Scheduling jobs with ready times and precedence constraints on parallel batch machines using metaheuristics

In this paper, we discuss a scheduling problem for parallel batch machines where the jobs have ready times. Problems of this type can be found in semiconductor wafer fabrication facilities (wafer fabs). In addition, we consider precedence constraints among the jobs. Such constraints arise, for example, in scheduling subproblems of the shifting bottleneck heuristic when complex job shop scheduling problems are tackled. We use the total weighted tardiness as the performance measure to be optimized. Hence, the problem is NP-hard and we have to rely on heuristic solution approaches. We consider a variable neighborhood search (VNS) scheme and a greedy randomized adaptive search procedure (GRASP) to compute efficient solutions. We assess the performance of the two metaheuristics based on a large set of randomly generated problem instances and based on instances from the literature. The obtained computational results demonstrate that VNS is a very fast heuristic that quickly leads to high-quality solutions, whereas the GRASP is slightly outperformed by the VNS approach. However, the GRASP approach has the advantage that it can be parallelized in a more natural manner compared to VNS.     

Heuristic scheduling of jobs on parallel batch machines with incompatible job families and unequal ready times

This research is motivated by a scheduling problem found in the diffusion and oxidation areas of semiconductor wafer fabrication, where the machines can be modeled as parallel batch processors. We attempt to minimize total weighted tardiness on parallel batch machines with incompatible job families and unequal ready times of the jobs. Given that the problem is NP-hard, we propose two different decomposition approaches. The first approach forms fixed batches, then assigns these batches to the machines using a genetic algorithm (GA), and finally sequences the batches on individual machines. The second approach first assigns jobs to machines using a GA, then forms batches on each machine for the jobs assigned to it, and finally sequences these batches. Dispatching and scheduling rules are used for the batching phase and the sequencing phase of the two approaches. In addition, as part of the second decomposition approach, we develop variations of a time window heuristic based on a decision theory approach for forming and sequencing the batches on a single machine.     

Variable neighborhood search approaches for scheduling jobs on parallel machines with sequence-dependent setup times, precedence constraints, and ready times

In this paper, we discuss a scheduling problem for jobs on identical parallel machines. Ready times of the jobs, precedence constraints, and sequence-dependent setup times are considered. We are interested in minimizing the performance measure total weighted tardiness that is important for achieving good on-time delivery performance. Scheduling problems of this type appear as subproblems in decomposition approaches for large scale job shops with automated transport of the jobs as, for example, in semiconductor manufacturing. We suggest several variants of variable neighborhood search (VNS) schemes for this scheduling problem and compare their performance with the performance of a list based scheduling approach based on the Apparent Tardiness Cost with Setups and Ready Times (ATCSR) dispatching rule. Based on extensive computational experiments with randomly generated test instances we are able to show that the VNS approach clearly outperforms heuristics based on the ATCSR dispatching rule in many situations with respect to solution quality. When using the schedule obtained by ATCSR as an initial solution for VNS, then the entire scheme is also fast and can be used as a subproblem solution procedure for complex job shop decomposition approaches.     

Machine learning techniques for scheduling jobs with incompatible families and unequal ready times on parallel batch machines

This research is motivated by a scheduling problem found in the diffusion and oxidation areas of semiconductor wafer fabrication facilities, where the machines can be modeled as parallel batch processors. Total weighted tardiness on parallel batch machines with incompatible job families and unequal ready times of the jobs is attempt to minimize. Given that the problem is NP hard, a simple heuristic based on the Apparent Tardiness Cost (ATC) Dispatching Rule is suggested. Using this rule, a look-ahead parameter has to be chosen. Because of the appearance of unequal ready times and batch machines it is hard to develop a closed formula to estimate this parameter. The use of inductive decision trees and neural networks from machine learning is suggested to tackle the problem of parameter estimation. The results of computational experiments based on stochastically generated test data are presented. The results indicate that a successful choice of the look-ahead parameter is possible by using the machine learning techniques.     

