A batch splitting method for a job shop scheduling problem in an MRP environment

The job shop scheduling problem has been a major target for many researchers. Unfortunately though, most of the previous research was based on assumptions that are different from the real manufacturing environment. Among those distorted assumptions, two assumptions about set-up time and job composition can greatly influence the performance of a schedule. First, most of the past studies ignored the impact of the before-arrival set-up time. If we know the sequence of operations in advance, we can obtain an improved schedule by preparing the setup before a job arrives. Secondly, most of the past studies assumed that a job consists of only a single part, that is a batch of size one. However, if we assume that a job consists of a batch size greater than one, as in many real manufacturing environments, then we can obtain an improved schedule because we can fill up the idle times of machines with jobs which have smaller processing times by splitting the original batches. However, the number of job orders may then increase due to the split, and the size of the scheduling problem would become too large to be solved in a practical time limit. Consequently, there may be an optimum batch size considering trade-off between better solution and tractability. The current study is the result of an attempt to find an acceptable solution when the production requirement from a MRP system for a planning period exceeds the capacity of a production system. We try to get an improved schedule by splitting the original batch into smaller batches, and consider setting up a machine before the actual arrival of jobs to that machine. Thereby we can meet the due date requirement without resorting to rescheduling of the master production schedule. For the given batch, we disaggregate it according to the algorithm we are proposing. A so-called 'modified shifting bottleneck procedure' is then applied to solve the job shop scheduling problem with a before-arrival family set-up time considering release date, transportation time and due date. The study also shows that we can adapt to unexpected dynamic events more elegantly by allowing the splitting of batches.     

Minimizing total tardiness on a batch processing machine with incompatible job families

Motivated by an application in semiconductor manufacturing, we study the problem of minimizing total tardiness on a batch processing machine with incompatibl8e job families, where all jobs of the same family have identical processing times and jobs of different families cannot be processed together. We present a dynamic programming algorithm which has polynomial time complexity when the number of job families and the batch machine capacity are fixed. We also examine various heuristic solution procedures which can provide near optimal solutions in a reasonable amount of computation time.     

反相容工件系统的加权完工时间和的重新排序问题(英文)

重新排序问题是指在原始工件已经安排好的情形下,新到的工件集与原始工件集一起重新再排序,这是实际工作中常见一类优化问题。本文考虑了单机上当工件加工时间与权重反相容时,在最大错位量约束下的加权完工时间和最小化的重新排序问题。对于提出的四个问题,即在最大序列错位、最大时间错位、总序列错位和总时间错位约束下的加权完工时间和重新排序,基于问题的结构性质,运用动态规划方法分别给出了这些问题的多项式时间或拟多项式时间算法。     

A computational study of heuristics for two-stage flexible flowshops

We consider the scheduling of two-stage flexible flowshops. This manufacturing environment involves two machine centres representing two consecutive stages of production. Each machine centre is composed of multiple parallel machines. Each job has to be processed serially through the two machine centres. In each machine centre, a job may be processed on any of the machines. There are n independent jobs to be scheduled without preemption. The jobs can wait in between the two machine centres and the intermediate storage is unlimited. Our objective will be to minimize the maximum completion time of the jobs. We formulate the problem as a mixed integer program. Given this problem class is NP-hard in the strong sense, we present three lower bounds to estimate the optimal solution. We then propose a sequence-first, allocate-second heuristic approach for its solution. We heuristically decompose the problem by first creating a priority list to order the jobs and then assign the jobs to the available machines in each machine centre based on this order. We describe seven rules for the sequencing phase. The assignment phase consists of a heuristic which attempts to minimize each partial schedule length while looking ahead at the future assignment of the currently unscheduled jobs. The computational performance of the heuristic approach was evaluated by comparing the value of each heuristic variant to the best among the three lower bounds. Its effectiveness was tested on scenarios pertinent to flexible flowshop environments, such as cellular manufacturing, by conducting a computational study of over 3400 problems. Our computational results indicate that the most effective approach used Johnson's rule to provide the priority list for job assignment. This provided integrality gaps which on the average were less than 0·73%.     

