Metaheuristics for single and multiple objectives production scheduling for the capital goods industry

In the capital goods industry, companies produce plant and machinery that is used to produce consumer products or commodities such as electricity or gas. Typical products produced in these companies include steam turbines, large boilers and oil rigs. Scheduling of these products is difficult due to the complexity of the product structure, which involves many levels of assembly and long complex routings of many operations which are operated in multiple machines. There are also many scheduling constraints such as machine capacity as well as operation and assembly precedence relationships. Products manufactured in the capital goods industry are usually highly customised in order to meet specific customer requirements. Delivery performance is a particularly important aspect of customer service and it is common for contracts to include severe penalties for late deliveries. Holding costs are incurred if items are completed before the due date. Effective planning and inventory control are important to ensure that products are delivered on time and that inventory costs are minimised. Capital goods companies also give priority to resource utilisation to ensure production efficiency. In practice there are tradeoffs between achieving on time delivery, minimising inventory costs whilst simultaneously maximising resource utilisation. Most production scheduling research has focused on job-shops or flow-shops which ignored assembly relationships. There is a limited literature that has focused on assembly production. However, production scheduling in capital goods industry is a combination of component manufacturing (using jobbing, batch and flow processes), assembly and construction. Some components have complex operations and routings. The product structures for major products are usually complex and deep. A practical scheduling tool not only needs to solve some extremely large scheduling problems, but also needs to solve these problems within a realistic time. Multiple objectives are usually encountered in production scheduling in the capital goods industry. Most literature has focused on minimisation of total flow time, or makespan and earliness and tardiness of jobs. In the capital goods industry, inventory costs, delivery performance and machine utilisation are crucial competitive. This research develops a scheduling tool that can successfully optimise these criteria simultaneously within a realistic time. ii The aim of this research was firstly to develop the Enhanced Single-Objective Genetic Algorithm Scheduling Tool (ESOGAST) to make it suitable for solving very large production scheduling problems in capital goods industry within a realistic time. This tool aimed to minimise the combination of earliness and lateness penalties caused by early or late completion of items. The tool was compared with previous approaches in literature and was proved superior in terms of the solution quality and the computational time. Secondly, this research developed a Multi-Objective Genetic Algorithm Scheduling Tool (MOGAST) that was based upon the development of ESOGAST but was able to solve scheduling problems with multiple objectives. The objectives of this tool were to optimise delivery performance, minimise inventory costs, and maximise resource utilisation simultaneously. Thirdly, this research developed an Artificial Immune System Scheduling Tool (AISST) that achieved the same objective of the ESOGAST. The performances of both tools were compared and analysed. Results showed that AISST performs better than ESOGAST on relatively small scheduling problems, but the computation time required by the AISST was several times longer. However ESOGAST performed better than the AISST for larger problems. Optimum configurations were identified in a series of experiments that conducted for each tool. The most efficient configuration was also successfully applied for each tool to solve the full size problem and all three tools achieved satisfactory results.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Modelling and Optimizing Supply Chain Integrated Production Scheduling Problems

