Efficient heuristics for the parallel blocking flow shop scheduling problem

We consider the NP-hard problem of scheduling n jobs in F identical parallel flow shops, each consisting of a series of m machines, and doing so with a blocking constraint. The applied criterion is to minimize the makespan, i.e., the maximum completion time of all the jobs in F flow shops (lines). The Parallel Flow Shop Scheduling Problem (PFSP) is conceptually similar to another problem known in the literature as the Distributed Permutation Flow Shop Scheduling Problem (DPFSP), which allows modeling the scheduling process in companies with more than one factory, each factory with a flow shop configuration. Therefore, the proposed methods can solve the scheduling problem under the blocking constraint in both situations, which, to the best of our knowledge, has not been studied previously. In this paper, we propose a mathematical model along with some constructive and improvement heuristics to solve the parallel blocking flow shop problem (PBFSP) and thus minimize the maximum completion time among lines. The proposed constructive procedures use two approaches that are totally different from those proposed in the literature. These methods are used as initial solution procedures of an iterated local search (ILS) and an iterated greedy algorithm (IGA), both of which are combined with a variable neighborhood search (VNS). The proposed constructive procedure and the improved methods take into account the characteristics of the problem. The computational evaluation demonstrates that both of them –especially the IGA– perform considerably better than those algorithms adapted from the DPFSP literature.Peer ReviewedPostprint (author's final draft

NEH-based heuristics for the permutation flowshop scheduling problem to minimize total tardiness

Since Johnson׳s seminal paper in 1954, scheduling jobs in a permutation flowshop has been receiving the attention of hundreds of practitioners and researchers, being one of the most studied topics in the Operations Research literature. Among the different objectives that can be considered, minimising the total tardiness (i.e. the sum of the surplus of the completion time of each job over its due date) is regarded as a key objective for manufacturing companies, as it entails the fulfilment of the due dates committed to customers. Since this problem is known to be NP-hard, most research has focused on proposing approximate procedures to solve it in reasonable computation times. Particularly, several constructive heuristics have been proposed, with NEHedd being the most efficient one, serving also to provide an initial solution for more elaborate approximate procedures. In this paper, we first analyse in detail the decision problem depending on the generation of the due dates of the jobs, and discuss the similarities with different related decision problems. In addition, for the most characteristic tardiness scenario, the analysis shows that a huge number of ties appear during the construction of the solutions done by the NEHedd heuristic, and that wisely breaking the ties greatly influences the quality of the final solution. Since no tie-breaking mechanism has been designed for this heuristic up to now, we propose several mechanisms that are exhaustively tested. The results show that some of them outperform the original NEHedd by about 25% while keeping the same computational requirements.Ministerio de Ciencia e Innovación DPI2010-15573/DPIMinisterio de Ciencia e Innovación DPI2013-44461-P/DP

