A hybrid genetic algorithm for parallel machine scheduling with setup times

Journal of Intelligent Manufacturing - This paper addresses the unrelated parallel machine scheduling problem with sequence and machine dependent setup times and machine eligibility constraints....     

An efficient hybrid genetic algorithm to solve assembly line balancing problem with sequence-dependent setup times

In this paper the setup assembly line balancing and scheduling problem (SUALBSP) is considered. Since this problem is NP-hard, a hybrid genetic algorithm (GA) is proposed to solve the problem. This problem involves assigning the tasks to the stations and scheduling them inside each station. A simple permutation is used to determine the sequence of tasks. To determine the assignment of tasks to stations, the algorithm is hybridized using a dynamic programming procedure. Using dynamic programming, at any time a chromosome can be converted to an optimal solution (subject to the chromosome sequence).     

A tabu search algorithm for the job shop problem with sequence dependent setup times

This paper addresses the classic job shop scheduling problem where sequence dependent setup times are present. Based on a modified disjunctive graph, we further investigate and generalize structural properties for the problem under study. A tabu search algorithm with a sophisticated neighbourhood structure is then developed. Compared to most studies in this research area, we are interested in moving internal critical operations rather than merely focusing on non-internal ones. Moreover, neighbourhood functions are defined using insertion techniques instead of simple swaps. Test results show that our algorithm outperforms a simulated annealing algorithm which is recently published. We have also conducted experiments considering the efficiency of developed propositions.     

A branch and bound enhanced genetic algorithm for scheduling a flowline manufacturing cell with sequence dependent family setup times

This paper addresses the permutation flowline manufacturing cell with sequence dependent family setup times problem with the objective to minimize the makespan criterion. We develop a cooperative approach including a genetic algorithm and a branch and bound procedure. The latter is probabilistically integrated in the genetic algorithm in order to enhance the current solution. Moreover, the application of the branch and bound algorithm is based upon the decomposition of the problem into subproblems. The performance of the proposed method is tested by numerical experiments on a large number of representative problems.     

A beam search heuristic for scheduling a single machine with release dates and sequence dependent setup times to minimize the makespan

This paper considers the problem of scheduling a set of jobs subject to arbitrary release dates and sequence-dependent setup times on a single machine with the objective of minimizing the maximum completion of all the jobs, or makespan. This problem is often found in manufacturing processes such as painting and metalworking. A new mixed integer linear program (MILP) is firstly proposed. Because the problem is known to be NP-hard, a beam search heuristic is developed. Computational experiments are carried out using a well-known set of instances from the literature. Our results show that the proposed heuristic is effective in finding high quality solutions at low computational cost.     

A hybrid genetic algorithm for the single machine scheduling problem with sequence-dependent setup times

This paper presents a hybrid approach based on the integration between a genetic algorithm (GA) and concepts from constraint programming, multi-objective evolutionary algorithms and ant colony optimization for solving a scheduling problem. The main contributions are the integration of these concepts in a GA crossover operator. The proposed methodology is applied to a single machine scheduling problem with sequence-dependent setup times for the objective of minimizing the total tardiness. A sensitivity analysis of the hybrid approach is carried out to compare the performance of the GA and the hybrid genetic algorithm (HGA) approaches on different benchmarks from the literature. The numerical experiments demonstrate the HGA efficiency and effectiveness which generates solutions that approach those of the known reference sets and improves several lower bounds.     

Hybridizing ant colony optimization via genetic algorithm for mixed-model assembly line balancing problem with sequence dependent setup times between tasks

This paper presents a new hybrid algorithm, which executes ant colony optimization in combination with genetic algorithm (ACO-GA), for type I mixed-model assembly line balancing problem (MMALBP-I) with some particular features of real world problems such as parallel workstations, zoning constraints and sequence dependent setup times between tasks. The proposed ACO-GA algorithm aims at enhancing the performance of ant colony optimization by incorporating genetic algorithm as a local search strategy for MMALBP-I with setups. In the proposed hybrid algorithm ACO is conducted to provide diversification, while GA is conducted to provide intensification. The proposed algorithm is tested on 20 representatives MMALBP-I extended by adding low, medium and high variability of setup times. The results are compared with pure ACO pure GA and hGA in terms of solution quality and computational times. Computational results indicate that the proposed ACO-GA algorithm has superior performance.     

