On insertion tie-breaking rules in heuristics for the permutation flowshop scheduling problem

The most efficient approximate procedures so far for the flowshop scheduling problem with makespan objective – i.e. the NEH heuristic and the iterated greedy algorithm – are based on constructing a sequence by iteratively inserting, one by one, the non-scheduled jobs into all positions of an existing subsequence, and then, among the so obtained subsequences, selecting the one yielding the lowest (partial) makespan. This procedure usually causes a high number of ties (different subsequences with the same best partial makespan) that must be broken via a tie-breaking mechanism. The particular tie-breaking mechanism employed is known to have a great influence in the performance of the NEH, therefore different procedures have been proposed in the literature. However, to the best of our knowledge, no tie-breaking mechanism has been proposed for the iterated greedy. In our paper, we present a new tie-breaking mechanism based on an estimation of the idle times of the different subsequences in order to pick the one with the lowest value of the estimation. The computational experiments carried out show that this mechanism outperforms the existing ones both for the NEH and the iterated greedy for different CPU times. Furthermore, embedding the proposed tie-breaking mechanism into the iterated greedy provides the most efficient heuristic for the problem so far.Ministerio de Ciencia e Innovación DPI2010-15573/DP

A review and classification of computer-based manufacturing scheduling tools

Computer-based manufacturing scheduling tools can play a key role in the management of industrial operations, as obtaining economic and reliable schedules is at the core of excellence in customer service and of efficiency in manufacturing companies. As a consequence, this topic has been receiving an increasing interest in the last decades, resulting in a number of case studies and descriptions of implementation of these tools. However, to the best of our knowledge, there is no review of these cases in order to classify existing references and to identify relevant issues still not properly addressed. Therefore, in this paper we carry out a systematic review of case studies of manufacturing scheduling tools. In order to provide a coherent taxonomy for the analysis of these tools, we develop a classification based on the functionalities of the manufacturing scheduling tools. Using this framework, existing contributions are classified and discussed, and a number of conclusions and open issues are identified. We hope that our work can establish a coherent picture of the topic so it serves as a starting point for future research

Reduction of permutation flowshop problems to single machine problems using machine dominance relations

The Permutation Flowshop Scheduling Problem with Makespan objective (PFSP-M) is known to be NP-hard for more than two machines, and literally hundreds of works in the last decades have proposed exact and approximate algorithms to solve it. These works—of computational/experimental nature—show that the PFSP-M is also empirically hard, in the sense that optimal or quasi-optimal sequences statistically represent a very small fraction of the space of feasible solutions, and that there are big differences among the corresponding makespan values. In the vast majority of these works, it has been assumed that (a) processing times are not job- and/or machine-correlated, and (b) all machines are initially available. However, some works have found that the problem turns to be almost trivial (i.e. almost every sequence yields an optimal or quasi-optimal solution) if one of these assumptions is dropped. To the best of our knowledge, no theoretical or experimental explanation has been proposed by this rather peculiar fact. Our hypothesis is that, under certain conditions of machine availability, or correlated processing times, the performance of a given sequence in a flowshop is largely determined by only one stage, thus effectively transforming the flowshop layout into a single machine. Since the single machine scheduling problem with makespan objective is a trivial problem where all feasible sequences are optimal, it would follow that, under these conditions, the equivalent PFSP-M is almost trivial. To address this working hypothesis from a general perspective, we investigate some conditions that allow reducing a permutation flowshop scheduling problem to a single machine scheduling problem, focusing on the two most common objectives in the literature, namely makespan and flowtime. Our work is a combination of theoretical and computational analysis, therefore several properties are derived to prove the conditions for an exact (theoretical) equivalence, together with an extensive computational evaluation to establish an empirical equivalence

A bounded-search iterated greedy algorithm for the distributed permutation flowshop scheduling problem

As the interest of practitioners and researchers in scheduling in a multi-factory environment is growing, there is an increasing need to provide efficient algorithms for this type of decision problems, characterised by simultaneously addressing the assignment of jobs to different factories/workshops and their subsequent scheduling. Here we address the so-called distributed permutation flowshop scheduling problem, in which a set of jobs has to be scheduled over a number of identical factories, each one with its machines arranged as a flowshop. Several heuristics have been designed for this problem, although there is no direct comparison among them. In this paper, we propose a new heuristic which exploits the specific structure of the problem. The computational experience carried out on a well-known testbed shows that the proposed heuristic outperforms existing state-of-the-art heuristics, being able to obtain better upper bounds for more than one quarter of the problems in the testbed.Ministerio de Ciencia e Innovación DPI2010-15573/DP

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

Efficient heuristics for the hybrid flow shop scheduling problem with missing operations