Unrelated parallel machine scheduling with setup times and a total weighted tardiness objective

This paper presents several search heuristics and their performance in batch scheduling of parallel, unrelated machines. Identical or similar jobs are typically processed in batches in order to decrease setup times and/or processing times. The problem accounts for allotting batched work parts into unrelated parallel machines, where each batch consists of a fixed number of jobs. Some batches may contain different jobs but all jobs within each batch should have an identical processing time and a common due date. Processing time of each job of a batch is determined according to the machine group as well as the batch group to which the job belongs. Major or minor setup times are required between two subsequent batches depending on batch sequence but are independent of machines. The objective of our study is to minimize the total weighted tardiness for the unrelated parallel machine scheduling. Four search heuristics are proposed to address the problem, namely (1) the earliest weighted due date, (2) the shortest weighted processing time, (3) the two-level batch scheduling heuristic, and (4) the simulated annealing method. These proposed local search heuristics are tested through computational experiments with data from dicing operations of a compound semiconductor manufacturing facility.     

A simultaneous and iterative approach for parallel machine scheduling with sequence-dependent family setups

In this paper, we address a parallel machine scheduling problem to minimize the total weighted completion time, where product families are involved. Major setups occur when processing jobs of different families, and sequence dependencies are also taken into account. Considering its high practical relevance, we focus on the special case where all jobs of the same family have identical processing times. In order to avoid redundant setups, batching jobs of the same family can be performed. We first develop a variable neighborhood search algorithm (VNS) to solve the interrelated subproblems in a simultaneous manner. To further reduce computing time, we also propose an iterative scheme which alternates between a specific heuristic to form batches and a VNS scheme to schedule entire batches. Computational experiments are conducted which confirm the benefits of batching. Test results also show that both simultaneous and iterative approach outperform heuristics based on a fixed batch size and list scheduling. Furthermore, the iterative procedure succeeds in balancing solution quality and computing time.     

A distributed shifting bottleneck heuristic for complex job shops

In this paper, we consider distributed versions of a modified shifting bottleneck heuristic for complex job shops. The considered job shop environment contains parallel batching machines, machines with sequence-dependent setup times and reentrant process flows. Semiconductor wafer fabrication facilities are typical examples for manufacturing systems with these characteristics. The used performance measure is total weighted tardiness (TWT). We suggest a two-layer hierarchical approach in order to decompose the overall scheduling problem. The upper (or top) layer works on an aggregated model. Based on appropriately aggregated routes it determines start dates and planned due dates for the jobs within each single work area, where a work area is defined as a set of parallel machine groups. The lower (or base) layer uses the start dates and planned due dates in order to apply shifting bottleneck heuristic type solution approaches for the jobs in each single work area. We conduct simulation experiments in a dynamic job shop environment in order to assess the performance of the heuristic. It turns out that the suggested approach outperforms a pure First In First Out (FIFO) dispatching scheme and provides a similar solution quality as the original modified shifting bottleneck heuristic.     

Scheduling algorithms for a semiconductor probing facility

This paper focuses on a scheduling problem in a semiconductor wafer probing facility. In the probing facility, wafer lots with distinct ready times are processed on a series of workstations, each with identical parallel machines. We develop a heuristic algorithm for the problem with the objective of minimizing total tardiness of orders. The algorithm employs a bottleneck-focused scheduling method, in which a schedule at the bottleneck workstation is constructed first and then schedules for other workstations are constructed based on the schedule at the bottleneck. For scheduling wafer lots at the bottleneck workstation, we consider prospective tardiness of the lots as well as sequence-dependent setup times required between different types of wafer lots. We also present a rolling horizon method for implementation of the scheduling method on a dynamic situation. The suggested methods are evaluated through a series of computational experiments and results show that the methods work better than existing heuristic methods.     

