Performance of an ant colony optimisation algorithm in dynamic job shop scheduling problems

The goal of the current study is to identify appropriate application domains of Ant Colony Optimisation (ACO) in the area of dynamic job shop scheduling problem. The algorithm is tested in a shop floor scenario with three levels of machine utilisations, three different processing time distributions, and three different performance measures for intermediate scheduling problems. The steady-state performances of ACO in terms of mean flow time, mean tardiness, total throughput on different experimental environments are compared with those from dispatching rules including first-in-first-out, shortest processing time, and minimum slack time. Two series of experiments are carried out to identify the best ACO strategy and the best performing dispatching rule. Those two approaches are thereafter compared with different variations of processing times. The experimental results show that ACO outperforms other approaches when the machine utilisation or the variation of processing times is not high.     

An evaluation of worker cross training and flexible workdays in job shops

Capacity flexibility is becoming increasingly important as a means for reducing inventory while maintaining customer service levels. We examine two means to increase capacity flexibility. In particular, we examine an environment where both cross training and flexible workdays are available to respond to workload variability. Flexible workdays are under consideration in the US Legislature. This proposed legislation provides the opportunity for workers to exchange overtime for time off. From a managerial perspective, flexible workdays allow management to shift capacity from periods of light load to periods of heavy load. We simulate the operation of a job shop with both cross training and flexible workdays. Our results indicate that cross training is a far more effective tool for improving performance as compared to flexible workdays. Flexible workdays can be valuable particularly in volatile conditions. However, our results indicate that the degree of cross training is a critical consideration in determining the impact of flexible workdays.     

基于灰色机会约束规划的不确定条件下车间作业调度

针对不确定条件下job shop调度问题的约束条件中含有灰色变量,提出用灰色机会约束规划方法解决不确定条件下job shop调度问题,建立了灰色机会约束规划调度模型.同时,使用灰色模拟的方法和手段解决了灰色机会约束规划问题.给出了如何使用灰色模拟技术处理复杂的灰色机会约束以及基于遗传算法的求最优解的过程,并提出用灰色模拟技术结合遗传算法求解生产调度问题中的灰色不确定规划问题.计算仿真结果表明,这种基于灰色机会约束规划的方法处理不确定条件下车间作业调度问题的模型是可行而有效的.     

Cultural algorithms,an alternative heuristic to solve the job shop scheduling problem

In this work, an approach for solving the job shop scheduling problem using a cultural algorithm is proposed. Cultural algorithms are evolutionary computation methods that extract domain knowledge during the evolutionary process. Additional to this extracted knowledge, the proposed approach also uses domain knowledge given a priori (based on specific domain knowledge available for the job shop scheduling problem). The proposed approach is compared with respect to a Greedy Randomized Adaptive Search Procedure (GRASP), a Parallel GRASP, a Genetic Algorithm, a Hybrid Genetic Algorithm, and a deterministic method called shifting bottleneck. The cultural algorithm proposed in this article is able to produce competitive results with respect to the two approaches previously indicated at a significantly lower computational cost than at least one of them and without using any sort of parallel processing.     

Costing-based coordination between mt-iPSS customer and providers for job shop production using game theory

The industrial product-service system for Computer Numerical Control machine tool (mt-iPSS) has drawn much interest. Under the new paradigm of functional result-oriented mt-iPSS, mt-iPSS customer (i.e. owner of the workshop) pays for time or results of mt-iPSS providers. The present problem for mt-iPSS customer is how to timely identify the optimal machine tools, sequence and cutting parameters of operation to finish the jobs while mt-iPSS providers try to maximise their benefit in a non-cooperative game structure. In this paper, a Stackelberg game model is put forward to solve the coordination problem based on the costing of different job shop scheduling solutions under the result-oriented mt-iPSS paradigm. Then, to solve the established bi-level programming model of the Stackelberg game, a solution procedure based on hierarchical particle swarm optimisation is proposed. Finally, a case from a printing machinery enterprise is analysed to validate the proposed model. This research is expected to improve the quality and effectiveness of coordination for scheduling and process planning decision between mt-iPSS customer and multi-providers.     

