Scheduling Optimization Modelling: A Case Study of a Woven Label Manufacturing Company

Production scheduling involves all activities of building production schedules, including coordinating and assigning activities to each person, group of people, or machine and arranging work orders in each workplace. Production scheduling must solve all problems such as minimizing customer wait time, storage costs, and production time; and effectively using the enterprise’s human resources. This paper studies the application of flexible job shop modelling on scheduling a woven labelling process. The labelling process includes several steps which are handled in different work-stations. Each workstation is also comprised of several identical parallel machines. In this study, job splitting is allowed so that the power of work stations can be utilized better. The final objective is to minimize the total completion time of all jobs. The results show a significant improvement since the new planning may save more than 60% of lead time compared to the current schedule. The contribution of this research is to propose a flexible job shop model for scheduling a woven labelling process. The proposed approach can also be applied to support complex production scheduling processes under fuzzy environments in different industries. A practical case study demonstrates the effectiveness of the proposed model.     

Multi-agent based real-time production scheduling method for radio frequency identification enabled ubiquitous shopfloor environment

The lack of timely feedback shopfloor information during manufacturing execution stage leads to significant difficulties in achieving real-time production scheduling. To address this problem, an overall architecture of multi-agent based real-time production scheduling is presented to close the loop of production planning and control. Several contributions are significant. Firstly, wireless devices such as radio frequency identification (RFID) are deployed into value-adding points in a ubiquitous shopfloor environment to form Machine Agent for the collection and processing of real-time shopfloor data. Secondly, Capability Evaluation Agent is designed to optimally assign the tasks to the involved machines at the process planning stage based on the real-time utilization ration of each machine. The third contribution is a Real-time Scheduling Agent for manufacturing tasks scheduling/re-scheduling strategy and methods according to the real-time feedback. Fourthly, a Process Monitor Agent model is designed for tracking and tracing the manufacturing execution based on a critical event structure. Finally, a case is used to demonstrate the proposed multi-agent based real-time production scheduling models and methods.     

Tsp-based scheduling in a batch-wise hybrid flow-shop

In the past few years, flexible production systems have allowed an extensive exploitation of new technologies, but have also led to new difficulties in production planning management science. The model presented in this paper extends the traditional HFS (hybrid flow-shop) scheduling problem to the case in which jobs are due to follow strict precedence constraints and batch assignment constraints and the parallel machines at a stage are served by a bottleneck machine. A variant of the well-known TSP problem is used to develop an efficient heuristic solution for the problem. The effectiveness of the proposed approach is validated through a comparison with different heuristics traditionally used in HFS scheduling problems. Furthermore, a simple insertion heuristic based on the TSP model of the problem is tested. Finally, a MIP-based approach is also explored to provide the optimum solutions within much larger times for comparison.     

一类复杂生产调度问题的基于符号演绎的调度方法

针对带有时问不确定件的复杂生产过程调度问题,提出一种基于符号演绎的调度方法.首先将时间的不确定性信息看作符号型数据,并提出一种用于处理这些符号型数据的基于不确定区间的符号演绎方法;然后将此符号演绎方法与遗传算法相结合,提出一种预排调度计划与实时调度规则相结合的调度方法来求解上述复杂生产调度问题.实验表明,将基于符号演绎的调度方法用于求解带有时间不确定性的复杂生产过程调度问题,能够取得较好的调度效果.     

A decision support system for production scheduling in an ion plating cell

Production scheduling is one of the major issues in production planning and control of individual production units which lies on the heart of the performance of manufacturing organizations. Traditionally, production planning decision, especially scheduling, was resolved through intuition, experience, and judgment. Machine loading is one of the process planning and scheduling problems that involves a set of part types and a set of tools needed for processing the parts on a set of machines. It provides solution on assigning parts and allocating tools to optimize some predefined measures of productivity. In this study, Ion Plating industry requires similar approaches on allocating customer's order, i.e. grouping production jobs into batches and arrangement of machine loading sequencing for (i) producing products with better quality products; and (ii) enabling to meet due date to satisfy customers. The aim of this research is to develop a Machine Loading Sequencing Genetic Algorithm (MLSGA) model to improve the production efficiency by integrating a bin packing genetic algorithm model in an Ion Plating Cell (IPC), such that the entire system performance can be improved significantly. The proposed production scheduling system will take into account the quality of product and service, inventory holding cost, and machine utilization in Ion Plating. Genetic Algorithm is being chosen since it is one of the best heuristics algorithms on solving optimization problems. In the case studies, industrial data of a precious metal finishing company has been used to simulate the proposed models, and the computational results have been compared with the industrial data. The results of developed models demonstrated that less resource could be required by applying the proposed models in solving production scheduling problem in the IPC.     