Globalization and advanced information technologies (e.g., Internet of Things) have considerably impacted supply chains (SCs) by persistently forcing original equipment manufacturers (OEMs) to switch production strategies from make-to-stock (MTS) to make-to-order (MTO) to survive in competition. Generally, an OEM follows the MTS strategy for products with steady demand. In contrast, the MTO strategy exists under a pull system with irregular demand in which the received customer orders are scheduled and launched into production. In comparison to MTS, MTO has the primary challenges of ensuring timely delivery at the lowest possible cost, satisfying the demands of high customization and guaranteeing the accessibility of raw materials throughout the production process. These challenges are increasing substantially since industrial productions are becoming more flexible, diversified, and customized. Besides, independently making the production scheduling decisions from other stages of these SCs often find sub-optimal results, creating substantial challenges to fulfilling demands timely and cost-effectively. Since adequately managing these challenges asynchronously are difficult, constructing optimization models by integrating SC decisions, such as customer requirements, supply portfolio (supplier selection and order allocation), delivery batching decisions, and inventory portfolio (inventory replenishment, consumption, and availability), with shop floor scheduling under a deterministic and dynamic environment is essential to fulfilling customer expectations at the least possible cost. These optimization models are computationally intractable. Consequently, designing algorithms to schedule or reschedule promptly is also highly challenging for these time-sensitive, operationally integrated optimization models. Thus, this thesis focuses on modelling and optimizing SC-integrated production scheduling problems, named SC scheduling problems (SCSPs). The objective of optimizing job shop scheduling problems (JSSPs) is to ensure that the requisite resources are accessible when required and that their utilization is maximally efficient. Although numerous algorithms have been devised, they can sometimes become computationally exorbitant and yield sub-optimal outcomes, rendering production systems inefficient. These could be due to a variety of causes, such as an imbalance in population quality over generations, recurrent generation and evaluation of identical schedules, and permitting an under-performing method to conduct the evolutionary process. Consequently, this study designs two methods, a sequential approach (Chapter 2) and a multi-method approach (Chapter 3), to address the aforementioned issues and to acquire competitive results in finding optimal or near-optimal solutions for JSSPs in a single objective setting. The devised algorithms for JSSPs optimize workflows for each job by accurate mapping between/among related resources, generating more optimal results than existing algorithms. Production scheduling can not be accomplished precisely without considering supply and delivery decisions and customer requirements simultaneously. Thus, a few recent studies have operationally integrated SCs to accurately predict process insights for executing, monitoring, and controlling the planned production. However, these studies are limited to simple shop-floor configurations and can provide the least flexibility to address the MTO-based SC challenges. Thus, this study formulates a bi-objective optimization model that integrates the supply portfolio into a flexible job shop scheduling environment with a customer-imposed delivery window to cost-effectively meet customized and on-time delivery requirements (Chapter 4). Compared to the job shop that is limited to sequence flexibility only, the flexible job shop has been deemed advantageous due to its capacity to provide increased scheduling flexibility (both process and sequence flexibility). To optimize the model, the performance of the multi-objective particle swarm optimization algorithm has been enhanced, with the results providing decision-makers with an increased degree of flexibility, offering a larger number of Pareto solutions, more varied and consistent frontiers, and a reasonable time for MTO-based SCs. Environmental sustainability is spotlighted for increasing environmental awareness and follow-up regulations. Consequently, the related factors strongly regulate the supply portfolio for sustainable development, which remained unexplored in the SCSP as those criteria are primarily qualitative (e.g., green production, green product design, corporate social responsibility, and waste disposal system). These absences may lead to an unacceptable supply portfolio. Thus, this study overcomes the problem by integrating VIKORSORT into the proposed solution methodology of the extended SCSP. In addition, forming delivery batches of heterogeneous customer orders is challenging, as one order can lead to another being delayed. Therefore, the previous optimization model is extended by integrating supply, manufacturing, and delivery batching decisions and concurrently optimizing them in response to heterogeneous customer requirements with time window constraints, considering both economic and environmental sustainability for the supply portfolio (Chapter 5). Since the proposed optimization model is an extension of the flexible job shop, it can be classified as a non-deterministic polynomial-time (NP)-hard problem, which cannot be solved by conventional optimization techniques, particularly in the case of larger instances. Therefore, a reinforcement learning-based hyper-heuristic (HH) has been designed, where four solution-updating heuristics are intelligently guided to deliver the best possible results compared to existing algorithms. The optimization model furnishes a set of comprehensive schedules that integrate the supply portfolio, production portfolio (work-center/machine assignment and customer orders sequencing), and batching decisions. This provides numerous meaningful managerial insights and operational flexibility prior to the execution phase. Recently, SCs have been experiencing unprecedented and massive disruptions caused by an abrupt outbreak, resulting in difficulties for OEMs to recover from disruptive demand-supply equilibrium. Hence, this study proposes a multi-portfolio (supply, production, and inventory portfolios) approach for a proactive-reactive scheme, which concerns the SCSP with complex multi-level products, simultaneously including unpredictably dynamic supply, demand, and shop floor disruptions (Chapter 6). This study considers fabrication and assembly in a multi-level product structure. To effectively address this time-sensitive model based on real-time data, a Q-learning-based multi-operator differential evolution algorithm in a HH has been designed to address disruptive events and generate a timely rescheduling plan. The numerical results and analyses demonstrate the proposed model's capability to effectively address single and multiple disruptions, thus providing significant managerial insights and ensuring SC resilience