An improved simulated annealing for hybrid flowshops with sequence-dependent setup and transportation times to minimize total completion time and total tardiness

In this communication, we strive to apply a novel simulated annealing to consider scheduling hybrid flowshop problems to minimize both total completion time and total tardiness. To narrow the gap between the theory and the practice of the hybrid flowshop scheduling, we integrate two realistic and practical assumptions which are sequence-dependent setup and transportation times into our problem. We apply a metaheuristic based on simulated annealing (SA) which strikes a compromise between intensification and diversification mechanisms to augment the competitive performance of our proposed SA. A comprehensive calibration of different parameters and operators are done. We employ Taguchi method to select the optimum parameters with the least possible number of experiments. For the purpose of performance evaluation of our proposed algorithm, we generate a benchmark against which the adaptations of high performing algorithms in the literature are brought into comparison. Moreover, we investigate the impacts of increase of number of jobs on the performance of our algorithm. The efficiency and effectiveness of our hybrid simulated annealing are inferred from all the computational results obtained in various situations.     

Supply chain-oriented two-stage assembly flowshops with sequence-dependent setup times

Supply chain-oriented scheduling problems have received recent recognition among production research scholars due to their ability in integrating production planning and control across manufacturing systems. This study contributes to the literature of the distributed scheduling problems developing an original Mixed-Integer Linear Programming (MILP) formulation to the Distributed Two-Stage Assembly Flowshop Scheduling Problem with Sequence-Dependent Setup Times (DTSAFSP-SDSTs). Besides, the Iterated Greedy algorithm is extended to effectively solve this relatively complex production scheduling situation considering the makespan as the optimization criterion. Extensive numerical tests and statistical analyses are conducted to evaluate the effectiveness of the developed solution algorithm. Results showed that the Improved Iterated Greedy (IIG) algorithm yields the best solution in nearly all of the large-scale instances. The statistical test of significance confirmed that IIG is superior to the current-best-performing algorithm. This study contributes to the transition from standalone optimization to integrated production planning and control of distributed manufacturing systems.     

Scheduling flowshops with finite buffers and sequence-dependent setup times

In this paper we explore flowshop scheduling problems containing both sequence-dependent setup times and finite buffers. To the best of our knowledge, problems containing both of these complexities have not been addressed previously in the literature. The problem is clearly NP-hard and therefore we only consider heuristic solution methods. We propose a tabu search based solution procedure. Computational results demonstrate the effectiveness of this approach relative to the other methods discussed.     

An evolutionary clustering search for the no-wait flow shop problem with sequence dependent setup times

This paper examines the m machine no-wait flow shop problem with setup times of a job separated from its processing time. The performance measure considered is the makespan. The hybrid metaheuristic Evolutionary Cluster Search (ECS_NSL) proposed in Nagano et al. (2012) is extended to solve the scheduling problem. The ECS_NSL performance is evaluated and the results are compared with the best method reported in the literature. Experimental tests show superiority of the ECS_NSL regarding the solution quality.     

An efficient hybrid evolutionary algorithm for scheduling with setup times and weighted tardiness minimization

We confront the job shop scheduling problem with sequence-dependent setup times and weighted tardiness minimization. To solve this problem, we propose a hybrid metaheuristic that combines the intensification capability of tabu search with the diversification capability of a genetic algorithm which plays the role of long term memory for tabu search in the combined approach. We define and analyze a new neighborhood structure for this problem which is embedded in the tabu search algorithm. The efficiency of the proposed algorithm relies on some elements such as neighbors filtering and a proper balance between intensification and diversification of the search. We report results from an experimental study across conventional benchmarks, where we analyze our approach and demonstrate that it compares favorably to the state-of-the-art methods.     