基于启发式规则的混合遗传算法及其在生产计划优化中的应用

以最优或近似最优的作业顺序编制满足关键资源约束的生产计划优化问题一直是企业生产管理中重要的研究课题之一。文章提出了一种基于传统启发式规则的混合遗传算法。该算法将染色体分为两段,前段表示资源安排策略,后段表示为优先分配规则序列,并设计了一种新的交叉算子。最后,介绍了根据此算法编制的一个制造企业生产控制的软件系统。     

Integrated scheduling and flexible maintenance in deteriorating multi-state single machine system using a reinforcement learning approach

This paper studies an integrated optimization problem of production scheduling and flexible preventive maintenance (PM) in a multi-state single machine system with deteriorating effects. A flexible PM strategy is proposed to proactively cope with machine failures while ensuring relatively regular PM intervals, which is composed of time-based PM (TBPM) and condition-based PM (CBPM). TBPM is conducted within every flexible time window and CBPM is implemented immediately after the most deteriorated yet still functional state. An illustrative case is presented using the enumeration approach to demonstrate the integration of production scheduling and machine maintenance. Then, Q-learning-based solution framework (QLSF) is further designed with proper state and action sets and reward functions to facilitate the determination of appropriate production scheduling rule under the constraint of the flexible maintenance. Numerical experiments show that the proposed QLSF outperforms the other four state-of-the-art scheduling rules in different scenarios. Moreover, the performance of the proposed flexible PM strategy is also examined and validated in comparison with three candidate maintenance strategies, i.e., run-to-failure corrective maintenance (CM), combination of TBPM and CM, and CBPM. The proposed flexible maintenance and solution approach can enrich the relevant academic knowledge base, and provide managerial insights and guidance in practical production systems.     

基于反馈平衡的多生产线调度算法与仿真

研究生产线平衡调度优化问题。传统的生产线产品调度中,由于生产线上的产品数量不定,造成生产线的负荷不平衡,容易造成生产线工序上产品堆积,导致生产线平衡能力下降,流水线发生阻塞。为了解决上述6问题,提出了一种反馈信息平衡的生产线产品调度算法。将产品在生产线上流动的顺畅情况,作为反馈信息传递给生产调度端。调度算法把各种信息作为指导后续生产线产品选择工序先后次序的依据,使得在生产线上负荷大幅增加的情况下,通过反馈信息改变产品调度顺序,使得生产线负荷达到平衡。实验结果表明,反馈信息平衡算法在产品负荷较大的情况下,有效地提高生产线的平滑指数,提高了生产线的效率。     

一种基于神经网络的生产调度方法

提出解决具有开、完工期限制的约束Job-shop生产调度问题的一种神经网络方法. 该方法通过约束神经网络,描述各种加工约束条件,并对不满足约束的开工时间进行相应调 节,得到可行调度方案;然后由梯度搜索算法优化可行调度方案,直至得到最终优化可行调度 解.理论分析、仿真实验表明了方法的有效性.     

Integration of FMS performance evaluation models using patterns for an information system design

The objective of our work is to create an information system able to integrate different view points concerning the design and the control of a Flexible Manufacturing System. Numerous methods based on generic reference frameworks have been proposed for the modeling of all the aspects of production systems. These models have to be instantiated in order to be applied to specific systems. The difficulties are then to integrate pre-existing models of the studied systems with those obtained by the instantiation of the generic reference framework.

The proposed approach tackles the problem from the information system point of view. A meta-modeling bottom-up approach is presented based on the notion of patterns in order to facilitate the integration step.

An example concerned with the performance evaluation and scheduling of a production system is presented to show how the product viewpoint can be built in order to be integrated later with other viewpoints.     

