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

Scheduling Models with Additional Features: Synchronization, Pliability and Resiliency

In this thesis we study three new extensions of scheduling models with both practical and theoretical relevance, namely synchronization, pliability and resiliency. Synchronization has previously been studied for flow shop scheduling and we now apply the concept to open shop models for the first time. Here, as opposed to the traditional models, operations that are processed together all have to be started at the same time. Operations that are completed are not removed from the machines until the longest operation in their group is finished. Pliability is a new approach to model flexibility in flow shops and open shops. In scheduling with pliability, parts of the processing load of the jobs can be re-distributed between the machines in order to achieve better schedules. This is applicable, for example, if the machines represent cross-trained workers. Resiliency is a new measure for the quality of a given solution if the input data are uncertain. A resilient solution remains better than some given bound, even if the original input data are changed. The more we can perturb the input data without the solution losing too much quality, the more resilient the solution is. We also consider the assignment problem, as it is the traditional combinatorial optimization problem underlying many scheduling problems. Particularly, we study a version of the assignment problem with a special cost structure derived from the synchronous open shop model and obtain new structural and complexity results. Furthermore we study resiliency for the assignment problem. The main focus of this thesis is the study of structural properties, algorithm development and complexity. For synchronous open shop we show that for a fixed number of machines the makespan can be minimized in polynomial time. All other traditional scheduling objectives are at least as hard to optimize as in the traditional open shop model. Starting out research in pliability we focus on the most general case of the model as well as two relevant special cases. We deliver a fairly complete complexity study for all three versions of the model. Finally, for resiliency, we investigate two different questions: `how to compute the resiliency of a given solution?' and `how to find a most resilient solution?'. We focus on the assignment problem and single machine scheduling to minimize the total sum of completion times and present a number of positive results for both questions. The main goal is to make a case that the concept deserves further study

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

Continuous Process Improvement Implementation Framework Using Multi-Objective Genetic Algorithms and Discrete Event Simulation

The file attached to this record is the author's final peer reviewed version. The Publisher's final version can be found by following the DOI link.Purpose Continuous process improvement is a hard problem, especially in high variety/low volume environments due to the complex interrelationships between processes. The purpose of this paper is to address the process improvement issues by simultaneously investigating the job sequencing and buffer size optimization problems. Design/methodology/approach This paper proposes a continuous process improvement implementation framework using a modified genetic algorithm (GA) and discrete event simulation to achieve multi-objective optimization. The proposed combinatorial optimization module combines the problem of job sequencing and buffer size optimization under a generic process improvement framework, where lead time and total inventory holding cost are used as two combinatorial optimization objectives. The proposed approach uses the discrete event simulation to mimic the manufacturing environment, the constraints imposed by the real environment and the different levels of variability associated with the resources. Findings Compared to existing evolutionary algorithm-based methods, the proposed framework considers the interrelationship between succeeding and preceding processes and the variability induced by both job sequence and buffer size problems on each other. A computational analysis shows significant improvement by applying the proposed framework. Originality/value Significant body of work exists in the area of continuous process improvement, discrete event simulation and GAs, a little work has been found where GAs and discrete event simulation are used together to implement continuous process improvement as an iterative approach. Also, a modified GA simultaneously addresses the job sequencing and buffer size optimization problems by considering the interrelationships and the effect of variability due to both on each other

Shop Scheduling In The Presence Of Batching, Sequence-dependent Setups And Incompatible Job Families Minimizing Earliness And Tardiness Penalties