A tabu search algorithm for parallel machine total tardiness problem

In this study, we consider the problem of scheduling a set of independent jobs with sequence dependent setups on a set of uniform parallel machines such that total tardiness is minimized. Jobs have non-identical due dates and arrival times. A tabu search (TS) approach is employed to attack this complex problem. In order to obtain a robust search mechanism, several key components of TS such as candidate list strategies, tabu classifications, tabu tenure and intensification/diversification strategies are investigated. Alternative approaches to each of these issues are developed and extensively tested on a set of problems obtained from the literature. The results obtained are considerably better than those reported previously and constitute the best solutions known for the benchmark problems as to date. Scope and purposeSeveral surveys on parallel machine scheduling with due date related objectives (Oper. Res. 38(1) (1990) 22; EJOR 38 (1989) 156; Oper. Res. 42 (1994) 1025) reveal that the NP-hard nature of the problem renders it a challenging area for many researchers who studied various versions. However, most of these studies make the assumption that jobs are available at the beginning of the scheduling period, which is an important deviation form reality. In this study, as well as distinct due dates and ready times, features such as sequence dependent setup times and different processing rates for machines are incorporated into the classical model. These enhancements approach the model to the actual practice at the expense of complicating the problem further. For this complex problem, we present a tabu search (TS) algorithm to minimize total tardiness and provide the best solutions known for a set of benchmark problems.     

Unrelated parallel machine scheduling with setup times using simulated annealing

This paper presents a scheduling problem for unrelated parallel machines with sequence-dependent setup times, using simulated annealing (SA). The problem accounts for allotting work parts of L jobs into M parallel unrelated machines, where a job refers to a lot composed of N items. Some jobs may have different items while every item within each job has an identical processing time with a common due date. Each machine has its own processing times according to the characteristics of the machine as well as job types. Setup times are machine independent but job sequence dependent. SA, a meta-heuristic, is employed in this study to determine a scheduling policy so as to minimize total tardiness. The suggested SA method utilizes six job or item rearranging techniques to generate neighborhood solutions. The experimental analysis shows that the proposed SA method significantly outperforms a neighborhood search method in terms of total tardiness.     

Heuristics for hybrid flow shops with controllable processing times and assignable due dates

This paper considers a generalization of the permutation flow shop problem that combines the scheduling function with the planning stage. In this problem, each work center consists of parallel identical machines. Each job has a different release date and consists of ordered operations that have to be processed on machines from different machine centers in the same order. In addition, the processing times of the operations on some machines may vary between a minimum and a maximum value depending on the use of a continuously divisible resource. We consider a nonregular optimization criterion based on due dates which are not a priori given but can be fixed by a decision-maker. A due date assignment cost is included into the objective function. For this type of problems, we generalize well-known approaches for the heuristic solution of classical problems and propose constructive algorithms based on job insertion techniques and iterative algorithms based on local search. For the latter, we deal with the design of appropriate neighborhoods to find better quality solution. Computational results for problems with up to 20 jobs and 10 machine centers are given.Scope and purposeTraditional research to solve multi-stage scheduling problems has focused on regular measures of performance based on a single criterion and assumes that several decisions related to due dates and processing times have already been made. However, in many industrial scheduling practices, managers develop schedules based on multicriteria and have to decide the due dates and processing times as part of the scheduling activities. Further, in practical scheduling situations, there are multiple machines at each stage and the objective function often reflects the total cost of processing, earliness and tardiness. Such scheduling problems require significantly more effort in finding acceptable solutions and hence have not received much attention in the literature. For this reason, this paper considers one such hybrid flow shop scheduling problem involving nonregular measures of performance, controllable processing times, and assignable due dates. We combine and generalize the existing approaches for the classical flow shop problem to the problem under consideration. Computational experiments are used to evaluate the utility of the proposed algorithms for the generalized scheduling problems. Brah and Hunsucker (European Journal of Operational Research 1991;51:88–99) and Nowicki and Smutnicki (European Journal of Operational Research 1998;106:226–253) describe branch and bound and tabu search algorithms for the approach used in the development of heuristic algorithms can also be adapted to several other complex practical scheduling problems.     