A priority scheduling approach for flexible job shops with multiple process plans

This paper considers the job shop scheduling problem with alternative operations and machines, called the flexible job shop scheduling problem. As an extension of previous studies, operation and routing flexibilities are considered at the same time in the form of multiple process plans, i.e. each job can be processed through alternative operations, each of which can be processed on alternative machines. The main decisions are: (a) selecting operation/machine pair; and (b) sequencing the jobs assigned to each machine. Since the problem is highly complicated, we suggest a practical priority scheduling approach in which the two decisions are done at the same time using a combination of operation/machine selection and job sequencing rules. The performance measures used are minimising makespan, total flow time, mean tardiness, the number of tardy jobs, and the maximum tardiness. To compare the performances of various rule combinations, simulation experiments were done on the data for hybrid systems with an advanced reconfigurable manufacturing system and a conventional legacy system, and the results are reported.     

Integrated scheduling and self-reconfiguration for assembly job shop in knowledgeable manufacturing

The problems of integrated assembly job shop (AJS) scheduling and self-reconfiguration in knowledgeable manufacturing are studied with the objective of minimising the weighted sum of completion cost of products, the earliness penalty of operations and the training cost of workers. In AJS, each workstation consists of a certain number of teams of workers. A product is assumed to have a tree structure consisting of components and subassemblies. The assembly of components, subassemblies and final products are optimised with the capacity of workstations simultaneously. A heuristic algorithm is developed to solve the problem. Dominance relations of operations are derived and applied in the development of the heuristic. A backward insertion search strategy is designed to locally optimise the operation sequence. Once the optimal schedule is acquired, the teams are reconfigured by transferring them from workstations of lower utilisation to those of higher utilisation. Effectiveness of the proposed algorithm is tested by a number of numerical experiments. The results show that the proposed algorithm promises lower total cost and desirable simultaneous self-reconfiguration in accordance with scheduling.     

A divide and conquer-based greedy search for two-machine no-wait job shop problems with makespan minimisation

This paper addresses a two-machine no-wait job shop problem with makespan minimisation. It is well known that this problem is strongly NP-hard. A divide-and-conquer approach (DC for short) is adopted to calculate the optimal timetable of a given sequence. It decomposes the given sequences into several independent parts and conquers them separately. A timetable enhancing method is introduced to further improve the timetable obtained by DC. It constructs a set of flow shop type jobs based on the result from DC and calculates the best timetable for these newly constructed jobs by the well-known Gilmore and Gomory method (GG for short). An efficient greedy search is proposed by integrating DC with GG to search for the best sequence. Experimental results show that the proposed algorithm can find the optimal solutions for 96% of the randomly generated test instances on average.     

遗传算法的双目标柔性作业车间调度研究

研究了FMS环境下先进制造车间路径柔性的优化调度问题.同时考虑现代生产准时制的要求,建立了柔性作业车间调度问题的双目标数学优化模型,并给出了求解模型的遗传算法的具体实现过程;针对模型的特殊性,提出了染色体两层编码结构,将AOV网络图应用到解码和适应度函数的计算中,通过一个调度实例进行验证,给出了相应的选择、交叉、变异操作设计方案.     