Evolutionary Computation 2020

Intelligent optimization is based on the mechanism of computational intelligence to refine a suitable feature model, design an effective optimization algorithm, and then to obtain an optimal or satisfactory solution to a complex problem. Intelligent algorithms are key tools to ensure global optimization quality, fast optimization efficiency and robust optimization performance. Intelligent optimization algorithms have been studied by many researchers, leading to improvements in the performance of algorithms such as the evolutionary algorithm, whale optimization algorithm, differential evolution algorithm, and particle swarm optimization. Studies in this arena have also resulted in breakthroughs in solving complex problems including the green shop scheduling problem, the severe nonlinear problem in one-dimensional geodesic electromagnetic inversion, error and bug finding problem in software, the 0-1 backpack problem, traveler problem, and logistics distribution center siting problem. The editors are confident that this book can open a new avenue for further improvement and discoveries in the area of intelligent algorithms. The book is a valuable resource for researchers interested in understanding the principles and design of intelligent algorithms

Offline Learning for Sequence-based Selection Hyper-heuristics

This thesis is concerned with finding solutions to discrete NP-hard problems. Such problems occur in a wide range of real-world applications, such as bin packing, industrial flow shop problems, determining Boolean satisfiability, the traveling salesman and vehicle routing problems, course timetabling, personnel scheduling, and the optimisation of water distribution networks. They are typically represented as optimisation problems where the goal is to find a ``best'' solution from a given space of feasible solutions. As no known polynomial-time algorithmic solution exists for NP-hard problems, they are usually solved by applying heuristic methods. Selection hyper-heuristics are algorithms that organise and combine a number of individual low level heuristics into a higher level framework with the objective of improving optimisation performance. Many selection hyper-heuristics employ learning algorithms in order to enhance optimisation performance by improving the selection of single heuristics, and this learning may be classified as either online or offline. This thesis presents a novel statistical framework for the offline learning of subsequences of low level heuristics in order to improve the optimisation performance of sequenced-based selection hyper-heuristics. A selection hyper-heuristic is used to optimise the HyFlex set of discrete benchmark problems. The resulting sequences of low level heuristic selections and objective function values are used to generate an offline learning database of heuristic selections. The sequences in the database are broken down into subsequences and the mathematical concept of a logarithmic return is used to discriminate between ``effective'' subsequences, that tend to lead to improvements in optimisation performance, and ``disruptive'' subsequences that tend to lead to worsening performance. Effective subsequences are used to improve hyper-heuristics performance directly, by embedding them in a simple hyper-heuristic design, and indirectly as the inputs to an appropriate hyper-heuristic learning algorithm. Furthermore, by comparing effective subsequences across different problem domains it is possible to investigate the potential for cross-domain learning. The results presented here demonstrates that the use of well chosen subsequences of heuristics can lead to small, but statistically significant, improvements in optimisation performance

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)

Evolutionary multi-objective optimization in scheduling problems

Ph.DDOCTOR OF PHILOSOPH

Evolutionary computing for routing and scheduling applications

Ph.DDOCTOR OF PHILOSOPH

Integrated Production and Distribution planning of perishable goods

Tese de doutoramento. Programa Doutoral em Engenharia Industrial e Gestão. Faculdade de Engenharia. Universidade do Porto. 201