Multitasking parallel-machine scheduling with machine-dependent slack due-window assignment

We consider the problem of parallel-machine scheduling with machine-dependent slack (SLK) due-window assignment in the multitasking environment, which exists in various application domains such as Internet services, project management, and manufacturing. Motivated by practical observations, we extend the original model of multitasking to a more general model where each job’s interruption proportion depends on the job itself and its processing position. In the light of individualised service, we consider SLK due-window assignment. Our objective is to minimise the total cost that comprises the earliness, tardiness, and due-window-related costs. Finding that an optimal schedule exists when each machine is occupied by at least one job, we show that the problem is polynomially solvable. We provide a more efficient solution algorithm for a special case of the problem. Finally, we present numerical examples to illustrate the application of the theoretical results and working of the solution algorithms.     

Control of a Batch Processing Machine Serving Compatible Job Families

We consider the control of a single batch processing machine with random arrivals, random processing times, and compatible job families (jobs from different families may be processed together in the same batch, with the processing time distribution of the entire batch determined by the job family in the batch having the greatest expected processing time). The objective is to minimize the long-run average time that jobs spend in the system. We present properties possessed by the optimal policies and discuss the structure of these policies. We next develop a simple heuristic scheduling policy to control the machine. Simulation results are provided to demonstrate the effectiveness of our heuristic over a wide range of problem instances.     

Single-machine scheduling problems with a batch-dependent aging effect and variable maintenance activities

We consider single-machine scheduling problems with a batch-dependent ageing effect and variable maintenance activities between batches. The machine can process several jobs as a batch. It requires maintenance activities where the maintenance time depends on the flow time of the pre-batch, i.e. the batch processed before a batch. A job’s actual processing time is an increasing exponential function of its operation time within a batch. The objectives are to minimise the makespan and the total completion time. We develop polynomial time algorithms for the makespan minimisation problem and the total completion time minimisation problem under the condition that the ageing factor is greater than one. We also provide a mathematical programming approach and two heuristic algorithms to analyse the total completion time minimisation problem when the ageing factor is less than one for even one batch. The computational analysis indicates that the proposed heuristic algorithms are more efficient for the smaller ageing factor, whereas the Modified Shortest Processing Time algorithm is more efficient than the proposed heuristic algorithms for the larger ageing factor.     

Scheduling about an unrestricted common due windowwith arbitrary earliness/tardiness penalty rates

We consider the NP-hard problem of scheduling jobs on a single machine about an unrestricted due window to minimize total weighted earliness and tardiness cost. Each job has an earliness penalty rate and a tardiness penalty rate that are allowed to be arbitrary. Earliness or tardiness cost is assessed when a job completes outside the due window, which may be an instant in time or a time increment defining acceptable job completion. In this paper we present properties that characterize the structure of an optimal schedule, present a lower bound, propose a two-step branch and bound algorithm, and report results from a computational experiment. We find that optimal solutions can be quickly obtained for medium-sized problem instances.     

Solving multi-objective rescheduling problems in dynamic permutation flow shop environments with disruptions

In multi-objective optimisation problems, optimal decisions need to be made in the presence of trade-offs among conflicting objectives which may sometimes be expressed in different units of measure. This makes it difficult to reduce the problem to a single-objective optimisation. Furthermore, when disruptive changes emerge in manufacturing environments, such as the arrival of new jobs or machine breakdowns, the scheduling system should be adapted by responding quickly. In this paper, we propose a rescheduling architecture for solving the problem based on a predictive-reactive strategy and a new method to calculate the reactive schedule in each rescheduling period. Additionally, we developed a methodology that allows the use of multi-objective performance metrics to evaluate dispatching rules. These rules are applied at a benchmark specifically designed for this paper considering three objective functions: makespan, total weighted tardiness and stability. Three types of disruptions are also considered: arrivals of new jobs, machine breakdowns and variations in job processing times. Results showed that the RANDOM rule provides a better behaviour compared to other evaluated rules and a lower ratio of non-dominated solutions compared to ATC (apparent tardiness cost) and FIFO (first-in-first-out) rules. Moreover, the behaviour of the hypervolume metric depends on the problem dimensions.     

SCHEDULING A SINGLE MACHINE TO MINIMIZE TWO CRITERIA: MAXIMUM TARDINESS AND NUMBER OF TARDY JOBS

In this paper we consider a single machine scheduling problem with two criteria; minimizing both maximum tardiness and the number of tardy jobs. We present both heuristic and branch-and-bound algorithms to find the schedule which minimizes the number of tardy jobs among all schedules having minimal maximum tardiness. Computational results show that problems with up to 40 jobs can be solved in less than one minute of computer time, and solution difficulty tends to increase as the range of due dates increases relative to the total processing time. We extend our results to generate all nondominated schedules for the two criteria. Computational experiments indicate that all non-dominated solutions to problems with 40 jobs can be generated. However, solution difficulty for these problems is highly dependent on problem parameters.     