An adaptive multi-population genetic algorithm to solve the multi-objective group scheduling problem in hybrid flexible flowshop with sequence-dependent setup times

In this paper we consider a multi-objective group scheduling problem in hybrid flexible flowshop with sequence-dependent setup times by minimizing total weighted tardiness and maximum completion time simultaneously. Whereas these kinds of problems are NP-hard, thus we proposed a multi-population genetic algorithm (MPGA) to search Pareto optimal solution for it. This algorithm comprises two stages. First stage applies combined objective of mentioned objectives and second stage uses previous stage’s results as an initial solution. In the second stage sub-population will be generated by re-arrangement of solutions of first stage. To evaluate performance of the proposed MPGA, it is compared with two distinguished benchmarks, multi-objective genetic algorithm (MOGA) and non-dominated sorting genetic algorithm II (NSGA-II), in three sizes of test problems: small, medium and large. The computational results show that this algorithm performs better than them.     

An efficient heuristic for a two-stage assembly scheduling problem with batch setup times to minimize makespan

This paper considers a two-stage assembly scheduling problem of N products with setup times to minimize the makespan. In this problem, there is a machining machine which produces components in the first stage. When the required components are available, a single assembly machine can assemble these components into products in the second stage. A setup time is needed whenever the machining machine starts processing components, or the item of component is switched on the machine. The problem is formulated as a mixed integer programming model, and several properties for finding optimal solutions are developed. Moreover, an efficient heuristic based on these optimal properties is proposed. A lower bound is derived to evaluate the performance of the proposed heuristic. Computational results show that the proposed heuristic can obtain a near optimal solution in almost zero time and the average percentage deviation is only 0.478.     

A novel algorithm for layout optimization of injection process with random demands and sequence dependent setup times

Injection molding is an ideal manufacturing process for producing high volumes of products from both thermoplastic and thermo setting materials. Nevertheless, in some cases, this type of manufacturing process decelerates the production rate as a bottleneck. Thus, layout optimization plays a crucial role in this type of problem in terms of increasing the efficiency of the production line. In this regard, a novel computer simulation–stochastic data envelopment analysis (CS-SDEA) algorithm is proposed in this paper to deal with a single row job-shop layout problem in an injection molding process. First, the system is modeled with discrete-event-simulation as a powerful tool for analyzing complex stochastic systems. Then, due to lack of information about some operational parameters, theory of uncertainty is imported to the simulation model. Finally, an output-oriented stochastic DEA model is used for ranking the outputs of simulation model. The proposed CS-SDEA algorithm is capable of modeling and optimizing non-linear, stochastic, and uncertain injection process problems. The solution quality is illustrated by an actual case study in a refrigerator manufacturing company.     

A discrete differential evolution algorithm for the single machine total weighted tardiness problem with sequence dependent setup times

This paper is concerned with solving the single machine total weighted tardiness problem with sequence dependent setup times by a discrete differential evolution algorithm developed by the authors recently. Its performance is enhanced by employing different population initialization schemes based on some constructive heuristics such as the well-known NEH and the greedy randomized adaptive search procedure (GRASP) as well as some priority rules such as the earliest weighted due date (EWDD) and the apparent tardiness cost with setups (ATCS). Additional performance enhancement is further achieved by the inclusion of a referenced local search (RLS) in the algorithm together with the use of destruction and construction (DC) procedure when obtaining the mutant population. Furthermore, to facilitate the greedy job insertion into a partial solution which will be employed in the NEH, GRASP, DC heuristics as well as in the RLS local search, some newly designed speed-up methods are presented for the insertion move for the first time in the literature. They are novel contributions of this paper to the single machine tardiness related scheduling problems with sequence dependent setup times. To evaluate its performance, the discrete differential evolution algorithm is tested on a set of benchmark instances from the literature. Through the analyses of experimental results, its highly effective performance with substantial margins both in solution quality and CPU time is shown against the best performing algorithms from the literature, in particular, against the very recent newly designed particle swarm and ant colony optimization algorithms of Anghinolfi and Paolucci [A new discrete particle swarm optimization approach for the single machine total weighted tardiness scheduling problem with sequence dependent setup times. European Journal of Operational Research 2007; doi:10.1016/j.ejor.2007.10.044] and Anghinolfi and Paolucci [A new ant colony optimization approach for the single machine total weighted tardiness scheduling problem. http://www.discovery.dist.unige.it/papers/Anghinolfi_Paolucci_ACO.pdf, respectively. Ultimately, 51 out of 120 overall aggregated best known solutions so far in the literature are further improved while other 50 instances are solved equally.     