The motivation of this research investigation stems from a particular job shop production environment at a large international communications and information technology company in which electro-mechanical assemblies (EMAs) are produced. The production environment of the EMAs includes the continuous arrivals of the EMAs (generally called jobs), with distinct due dates, degrees of importance and routing sequences through the production workstations, to the job shop. Jobs are processed in batches at the workstations, and there are incompatible families of jobs, where jobs from different product families cannot be processed together in the same batch. In addition, there are sequence-dependent setups between batches at the workstations. Most importantly, it is imperative that all product deliveries arrive on time to their customers (internal and external) within their respective delivery time windows. Delivery is allowed outside a time window, but at the expense of a penalty. Completing a job and delivering the job before the start of its respective time window results in a penalty, i.e., inventory holding cost. Delivering a job after its respective time window also results in a penalty, i.e., delay cost or emergency shipping cost. This presents a unique scheduling problem where an earlinesstardiness composite objective is considered. This research approaches this scheduling problem by decomposing this complex job shop scheduling environment into bottleneck and non-bottleneck resources, with the primary focus on effectively scheduling the bottleneck resource. Specifically, the problem of scheduling jobs with unique due dates on a single workstation under the conditions of batching, sequence-dependent iii setups, incompatible job families in order to minimize weighted earliness and tardiness is formulated as an integer linear program. This scheduling problem, even in its simplest form, is NP-Hard, where no polynomial-time algorithm exists to solve this problem to optimality, especially as the number of jobs increases. As a result, the computational time to arrive at optimal solutions is not of practical use in industrial settings, where production scheduling decisions need to be made quickly. Therefore, this research explores and proposes new heuristic algorithms to solve this unique scheduling problem. The heuristics use order review and release strategies in combination with priority dispatching rules, which is a popular and more commonly-used class of scheduling algorithms in real-world industrial settings. A computational study is conducted to assess the quality of the solutions generated by the proposed heuristics. The computational results show that, in general, the proposed heuristics produce solutions that are competitive to the optimal solutions, yet in a fraction of the time. The results also show that the proposed heuristics are superior in quality to a set of benchmark algorithms within this same class of heuristic

Four decades of research on the open-shop scheduling problem to minimize the makespan

One of the basic scheduling problems, the open-shop scheduling problem has a broad range of applications across different sectors. The problem concerns scheduling a set of jobs, each of which has a set of operations, on a set of different machines. Each machine can process at most one operation at a time and the job processing order on the machines is immaterial, i.e., it has no implication for the scheduling outcome. The aim is to determine a schedule, i.e., the completion times of the operations processed on the machines, such that a performance criterion is optimized. While research on the problem dates back to the 1970s, there have been reviving interests in the computational complexity of variants of the problem and solution methodologies in the past few years. Aiming to provide a complete road map for future research on the open-shop scheduling problem, we present an up-to-date and comprehensive review of studies on the problem that focuses on minimizing the makespan, and discuss potential research opportunities

Benchmarking Permutation Flow Shop Problem: Adaptive and Enumerative Approaches Implementations via Novel Threading Techniques

A large number of real-world planning problems are combinatorial optimization problems which are easy to state and have a finite but usually very large number of feasible solutions. The minimum spanning tree problem and the shortest path problem are some which are solvable through polynomial algorithms. Even though there are other problems such as crew scheduling, vehicle routing, production planning, and hotel room operations which have no properties such as to solve the problem with polynomial algorithms. All these problems are NP-hard. The permutation flow shop problem is also NP-hard problem and they require high computation. These problems are solvable as in the form of the optimal and near-optimal solution. Some approach to get optimal are exhaustive search and branch and bound whereas near optimal are achieved annealing, Genetic algorithm, and other various methods. We here have used different approach exhaustive search, branch and bound and genetic algorithm. We optimize these algorithms to get performance in time as well as get the result closer to optimal. The exhaustive search and branch and bound gives all possible optimal solutions. We here have shown the comparative result of optimal calculation for 10 jobs with varying machine number up to 20. The genetic algorithm scales up and gives results to the instances with a larger number of jobs and machines

Shared Arrangements: practical inter-query sharing for streaming dataflows

Current systems for data-parallel, incremental processing and view maintenance over high-rate streams isolate the execution of independent queries. This creates unwanted redundancy and overhead in the presence of concurrent incrementally maintained queries: each query must independently maintain the same indexed state over the same input streams, and new queries must build this state from scratch before they can begin to emit their first results. This paper introduces shared arrangements: indexed views of maintained state that allow concurrent queries to reuse the same in-memory state without compromising data-parallel performance and scaling. We implement shared arrangements in a modern stream processor and show order-of-magnitude improvements in query response time and resource consumption for interactive queries against high-throughput streams, while also significantly improving performance in other domains including business analytics, graph processing, and program analysis