A memetic algorithm for minimizing total weighted tardiness on parallel batch machines with incompatible job families and dynamic job arrival

This paper addresses a scheduling problem motivated by scheduling of diffusion operations in the wafer fabrication facility. In the target problem, jobs arrive at the batch machines at different time instants, and only jobs belonging to the same family can be processed together. Parallel batch machine scheduling typically consists of three types of decisions—batch forming, machine assignment, and batch sequencing. We propose a memetic algorithm with a new genome encoding scheme to search for the optimal or near-optimal batch formation and batch sequence simultaneously. Machine assignment is resolved in the proposed decoding scheme. Crossover and mutation operators suitable for the proposed encoding scheme are also devised. Through the experiment with 4860 problem instances of various characteristics including the number of machines, the number of jobs, and so on, the proposed algorithm demonstrates its advantages over a recently proposed benchmark algorithm in terms of both solution quality and computational efficiency.     

Scheduling of parallel machines with sequence-dependent batches and product incompatibilities in an automotive glass facility

This application is motivated by a complex real-world scheduling problem found in the bottleneck workstation of the production line of an automotive safety glass manufacturing facility. The scheduling problem consists of scheduling jobs (glass parts) on a number of parallel batch processing machines (furnaces), assigning each job to a batch, and sequencing the batches on each machine. The two main objectives are to maximize the utilization of the parallel machines and to minimize the delay in the completion date of each job in relation to a required due date (specific for each job). Aside from the main objectives, the output batches should also produce a balanced workload on the parallel machines, balanced job due dates within each batch, and minimal capacity loss in the batches. The scheduling problem also considers a batch capacity constraint, sequence-dependent processing times, incompatible product families, additional resources, and machine capability. We propose a two-phase heuristic approach that combines exact methods with search heuristics. The first phase comprises a four-stage mixed-integer linear program for building the batches; the second phase is based on a Greedy Randomized Adaptive Search Procedure for sequencing the batches assigned to each machine. We conducted experiments on instances with up to 100 jobs built with real data from the manufacturing facility. The results are encouraging both in terms of computing time—5 min in average—and quality of the solutions—less than 10 % relative gap from the optimal solution in the first phase and less than 5 % in the second phase. Additional experiments were conducted on randomly generated instances of small, medium, and large size.     

A heuristic for job shop scheduling to minimize total weighted tardiness

This paper considers the job shop scheduling problem to minimize the total weighted tardiness with job-specific due dates and delay penalties, and a heuristic algorithm based on the tree search procedure is developed for solving the problem. A certain job shop scheduling to minimize the maximum tardiness subject to fixed sub-schedules is solved at each node of the search tree, and the successor nodes are generated, where the sub-schedules of the operations are fixed. Thus, a schedule is obtained at each node, and the sub-optimum solution is determined among the obtained schedules. Computational results on some 10 jobs and 10 machines problems and 15 jobs and 15 machines problems show that the proposed algorithm can find the sub-optimum solutions with a little computation time.     

Minimizing weighted earliness–tardiness on parallel machines using hybrid metaheuristics

We consider the problem of scheduling a set of jobs on a set of identical parallel machines where the objective is to minimize the total weighted earliness and tardiness penalties with respect to a common due date. We propose a hybrid heuristic algorithm for constructing good solutions, combining priority rules for assigning jobs to machines and a local search with exact procedures for solving the one-machine subproblems. These solutions are then used in two metaheuristic frameworks, Path Relinking and Scatter Search, to obtain high quality solutions for the problem.The algorithms are tested on a large number of test instances to assess the efficiency of the proposed strategies.The results show that our algorithms consistently outperform the best reported results for this problem.     

