effective ways of scheduling jobs could increase profitability through increasing throughput and decreasing costs. Dispatching rules (DRs) are one of the most popular scheduling heuristics. DRs are easy to implement, have low computational cost, and cope well with the dynamic nature of real-world manufacturing environments. However, the manual development of DRs is time consuming and requires expert knowledge of the scheduling environment. Genetic programming (GP) is an evolutionary computation method which is ideal for automatically discovering DRs. This is a hyper-heuristic approach, as GP is searching the search space of heuristic (DR) solutions rather than constructing a schedule directly. The overall goal of this thesis is to develop GP based hyper-heuristics for the efficient evolution (automatic generation) of robust, reusable and effective scheduling heuristics for JSS environments, with greater interpretability. Firstly, this thesis investigates using GP to evolve optimal DRs for the static two-machine JSS problem with makespan objective function. The results show that some evolved DRs were equivalent to an optimal scheduling algorithm. This validates both the GP based hyper-heuristic approach for generating DRs for JSS and the representation used. Secondly, this thesis investigates developing ``less-myopic'' DRs through the use of wider-looking terminals and local search to provide additional fitness information. The results show that incorporating features of the state of the wider shop improves the mean performance of the best evolved DRs, and that the inclusion of local search in evaluation evolves DRs which make better decisions over the local time horizon, and attain lower total weighted tardiness. Thirdly, this thesis proposes using strongly typed GP (STGP) to address the challenging issue of interpretability of DRs evolved by GP. Several grammars are investigated and the results show that the DRs evolved in the semantically constrained search space of STGP do not have (on average) performance that is as good as unconstrained. However, the interpretability of evolved rules is substantially improved. Fourthly, this thesis investigates using multiobjective GP to encourage evolution of DRs which are more readily interpretable by human operators. This approach evolves DRs with similar performance but smaller size. Fragment analysis identifies popular combinations of terminals which are then used as high level terminals; the inclusion of these terminals improved the mean performance of the best evolved DRs. Through this thesis the following major contributions have been made: (1) the first use of GP to evolve optimal DRs for the static two-machine job shop with makespan objective function; (2) an approach to developing less-myopic DRs through the inclusion of wider looking terminals and the use of local search to provide additional fitness information over an extended decision horizon; (3) the first use of STGP for the automatic discovery of DRs with better interpretability and semantic validity for increased trust; and (4) the first multiobjective GP approach that considers multiple objectives investigating the trade-off between scheduling behaviour and interpretability. This is also the first work that uses analysis of evolved GP individuals to perform feature selection and construction for JSS