A generalized permutation approach to job shop scheduling with genetic algorithms

In order to sequence the tasks of a job shop problem (JSP) on a number of machines related to the technological machine order of jobs, a new representation technique — mathematically known as permutation with repetition is presented. The main advantage of this single chromosome representation is — in analogy to the permutation scheme of the traveling salesman problem (TSP) — that it cannot produce illegal operation sequences. As a consequence of the representation scheme a new crossover operator preserving the initial scheme structure of permutations with repetition will be sketched. Its behavior is similar to the well known Order-Crossover for simple permutation schemes. Actually theGOX operator for permutations with repetition arises from aGeneralisation ofOX. Computational experiments show, that GOX passes the information from a couple of parent solutions efficiently to offspring solutions. Together, the new representation and GOX support the cooperative aspect of genetic search for scheduling problems strongly.Supported by the Deutsche Forschungsgemeinschaft (Project Parnet)     

A rule-centric memetic algorithm to minimize the number of tardy jobs in the job shop

This paper addresses the job shop-scheduling problem with minimizing the number of tardy jobs as the objective. This problem is usually treated as a job-sequencing problem, and the permutation-based representation of solutions was commonly used in the existing search-based approaches. In this paper, the flaw of the permutation-based representation is discussed, and a rule-centric concept is proposed to deal with it. A memetic algorithm is then developed to realize the proposed idea by tailored genome encoding/decoding schemes and a local search procedure. Two benchmark approaches, a multi-start hill-climbing approach and a simulated annealing approach, are compared in the experiments. The results show that the proposed approach significantly outperforms the benchmarks.     

A first introduction of customer-driven capacity exchange for job shops

With demand variability and unpredictability, decreasing product life cycles, globalisation and increasing competition, rush orders are increasingly being received at job shops. However, these rush orders can be difficult to fulfil owing to a lack of capacity during boom and heavy workload periods. In this situation, a feasible solution is capacity exchange, through which capacity is transacted and exchanged with other customers for whom the manufacturer has already reserved capacity. Accordingly, this study develops a customer-driven capacity exchange mechanism for solving the foregoing problem of temporary capacity shortage caused by the receipt of rush orders in a job shop. Notably, this innovative concept and mechanism can be expected to concurrently benefit capacity holders, capacity demanders and manufacturers. Additionally, this study presents a comprehensive design scheme, working scenario, and possible implementation for a capacity exchange mechanism.     

Studying the effect of different combinations of timetabling with sequencing algorithms to solve the no-wait job shop scheduling problem

This paper considers the no-wait job shop (NWJS) problem with makespan minimisation criteria. It is well known that this problem is strongly NP-hard. Most of the previous studies decompose the problem into a timetabling sub-problem and a sequencing sub-problem. Each study proposes a different sequencing and timetabling algorithm to solve the problem. In this research, this important question is aimed to be answered: is the timetabling or the sequencing algorithm more important to the effectiveness of the developed algorithm? In order to find the answer, three different sequencing algorithms are developed; a tabu search (TS), a hybrid of tabu search with variable neighbourhood search (TSVNS), and a hybrid of tabu search with particle swarm optimisation (TSPSO). Afterwards, the sequencing algorithms are combined with four different timetabling methods. All the approaches are applied to a large number of test problems available in the literature. Statistical analysis reveals that although some of the sequencing and timetabling algorithms are more complicated than the others, they are not necessarily superior to simpler algorithms. In fact, some of the simpler algorithms prove to be more effective than complicated and time-consuming methods.     

Scheduling algorithms to minimise the total family flow time for job shops with job families

This paper considers the job scheduling problem in which jobs are grouped into job families, but they are processed individually. The decision variable is the sequence of the jobs assigned to each machine. This type of job shop scheduling can be found in various production systems, especially in remanufacturing systems with disassembly, reprocessing and reassembly shops. In other words, the reprocessing shop can be regarded as the job shop with job families since it performs the operations required to bring parts or sub-assemblies disassembled back to like-new condition before reassembling them. To minimise the deviations of the job completion times within each job family, we consider the objective of minimising the total family flow time. Here, the family flow time implies the maximum among the completion times of the jobs within a job family. To describe the problem clearly, a mixed integer programming model is suggested and then, due to the complexity of the problem, two types of heuristics are suggested. They are: (a) priority rule based heuristics; and (b) meta-heuristics. Computational experiments were performed on a number of test instances and the results show that some priority rule based heuristics are better than the existing ones. Also, the meta-heuristics improve the priority rule based heuristics significantly.     