A bi-layer optimization approach for a hybrid flow shop scheduling problem involving controllable processing times in the steelmaking industry

A steelmaking-continuous casting (SCC) scheduling problem is an example of complex hybrid flow shop scheduling problem (HFSSP) with a strong industrial background. This paper investigates the SCC scheduling problem that involves controllable processing times (CPT) with multiple objectives concerning the total waiting time, earliness/tardiness and adjusting cost. The SCC scheduling problem with CPT is seldom discussed in the existing literature. This study is motivated by the practical situation of a large integrated steel company in which the just-in-time (JIT) and cost-cutting production strategy have become a significant concern. To address this complex HFSSP, the scheduling problem is decomposed into two subproblems: a parallel machine scheduling problem (PMSP) in the last stage and an HFSSP in the upstream stages. First, a hybrid differential evolution (HDE) algorithm combined with a variable neighborhood decomposition search (VNDS) is proposed for the former subproblem. Second, an iterative backward list scheduling (IBLS) algorithm is presented to solve the latter subproblem. The effectiveness of this bi-layer optimization approach is verified by computational experiments on well-designed and real-world scheduling instances. This study provides a new perspective on modeling and solving practical SCC scheduling problems.     

基于规则的平行机台生产调度系统

针对某电器生产的平行机台调度系统，描述了该系统的组成结构与数据接口界定。     

A variable neighborhood search approach for planning and scheduling of jobs on unrelated parallel machines

In this paper, we study a planning and scheduling problem for unrelated parallel machines. There are n jobs that have to be assigned and sequenced on m unrelated parallel machines. Each job has a weight that represents the priority of the corresponding customer order, a given due date, and a release date. An Automated Guided Vehicle is used to transport at maximum Load _max jobs into a storage space in front of the machines in a given period of time. We consider t _max consecutive periods. We are interested in minimizing the total weighted tardiness of the jobs across the periods. This measure is important when we are interested in a good on-time delivery performance. We present an appropriate mixed integer program. To solve this NP-hard problem, we develop a heuristic methodology based on decomposition and variable neighborhood search (VNS). The proposed approaches are assessed using randomly generated problem instances. We compare them with a simple heuristic based on decomposition and list scheduling using the Apparent Tardiness Cost dispatching rule. The results demonstrate that the heuristic approach based on VNS performs comparably to the mixed integer program while having reasonable solution times and outperforms the simple heuristic and a genetic algorithm (GA) from previous research.     

Tabu search for scheduling on identical parallel machines to minimize mean tardiness

This paper presents a tabu search approach for scheduling jobs on identical parallel machines with the objective of minimizing the mean tardiness. Initially, we consider a basic tabu search that uses short term memory only. Local search is performed on a neighborhood defined by two types of moves. Insert moves consist of transferring each job from one machine to another and swap moves are those obtained by exchanging each pair of jobs between two machines. Next, we analyze the incorporation of two diversification strategies with the aim of exploring unvisited regions of the solution space. The first strategy uses long term memory to store the frequency of the moves executed throughout the search and the second makes use of influential moves. Computational tests are performed on problems with up to 10 machines and 150 jobs. The heuristic performance is evaluated through a lower bound given by Lagrangean relaxation. A comparison is also made with respect to the best constructive heuristic reported in the literature.     

Simulated-annealing heuristics for the single-machine scheduling problem with learning and unequal job release times

In scheduling of batch processing machines in the diffusion and oxidation areas of a wafer fabrication facility, it can be found that the processing times of these batching operations can be extremely long (10 h) when compared to other operations (1-2 h) in a wafer fab. Moreover, the jobs to be processed may have different priorities/weights, due dates and ready times. In the presence of unequal ready times, it would be better to wait for future job arrivals in order to increase the fullness of the batch. On the other hand, repeated processing of similar tasks improves workers’ skills. Motivated by these observations, we consider a single-machine problem with the sum of processing times based learning effect and release times. The objective is to find a schedule to minimize the total completion times. We first develop a branch-and-bound algorithm for the optimal solution. Then we propose a simulated-annealing heuristic algorithm for a near-optimal solution. Finally, we conduct a computational experiment to evaluate the performances of the proposed algorithms. The results show that the branch-and-bound algorithm can solve instances up to 24 jobs, and the average error percentage of the simulated-annealing algorithm is less than 0.1482%.