Exact and approximate methods for parallel multiple-area spatial scheduling with release times

Spatial scheduling problems involve scheduling jobs that each require certain amounts of two-dimensional space within a processing area of limited width and length. Thus, this requires not only assigning time slots to each job but also locations and orientations within the limited physical processing space as well. Such problems, often encountered in shipbuilding and aircraft manufacturing, are generally difficult to solve, and there is a relatively small amount of literature addressing these problems compared to other types of scheduling. In this paper, we consider a particularly complex class of spatial scheduling problems that involve scheduling each job into one of several possible processing areas in parallel to minimize the total amount of tardy time. In addition, each job has a release time before which it may not be processed. We introduce two methods for solving this type of problem: an integer programming (IP) model and a heuristic algorithm. We perform computational tests and comparisons of each method over a large number of generated benchmark problems with varying characteristics, and also compare these to a more naïve heuristic. Solving the IP model was effective for small problems but required excessive amounts of time for larger ones. The heuristic was effective and produced solutions of comparable quality to the IP model for many problems while requiring very little computational time.     

On-line maintenance of optimal machine schedules

Effective and efficient scheduling in a dynamically changing environment is important for real-time control of manufacturing, computer, and telecommunication systems. This paper illustrates the algorithmic and analytical issues associated with developing efficient and effective methods to update schedules on-line. We consider the problem of dynamically scheduling precedence-constrained jobs on a single processor to minimize the maximum completion time penalty. We first develop an efficient technique to reoptimize a rolling schedule when new jobs arrive. The effectiveness of reoptimizing the current schedule as a long-term on-line strategy is measured by bounding its performance relative to oracles that have perfect information about future job arrivals.     

Scheduling a no-wait flow shop containing unbounded batching machines

We study the problem of scheduling n jobs in a no-wait flow shop consisting of m batching machines. Each job has to be processed by all the machines. All jobs visit the machines in the same order. A job completed on an upstream machine should be immediately transferred to the downstream machine. Batching machines can process several jobs simultaneously in a batch so that all jobs of the same batch start and complete together. The processing time of a batch is equal to the maximum processing time of the jobs in this batch. We assume that the capacity of any batch is unbounded. The problem is to find an optimal batch schedule such that the maximum job completion time, that is the makespan, is minimized. For m = 2, we prove that there exists an optimal schedule with at most two batches and construct such a schedule in O(n log n) time. For m = 3, we prove that the number of batches can be limited to nine and give an example where all optimal schedules have seven batches. Furthermore, we prove that the best schedules with at most one, two and three batches are 3-, 2- and 3/2-approximate solutions, respectively. The first two bounds are tight for corresponding schedules. Finally, we suggest an assignment method that solves the problem with m machines and at most r batches in O(n^{m(r-2)+1+[m/r]}) time, if m and r are fixed. The method can be generalized to minimize an arbitrary maximum cost or total cost objective function.     

β-Robust scheduling for single-machine systems with uncertain processing times

In scheduling environments with processing time uncertainty, system performance is determined by both the sequence in which jobs are ordered and the actual processing times of jobs. For these situations, the risk of achieving substandard system performance can be an important measure of scheduling effectiveness. To hedge this risk requires an explicit consideration of both the mean and the variance of system performance associated with alternative schedules, and motivates a β-robustness objective to capture the likelihood that a schedule yields actual performance no worse than a given target level. In this paper we focus on β-robust scheduling issues in single-stage production environments with uncertain processing times. We define a general β-robust scheduling objective, formulate the β-robust scheduling problem that results when job processing times are independent random variables and the performance measure of interest is the total flow time across all jobs, establish problem complexity, and develop exact and heuristic solution approaches. We then extend the 0-robust scheduling model to consider situations where the uncertainty associated with individual job processing times can be selectively controlled through resource allocation. Computational results are reported to demonstrate the efficiency and effectiveness of the solution procedures.     