The Distributed and Assembly Scheduling Problem

Tesis por compendio[EN] Nowadays, manufacturing systems meet different new global challenges and the existence of a collaborative manufacturing environment is essential to face with. Distributed manufacturing and assembly systems are two manufacturing systems which allow industries to deal with some of these challenges. This thesis studies a production problem in which both distributed manufacturing and assembly systems are considered. Although distributed manufacturing systems and assembly systems are well-known problems and have been extensively studied in the literature, to the best of our knowledge, considering these two systems together as in this thesis is the first effort in the literature. Due to the importance of scheduling optimization on production performance, some different ways to optimize the scheduling of the considered problem are discussed in this thesis. The studied scheduling setting consists of two stages: A production and an assembly stage. Various production centers make the first stage. Each of these centers consists of several machines which are dedicated to manufacture jobs. A single assembly machine is considered for the second stage. The produced jobs are assembled on the assembly machine to form final products through a defined assembly program. In this thesis, two different problems regarding two different production configurations for the production centers of the first stage are considered. The first configuration is a flowshop that results in what we refer to as the Distributed Assembly Permutation Flowshop Scheduling Problem (DAPFSP). The second problem is referred to as the Distributed Parallel Machine and Assembly Scheduling Problem (DPMASP), where unrelated parallel machines configure the production centers. Makespan minimization of the product on the assembly machine located in the assembly stage is considered as the objective function for all considered problems. In this thesis some extensions are considered for the studied problems so as to bring them as close as possible to the reality of production shops. In the DAPFSP, sequence dependent setup times are added for machines in both production and assembly stages. Similarly, in the DPMASP, due to technological constraints, some defined jobs can be processed only in certain factories. Mathematical models are presented as an exact solution for some of the presented problems and two state-of-art solvers, CPLEX and GUROBI are used to solve them. Since these solvers are not able to solve large sized problems, we design and develop heuristic methods to solve the problems. In addition to heuristics, some metaheuristics are also designed and proposed to improve the solutions obtained by heuristics. Finally, for each proposed problem, the performance of the proposed solution methods is compared through extensive computational and comprehensive ANOVA statistical analysis.[ES] Los sistemas de producción se enfrentan a retos globales en los que el concepto de fabricación colaborativa es crucial para poder tener éxito en el entorno cambiante y complejo en el que nos encontramos. Una característica de los sistemas productivos que puede ayudar a lograr este objetivo consiste en disponer de una red de fabricación distribuida en la que los productos se fabriquen en localizaciones diferentes y se vayan ensamblando para obtener el producto final. En estos casos, disponer de modelos y herramientas para mejorar el rendimiento de sistemas de producción distribuidos con ensamblajes es una manera de asegurar la eficiencia de los mismos. En esta tesis doctoral se estudian los sistemas de fabricación distribuidos con operaciones de ensamblaje. Los sistemas distribuidos y los sistemas con operaciones de ensamblaje han sido estudiados por separado en la literatura. De hecho, no se han encontrado estudios de sistemas con ambas características consideradas de forma conjunta. Dada la complejidad de considerar conjuntamente ambos tipos de sistemas a la hora de realizar la programación de la producción en los mismos, se ha abordado su estudio considerando un modelo bietápico en la que en la primera etapa se consideran las operaciones de producción y en la segunda se plantean las operaciones de ensamblaje. Dependiendo de la configuración de la primera etapa se han estudiado dos variantes. En la primera variante se asume que la etapa de producción está compuesta por sendos sistemas tipo flowshop en los que se fabrican los componentes que se ensamblan en la segunda etapa (Distributed Assembly Permutation Flowshop Scheduling Problem o DAPFSP). En la segunda variante se considera un sistema de máquinas en paralelo no relacionadas (Distributed Parallel Machine and Assembly Scheduling Problem o DPMASP). En ambas variantes se optimiza la fecha de finalización del último trabajo secuenciado (Cmax) y se contempla la posibilidad que existan tiempos de cambio (setup) dependientes de la secuencia de trabajos fabricada. También, en el caso DPMASP se estudia la posibilidad de prohibir o no el uso de determinadas máquinas de la etapa de producción. Se han desarrollado modelos matemáticos para resolver algunas de las variantes anteriores. Estos modelos se han resuelto mediante los programas CPLEX y GUROBI en aquellos casos que ha sido posible. Para las instancias en los que el modelo matemático no ofrecía una solución al problema se han desarrollado heurísticas y metaheurísticas para ello. Todos los procedimientos anteriores han sido estudiados para determinar el rendimiento de los diferentes algoritmos planteados. Para ello se ha realizado un exhaustivo estudio computacional en el que se han aplicado técnicas ANOVA. Los resultados obtenidos en la tesis permiten avanzar en la comprensión del comportamiento de los sistemas productivos distribuidos con ensamblajes, definiendo algoritmos que permiten obtener buenas soluciones a este tipo de problemas tan complejos que aparecen tantas veces en la realidad industrial.[CA] Els sistemes de producció s'enfronten a reptes globals en què el concepte de fabricació col.laborativa és crucial per a poder tindre èxit en l'entorn canviant i complex en què ens trobem. Una característica dels sistemes productius que pot ajudar a aconseguir este objectiu consistix a disposar d'una xarxa de fabricació distribuïda en la que els productes es fabriquen en localitzacions diferents i es vagen acoblant per a obtindre el producte final. En estos casos, disposar de models i ferramentes per a millorar el rendiment de sistemes de producció distribuïts amb acoblaments és una manera d'assegurar l'eficiència dels mateixos. En esta tesi doctoral s'estudien els sistemes de fabricació distribuïts amb operacions d'acoblament. Els sistemes distribuïts i els sistemes amb operacions d'acoblament han sigut estudiats per separat en la literatura però, en allò que es coneix, no s'han trobat estudis de sistemes amb ambdós característiques conjuntament. Donada la complexitat de considerar conjuntament ambdós tipus de sistemes a l'hora de realitzar la programació de la producció en els mateixos, s'ha abordat el seu estudi considerant un model bietàpic en la que en la primera etapa es consideren les operacions de producció i en la segona es plantegen les operacions d'acoblament. Depenent de la configuració de la primera etapa s'han estudiat dos variants. En la primera variant s'assumix que l'etapa de producció està composta per sengles sistemes tipus flowshop en els que es fabriquen els components que s'acoblen en la segona etapa (Distributed Assembly Permutation Flowshop Scheduling Problem o DAPFSP). En la segona variant es considera un sistema de màquines en paral.lel no relacionades (Distributed Parallel Machine and Assembly Scheduling Problem o DPMASP). En ambdós variants s'optimitza la data de finalització de l'últim treball seqüenciat (Cmax) i es contempla la possibilitat que existisquen temps de canvi (setup) dependents de la seqüència de treballs fabricada. També, en el cas DPMASP s'estudia la possibilitat de prohibir o no l'ús de determinades màquines de l'etapa de producció. S'han desenvolupat models matemàtics per a resoldre algunes de les variants anteriors. Estos models s'han resolt per mitjà dels programes CPLEX i GUROBI en aquells casos que ha sigut possible. Per a les instàncies en què el model matemàtic no oferia una solució al problema s'han desenrotllat heurístiques i metaheurísticas per a això. Tots els procediments anteriors han sigut estudiats per a determinar el rendiment dels diferents algoritmes plantejats. Per a això s'ha realitzat un exhaustiu estudi computacional en què s'han aplicat tècniques ANOVA. Els resultats obtinguts en la tesi permeten avançar en la comprensió del comportament dels sistemes productius distribuïts amb acoblaments, definint algoritmes que permeten obtindre bones solucions a este tipus de problemes tan complexos que apareixen tantes vegades en la realitat industrial.Hatami, S. (2016). The Distributed and Assembly Scheduling Problem [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/64072TESISCompendi