柔性车间生产排产调度优化方法

为满足柔性制造企业在车间生产中合理安排生产排产调度的需要,提出柔性车间生产排产调度优化方法。首先,通过分析车间生产排产问题的特点,制定满足车间应用需求和各种资源限制的生产排产总体流程,从而设计基于约束条件的生产对象关系模型;其次,提出一种动态策略差分进化算法,根据个体之间的拥挤度动态选择变异策略,设计基于工序位置的编解码方案,其能快速有效地进行求解,从而得到最佳调度方案,提高设备运行效率,实现资源利用的最大化;最后,通过6个标准测试函数、FT6-6测试问题及生产调度应用实例验证了算法的有效性。     

A robust scheduling method based on a multi-objective immune algorithm

A robust scheduling method is proposed to solve uncertain scheduling problems. An uncertain scheduling problem is modeled by a set of workflow models, and then a scheduling scheme (solution) of the problem can be evaluated by workflow simulations executed with the workflow models in the set. A multi-objective immune algorithm is presented to find Pareto optimal robust scheduling schemes that have good performance for each model in the set. The two optimization objectives for scheduling schemes are the indices of the optimality and robustness of the scheduling results. An antibody represents a resource allocation scheme, and the methods of antibody coding and decoding are designed to deal with resource conflicts during workflow simulations. Experimental tests show that the proposed method can generate a robust scheduling scheme that is insensitive to uncertain scheduling environments.     

Knowledge based scheduling systems: a framework

Scheduling is a complex problem which occurs often in a manufacturing environment. There are many possible variations within the context of a scheduling problem, enough to overwhelm anyone but an expert. A production manager, faced with the task of job scheduling for a particular process, might well benefit from the advice of a scheduling expert. Even though the scheduling literature is full of optimizing rules for a variety of manufacturing environments few, if any, of these rules have been used in practice. The bewildering variety of theoretical results, the lack of a mechanism to match theoretical results to practical problems and the difficulty in establishing the practical efficacy of the theoretical results are among the reasons for this gap between scheduling theory and practice. This paper describes a scheduling expert system framework which addresses these problems and helps bridge this gap. The solution techniques available in SCHEDEX produce a specific schedule for the problem according to a procedure which has been mathematically proven to provide a satisfactory and often optimal solution, given the criteria for the problem. A simulation model also tests for the effectiveness of a selected technique with respect to the chosen performance measure(s).     

Planning,scheduling and dispatching tasks in production control

"What is the difference between planning and scheduling?" Production control encompasses many tasks performed by humans, three of which are planning, scheduling, and dispatching. In the past, the only criterion that could distinguish between the tasks was that planning is usually on a higher level than scheduling and scheduling is on a higher level than dispatching. Hence, the tasks are often ambiguous, unclear, and subject to speculation. There are few formal studies on the actual tasks of planning, scheduling, and dispatching, and there are no known studies that compare or discuss all three. In this paper it is argued that it is important to understand the differences between the tasks. An action science and ethnographic case study is presented as the empirical basis for the discussion, and the implications for decision support systems in production control tasks are presented.     

柔性作业车间生产计划与调度集成优化求解策略

针对柔性作业车间(Flexible job-shop, FJS)生产计划(Production planning, PP)与调度紧密衔接的特点, 建立了生产计划与调度集成优化模型. 模型综合考虑了安全库存、需求损失及工件加工路线柔性等方面因素. 提出了一种基于拉格朗日松弛(Lagrangian relaxation, LR)的分解算法, 将原问题分解为计划子问题与调度子问题. 针对松弛的生产计划子问题, 提出一种新的费用结构, 以保证生产计划决策与实际情况相符, 并设计了一种变量固定—松弛策略与滚动时域组合算法进行求解. 对于调度子问题中的加工路线柔性问题, 提出了一种新的机器选择策略. 通过数值实验验证了模型与算法的有效性.     