Minimizing earliness–tardiness on a single burn-in oven with a common due date and maximum allowable tardiness constraint

This paper considers a scheduling problem for a single burn-in oven in the semiconductor manufacturing industry where the oven is a batch processing machine with restricted capacity. The batch processing time is set by the longest processing time among those of all the jobs contained in the batch. All jobs are assumed to have the same due date. The objective is to minimize the sum of the absolute deviations of completion times from the due date (earliness–tardiness) of all jobs under the constraint that the maximum tardiness should be less than or equal to the maximum allowable time value. We suggest several two-phase heuristic algorithms for this problem. In the first phase, some heuristic algorithms are developed without maximum allowable tardiness constraint. If the schedule from the first phase violates the maximum tardiness constraint, then the schedule is changed to satisfy maximum allowable tardiness constraint in the second phase. The suggested heuristics are based on genetic algorithms and dominance properties of optimal schedules. We present the results of computational experiments that clearly show the solution quality obtained by the suggested heuristics.     

A flowshop scheduling problem with two operations per job

This paper considers a special case of the flowshop scheduling problem where each job requires only two operations on specified machines and shows that this problem is NP-hard in the strong sense even if the first operation of all jobs is processed on the same machine and the number of machines performing the second operation equals two. For the case when the first operation of all jobs is performed on the same machine, it is sufficient to consider only permutation schedules for minimizing any regular measure of performance. Five polynomially bounded heuristic algorithms are described for minimizing makespan for this case and their performance in finding a minimum makespan schedule is theoretically and empirically evaluated.     

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We consider the problem of minimizing makespan Cmax on a single batch processing machine in the presence of dynamic job arrivals. The batch processing machine can process up to B jobs simultaneously. The processing time of a batch is given by the processing time of the longest job in the batch. We present polynomial and pseudopolynomial-time algorithms for several special cases, develop efficient heuristics for the general problem and evaluate their performance through extensive computational experiments. Our results indicate that several of the heuristics have an excellent average performance with a modest computational burden.     

Minimising makespan on a single batch processing machine with dynamic job arrivals and non-identical job sizes

Batch scheduling is a prevalent policy in many industries such as burn-in operations in semiconductor manufacturing and heat treatment operations in metalworking. In this paper, we consider the problem of minimising makespan on a single batch processing machine in the presence of dynamic job arrivals and non-identical job sizes. The problem under study is NP-hard. Consequently, we develop a number of efficient construction heuristics. The performance of the proposed heuristics is evaluated by comparing their results to two lower bounds, and other solution approaches published in the literature, namely the first-fit longest processing time-earliest release time (FFLPT-ERT) heuristic, hybrid genetic algorithm (HGA), joint genetic algorithm and dynamic programming (GA+DP) approach and ant colony optimisation (ACO) algorithm. The computational experiments demonstrate the superiority of the proposed heuristics with respect to solution quality, especially for the problems with small size jobs. Moreover, the computational costs of the proposed heuristics are very low.     

Robust scheduling of a two-machine flow shop with uncertain processing times

This paper focuses on manufacturing environments where job processing times are uncertain. In these settings, scheduling decision makers are exposed to the risk that an optimal schedule with respect to a deterministic or stochastic model will perform poorly when evaluated relative to actual processing times. Since the quality of scheduling decisions is frequently judged as if processing times were known a priori, robust scheduling, i.e., determining a schedule whose performance (compared to the associated optimal schedule) is relatively insensitive to the potential realizations of job processing times, provides a reasonable mechanism for hedging against the prevailing processing time uncertainty. In this paper we focus on a two-machine flow shop environment in which the processing times of jobs are uncertain and the performance measure of interest is system makespan. We present a measure of schedule robustness that explicitly considers the risk of poor system performance over all potential realizations of job processing times. We discuss two alternative frameworks for structuring processing time uncertainty. For each case, we define the robust scheduling problem, establish problem complexity, discuss properties of robust schedules, and develop exact and heuristic solution approaches. Computational results indicate that robust schedules provide effective hedges against processing time uncertainty while maintaining excellent expected makespan performance     

Parallel-machine scheduling with controllable processing times and rate-modifying activities to minimise total cost involving total completion time and job compressions

In this paper, we consider unrelated parallel-machine scheduling involving controllable processing times and rate-modifying activities simultaneously. We assume that the actual processing time of a job can be compressed by allocating a greater amount of a common resource to process the job. We further assume that each machine may require a rate-modifying activity during the scheduling horizon. The objective is to determine the optimal job compressions, the optimal positions of the rate-modifying activities and the optimal schedule to minimise a total cost function that depends on the total completion time and total job compressions. If the number of machines is a given constant, we propose an efficient polynomial time algorithm to solve the problem.