Heuristics for scheduling a two-stage hybrid flow shop with parallel batching machines: application at a hospital sterilisation plant

The model of a two-stage hybrid (or flexible) flow shop, with sequence-independent uniform setup times, parallel batching machines and parallel batches has been analysed with the purpose of reducing the number of tardy jobs and the makespan in a sterilisation plant. Jobs are processed in parallel batches by multiple identical parallel machines. Manual operations preceding each of the two stages have been dealt with as machine setup with standardised times and are sequence-independent. A mixed-integer model is proposed. Two heuristics have been tested on real benchmark data from an existing sterilisation plant: constrained size of parallel batches and fixed time slots. Computation experiments performed on combinations of machines and operator numbers suggest balancing the two stages by assigning operators proportionally to the setup time requirements

Scheduling flow lines with buffers by ant colony digraph

This work starts from modeling the scheduling of n jobs on m machines/stages as flowshop with buffers in manufacturing. A mixed-integer linear programing model is presented, showing that buffers of size n - 2 allow permuting sequences of jobs between stages. This model is addressed in the literature as non-permutation flowshop scheduling (NPFS) and is described in this article by a disjunctive graph (digraph) with the purpose of designing specialized heuristic and metaheuristics algorithms for the NPFS problem. Ant colony optimization (ACO) with the biologically inspired mechanisms of learned desirability and pheromone rule is shown to produce natively eligible schedules, as opposed to most metaheuristics approaches, which improve permutation solutions found by other heuristics. The proposed ACO has been critically compared and assessed by computation experiments over existing native approaches. Most makespan upper bounds of the established benchmark problems from Taillard (1993) and Demirkol, Mehta, and Uzsoy (1998) with up to 500 jobs on 20 machines have been improved by the proposed ACO