In this paper, we address the hybrid flowshop scheduling problem for makespan minimisation. More specifically, we are interested in the special case where there are missing operations, i.e. some stages are skipped, a condition inspired in a realistic problem found in a plastic manufacturer. The main contribution of our paper is twofold. On the one hand we carry out a computational analysis to study the hardness of the hybrid flowshop scheduling problem with missing operations as compared to the classical hybrid flowshop problem. On the other hand, we propose a set of heuristics that captures some special features of the missing operations and compare these algorithms with already existing heuristics for the classical hybrid flowshop, and for the hybrid flowshop problem with missing operations. The extensive computational experience carried out shows that our proposal outperforms existing methods for the problem, indicating that it is possible to improve the makespan by interacting with the jobs with missing operations.Ministerio de Ciencia e Innovación DPI2016-80750-

A beam-search-based constructive heuristic for the PFSP to minimise total flowtime

In this paper we present a beam-search-based constructive heuristic to solve the permutation flowshop scheduling problem with total flowtime minimisation as objective. This well-known problem is NP-hard, and several heuristics have been developed in the literature. The proposed algorithm is inspired in the logic of the beam search, although it remains a fast constructive heuristic. The results obtained by the proposed algorithm outperform those obtained by other constructive heuristics in the literature for the problem, thus modifying substantially the state-of-the-art of efficient approximate procedures for the problem. In addition, the proposed algorithm even outperforms two of the best metaheuristics for many instances of the problem, using much lesser computation effort. The excellent performance of the proposal is also proved by the fact that the new heuristic found new best upper bounds for 35 of the 120 instances in Taillard’s benchmark.Ministerio de Ciencia e Innovación DPI2013-44461-PMinisterio de Ciencia e Innovación DPI2016-80750-

New efficient constructive heuristics for the hybrid flowshop to minimise makespan: A computational evaluation of heuristics

This paper addresses the hybrid flow shop scheduling problem to minimise makespan, a well-known scheduling problem for which many constructive heuristics have been proposed in the literature. Nevertheless, the state of the art is not clear due to partial or non homogeneous comparisons. In this paper, we review these heuristics and perform a comprehensive computational evaluation to determine which are the most efficient ones. A total of 20 heuristics are implemented and compared in this study. In addition, we propose four new heuristics for the problem. Firstly, two memory-based constructive heuristics are proposed, where a sequence is constructed by inserting jobs one by one in a partial sequence. The most promising insertions tested are kept in a list. However, in contrast to the Tabu search, these insertions are repeated in future iterations instead of forbidding them. Secondly, we propose two constructive heuristics based on Johnson’s algorithm for the permutation flowshop scheduling problem. The computational results carried out on an extensive testbed show that the new proposals outperform the existing heuristics.Ministerio de Ciencia e Innovación DPI2016-80750-

Linking Scheduling Criteria to Shop Floor Performance in Permutation Flowshops

The goal of manufacturing scheduling is to allocate a set of jobs to the machines in the shop so these jobs are processed according to a given criterion (or set of criteria). Such criteria are based on properties of the jobs to be scheduled (e.g., their completion times, due dates); so it is not clear how these (short-term) criteria impact on (long-term) shop floor performance measures. In this paper, we analyse the connection between the usual scheduling criteria employed as objectives in flowshop scheduling (e.g., makespan or idle time), and customary shop floor performance measures (e.g., work-in-process and throughput). Two of these linkages can be theoretically predicted (i.e., makespan and throughput as well as completion time and average cycle time), and the other such relationships should be discovered on a numerical/empirical basis. In order to do so, we set up an experimental analysis consisting in finding optimal (or good) schedules under several scheduling criteria, and then computing how these schedules perform in terms of the different shop floor performance measures for several instance sizes and for different structures of processing times. Results indicate that makespan only performs well with respect to throughput, and that one formulation of idle times obtains nearly as good results as makespan, while outperforming it in terms of average cycle time and work in process. Similarly, minimisation of completion time seems to be quite balanced in terms of shop floor performance, although it does not aim exactly at work-in-process minimisation, as some literature suggests. Finally, the experiments show that some of the existing scheduling criteria are poorly related to the shop floor performance measures under consideration. These results may help to better understand the impact of scheduling on flowshop performance, so scheduling research may be more geared towards shop floor performance, which is sometimes suggested as a cause for the lack of applicability of some scheduling models in manufacturing

Available-to-promise (ATP) systems: a classification and framework for analysis

Available-to-promise (ATP) systems deal with a number of managerial decisions related to order capture activities in a company, including order acceptance/rejection, due date setting, and resource scheduling. These different but interrelated decisions have often been studied in an isolated manner, and, to the best of our knowledge, no framework has been presented to integrate them into the broader perspective of order capture. This paper attempts to provide a general framework for ATP-related decisions. By doing so, we: (1) identify the different decision problems to be addressed; (2) present the different literature-based models supporting related decisions into a coherent framework; and (3) review the main contributions in the literature for each one of these. We first describe different approaches for order capture available in the literature, depending on two parameters related to the application context of ATP systems, namely the inclusion of explicit information about due dates in the decision model, and the level of integration among decisions. According to these parameters, up to six approaches for ATP-related decisions are identified. Secondly, we show the subsequent decision problems derived from the different approaches, and describe the main issues and key references involving each one of these decision problems. Finally, a number of conclusions and future research lines are discussed.Ministerio de Ciencia e Innovación DPI2007-6134