Multiscale production routing in multicommodity supply chains with complex production facilities

In this work, we introduce the multiscale production routing problem (MPRP), which considers the coordination of production, inventory, distribution, and routing decisions in multicommodity supply chains with complex continuous production facilities. We propose an MILP model involving two different time grids. While a detailed mode-based production scheduling model captures all critical operational constraints on the fine time grid, vehicle routing is considered in each time period of the coarse time grid. In order to solve large instances of the MPRP, we propose an iterative MILP-based heuristic approach that solves the MILP model with a restricted set of candidate routes at each iteration and dynamically updates the set of candidate routes for the next iteration. The results of an extensive computational study show that the proposed algorithm finds high-quality solutions in reasonable computation times, and in large instances, it significantly outperforms a standard two-phase heuristic approach and a solution strategy involving a one-time heuristic pre-generation of candidate routes. Similar results are achieved in an industrial case study, which considers a real-world industrial gas supply chain.     

A methodology for joint optimization for maintenance planning, process quality and production scheduling

Performance of a manufacturing system depends significantly on the shop floor performance. Traditionally, shop floor operational policies concerning maintenance scheduling, quality control and production scheduling have been considered and optimized independently. However, these three aspects of operations planning do have an interaction effect on each other and hence need to be considered jointly for improving the system performance. In this paper, a model is developed for joint optimization of these three aspects in a manufacturing system. First, a model has been developed for integrating maintenance scheduling and process quality control policy decisions. It provided an optimal preventive maintenance interval and control chart parameters that minimize expected cost per unit time. Subsequently, the optimal preventive maintenance interval is integrated with the production schedule in order to determine the optimal batch sequence that will minimize penalty-cost incurred due to schedule delay. An example is presented to illustrate the proposed model. It also compares the system performance employing the proposed integrated approach with that obtained by considering maintenance, quality and production scheduling independently. Substantial economic benefits are seen in the joint optimization.     

A Case Study on Integrated Production Planning and Scheduling in a Three-Stage Manufacturing System

This paper presents an integrated optimization model of production planning and scheduling for a three-stage manufacturing system, which is composed of a forward chain of three kinds of workshops: a job shop, a parallel flow shop consisting of parallel production lines, and a single machine shop. As the products at the second stage are assembled from the parts produced in its upstream workshop, a complicated production process is involved. On the basis of the analysis of the batch production, a dynamic batch splitting and amalgamating algorithm is proposed. Then, a heuristic algorithm based on a genetic algorithm (known as the integrated optimization algorithm) is proposed for solving the problem. Note to Practitioners-This paper presents a method for integrated production planning and scheduling in a three-stage manufacturing system consisting of a forward chain of three kinds of workshops, which is common in such enterprises as producers of automobiles and household electric appliances, as in the case of an autobody plant usually with the stamping workshop, the welding and assembling workshop, and the painting workshop. Herein, the production planning and scheduling problems are simultaneously addressed in the way that a feasible production plan can be obtained and the inventory reduced. A batch splitting and amalgamating algorithm is proposed for balancing the production time of the production lines. And a case study of the integrated planning and scheduling problem in a real autobody plant verifies the effectiveness of our method     

多约束条件下生产排程智能优化技术

针对当前企业智能化生产中,多条工艺路线共享工序以及工单在生产过程中具有多个约束条件(如工期、优先级、产量等)的问题,提出了一种以"等待时间最短"为主的生产排程智能优化算法.综合考虑工单优先级、工期长短和紧急任务插单等因素,通过一种递归算法来计算工单等待时间,以最小化工单完成时间、最大化资源利用率为优化目标,建立了多约束...     

Development of hybrid evolutionary algorithms for production scheduling of hot strip mill

A hot strip mill (HSM) produces hot rolled products from steel slabs, and is one of the most important production lines in a steel plant. The aim of HSM scheduling is to construct a rolling sequence that optimizes a set of given criteria under constraints. Due to the complexity in modeling the production process and optimizing the rolling sequence, the HSM scheduling is a challenging task for hot rolling production schedulers. This paper first introduces the HSM production process and requirements, and then reviews previous research on the modeling and optimization of the HSM scheduling problem. According to the practical requirements of hot rolling production, a mathematical model is formulated to describe two important scheduling sub-tasks: (1) selecting a subset of manufacturing orders and (2) generating an optimal rolling sequence from the selected manufacturing orders. Further, hybrid evolutionary algorithms with integration of genetic algorithm (GA) and extremal optimization (EO) are proposed to solve the HSM scheduling problem. Computational results on industrial data show that the proposed HSM scheduling solution can be applied in practice to provide satisfactory performance.