An Iterated Greedy Heuristic for Mixed No-Wait Flowshop Problems

[EN] The mixed no-wait flowshop problem with both wait and no-wait constraints has many potential real-life applications. The problem can be regarded as a generalization of the traditional permutation flowshop and the no-wait flowshop. In this paper, we study, for the first time, this scheduling setting with makespan minimization. We first propose a mathematical model and then we design a speed-up makespan calculation procedure. By introducing a varying number of destructed jobs, a modified iterated greedy algorithm is proposed for the considered problem which consists of four components: 1) initialization solution construction; 2) destruction; 3) reconstruction; and 4) local search. To further improve the intensification and efficiency of the proposal, insertion is performed on some neighbor jobs of the best position in a sequence during the initialization, solution construction, and reconstruction phases. After calibrating parameters and components, the proposal is compared with five existing algorithms for similar problems on adapted Taillard benchmark instances. Experimental results show that the proposal always obtains the best performance among the compared methods.This work was supported in part by the National Natural Science Foundation of China under Grant 61572127 and 61272377, in part by the Key Research and Development Program in Jiangsu Province under Grant BE2015728, and in part by the Collaborative Innovation Center of Wireless Communications Technology. The work of R. Ruiz was supported in part by the Spanish Ministry of Economy and Competitiveness through the project "SCHEYARD-Optimization of Scheduling Problems in Container Yards" under Grant DPI2015-65895-R, and in part by the FEDER Funds.Wang, Y.; Li, X.; Ruiz García, R.; Sui, S. (2018). An Iterated Greedy Heuristic for Mixed No-Wait Flowshop Problems. IEEE Transactions on Cybernetics. 48(5):1553-1566. https://doi.org/10.1109/TCYB.2017.2707067S1553156648

Minimizing the makespan in a flexible flowshop with sequence dependent setup times, uniform machines, and limited buffers

This research addresses the problem of minimizing the makespan in a flexible flowshop with sequence dependent setup times, uniform machines, and limited buffers. A mathematical model was developed to solve this problem. The problem is NP-Hard in the strong sense and only very small problems could be solved optimally. For exact methods, the computation times are long and not practical even when the problems are relatively small. Two construction heuristics were developed that could find solutions quickly. Also a simulated annealing heuristic was constructed that improved the solutions obtained from the construction heuristics. The combined heuristics could compute a good solution in a short amount of time. The heuristics were tested in three different environments: 3 stages, 4 stages, and 5 stages. To assess the quality of the solutions, a lower bound and two simple heuristics were generated for comparison purposes. The proposed heuristics showed steady improvement over the simple heuristics. When compared to the lower bounds, the heuristics performed well for the smaller environment, but the performance quality decreased as the number of stages increased. The combination of these heuristics defiantly shows promise for solving the problem

The distributed assembly permutation flowshop scheduling problem

Nowadays, improving the management of complex supply chains is a key to become competitive in the twenty-first century global market. Supply chains are composed of multi-plant facilities that must be coordinated and synchronised to cut waste and lead times. This paper proposes a Distributed Assembly Permutation Flowshop Scheduling Problem (DAPFSP) with two stages to model and study complex supply chains. This problem is a generalisation of the Distributed Permutation Flowshop Scheduling Problem (DPFSP). The first stage of the DAPFSP is composed of f identical production factories. Each one is a flowshop that produces jobs to be assembled into final products in a second assembly stage. The objective is to minimise the makespan. We present first a Mixed Integer Linear Programming model (MILP). Three constructive algorithms are proposed. Finally, a Variable Neighbourhood Descent (VND) algorithm has been designed and tested by a comprehensive ANOVA statistical analysis. The results show that the VND algorithm offers good performance to solve this scheduling problem.Ruben Ruiz is partially supported by the Spanish Ministry of Science and Innovation, under the project 'RESULT - Realistic Extended Scheduling Using Light Techniques' with reference DPI2012-36243-C02-01. Carlos Andres-Romano is partially supported by the Spanish Ministry of Science and Innovation, under the project 'INSAMBLE' - Scheduling at assembly/disassembly synchronised supply chains with reference DPI2011-27633.Hatami, S.; Ruiz García, R.; Andrés Romano, C. (2013). The distributed assembly permutation flowshop scheduling problem. International Journal of Production Research. 51(17):5292-5308. https://doi.org/10.1080/00207543.2013.807955S529253085117Basso, D., Chiarandini, M., & Salmaso, L. (2007). Synchronized permutation tests in replicated designs. Journal of Statistical Planning and Inference, 137(8), 2564-2578. doi:10.1016/j.jspi.2006.04.016Biggs, D., De Ville, B., & Suen, E. 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Approximation algorithms for the parallel flow shop problem

We consider the NP-hard problem of scheduling n jobs in m two-stage parallel flow shops so as to minimize the makespan. This problem decomposes into two subproblems: assigning the jobs to parallel flow shops; and scheduling the jobs assigned to the same flow shop by use of Johnson's rule. For m = 2, we present a 32-approximation algorithm, and for m = 3, we present a 127-approximation algorithm. Both these algorithms run in O(n log n) time. These are the first approximation algorithms with fixed worst-case performance guarantees for the parallel flow shop problem

A survey of scheduling problems with setup times or costs

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