Hybrid flexible flowshops with sequence-dependent setup times and machine availability constraints

One of the common assumptions in the field of scheduling is that machines are always available in the planning horizon. This may not be true in realistic problems since machines might be busy processing some jobs left from previous production horizon, breakdowns or preventive maintenance activities. Another common assumption is the consideration of setup times as a part of processing times, while in some industries, such as printed circuit board and automobile manufacturing, not only setups are an important factor but also setup magnitude of a job depends on its immediately preceding job on the same machine, known as sequence-dependent setup times. In this paper, we consider hybrid flexible flowshops with sequence-dependent setup times and machine availability constraints caused by preventive maintenance. The optimization criterion is the minimization of makespan. Since this problem is NP-hard in the strong sense, we propose three heuristics, based on SPT, LPT and Johnson rule and two metaheuristics based on genetic algorithm and simulated annealing. Computational experiments are performed to evaluate the efficiencies of the algorithms.     

Production sequencing problem with reentrant work flows and sequence dependent setup times

This paper addresses a shop scheduling problem for the side frame press shop in a truck manufacturing company. In the problem, a set of n jobs to be scheduled on two machines. All the jobs require processing by the first machine more than once in their operation sequences with reentrant work flows. An unusual aspect of the problem is that the setup times required for a job in the first machine depend not on the immediately preceding job but on the job which is two steps prior to it. Redefining the job elements, the problem is formulated into a general two machine flow shop problem which has a set of job-element precedence constraints. The problem is solved with a modified dynamic programming with the objective of the minimum makespan. An optimal schedule is found utilizing the sequence dominance condition and a decision-delay scheme. A numerical example is presented for the illustration purpose.     

Metaheuristics for scheduling a non-permutation flowline manufacturing cell with sequence dependent family setup times

The broad applications of cellular manufacturing make flowline manufacturing cell scheduling problems with sequence dependent family setup times a core topic in the field of scheduling. Due to computational complexity, almost all published studies focus on using permutation schedules to deal with this problem. To explore the potential effectiveness of treating this argument using non-permutation schedules, three prominent types of metaheuristics—a simulated annealing, a genetic algorithm and a tabu search—are proposed and empirically evaluated. The experimental results demonstrate that in general, the improvement made by non-permutation schedules over permutation schedules for the due-date-based performance criteria were significantly better than that for the completion-time-based criteria. The results of this study will provide practitioners a guideline as to when to adopt a non-permutation schedule, which may exhibit better performance with additional computational efforts.     

Lateness minimization with Tabu search for job shop scheduling problem with sequence dependent setup times

We tackle the job shop scheduling problem with sequence dependent setup times and maximum lateness minimization by means of a tabu search algorithm. We start by defining a disjunctive model for this problem, which allows us to study some properties of the problem. Using these properties we define a new local search neighborhood structure, which is then incorporated into the proposed tabu search algorithm. To assess the performance of this algorithm, we present the results of an extensive experimental study, including an analysis of the tabu search algorithm under different running conditions and a comparison with the state-of-the-art algorithms. The experiments are performed across two sets of conventional benchmarks with 960 and 17 instances respectively. The results demonstrate that the proposed tabu search algorithm is superior to the state-of-the-art methods both in quality and stability. In particular, our algorithm establishes new best solutions for 817 of the 960 instances of the first set and reaches the best known solutions in 16 of the 17 instances of the second set.