Mathematical modelling and a meta-heuristic for flexible job shop scheduling

This study develops new solution methodologies for the flexible job shop scheduling problem (F-JSSP). As a first step towards dealing with this complex problem, mathematical modellings have been used; two novel effective position- and sequence-based mixed integer linear programming (MILP) models have been developed to fully characterise operations of the shop floor. The developed MILP models are capable of solving both partially and totally F-JSSPs. Size complexities, solution effectiveness and computational efficiencies of the developed MILPs are numerically explored and comprehensively compared vis-à-vis the makespan optimisation criterion. The acquired results demonstrate that the proposed MILPs, by virtue of its structural efficiencies, outperform the state-of-the-art MILPs in literature. The F-JSSP is strongly NP-hard; hence, it renders even the developed enhanced MILPs inefficient in generating schedules with the desired quality for industrial scale problems. Thus, a meta-heuristic that is a hybrid of Artificial Immune and Simulated Annealing (AISA) Algorithms has been proposed and developed for larger instances of the F-JSSP. Optimality gap is measured through comparison of AISA’s suboptimal solutions with its MILP exact optimal counterparts obtained for small- to medium-size benchmarks of F-JSSP. The AISA’s results were examined further by comparing them with seven of the best-performing meta-heuristics applied to the same benchmark. The performed comparative analysis demonstrated the superiority of the developed AISA algorithm. An industrial problem in a mould- and die-making shop was used for verification.     

A shuffled frog-leaping algorithm for flexible job shop scheduling with the consideration of energy consumption

Flexible job shop scheduling problem (FJSP) has been extensively investigated and objectives are often related to time. Energy-related objective should be considered fully in FJSP with the advent of green manufacturing. In this study, FJSP with the minimisation of workload balance and total energy consumption is considered and the conflicting between two objectives is analysed. A shuffled frog-leaping algorithm (SFLA) is proposed based on a three-string coding approach. Population and a non-dominated set are used to construct memeplexes according to tournament selection and the search process of each memeplex is done on its non-dominated member. Extensive experiments are conducted to test the search performance of SFLA and computational results show the conflicting between two objectives of FJSP and the promising advantages of SFLA on the considered FJSP.     

Optimal scheduling for flexible job shop operation

This paper presents a new integer linear programming (ILP) model to schedule flexible job shop, discrete parts manufacturing industries that operate on a make-to-order basis. The model considers groups of parallel homogeneous machines, limited intermediate buffers and negligible set-up effects. Orders consist of a number of discrete units to be produced and follow one of a given number of processing routes. The model allows re-circulation to take place, an important issue in practice that has received scant treatment in the scheduling literature. Good solution times were obtained using commercial mixed-integer linear programming (MILP) software to solve realistic examples of flexible job shops to optimality. This supports the claim that recent advances in computational power and MILP solution algorithms are making this approach competitive with others traditionally applied in job shop scheduling.     

A heuristic model for dynamic flexible job shop scheduling problem considering variable processing times

In real scheduling problems, unexpected changes may occur frequently such as changes in task features. These changes cause deviation from primary scheduling. In this article, a heuristic model, inspired from Artificial Bee Colony algorithm, is proposed for a dynamic flexible job-shop scheduling (DFJSP) problem. This problem consists of n jobs that should be processed by m machines and the processing time of jobs deviates from estimated times. The objective is near-optimal scheduling after any change in tasks in order to minimise the maximal completion time (Makespan). In the proposed model, first, scheduling is done according to the estimated processing times and then re-scheduling is performed after determining the exact ones considering machine set-up. In order to evaluate the performance of the proposed model, some numerical experiments are designed in small, medium and large sizes in different levels of changes in processing times and statistical results illustrate the efficiency of the proposed algorithm.     

A hybrid artificial bee colony algorithm for flexible job shop scheduling with worker flexibility

The traditional flexible job shop scheduling problem (FJSP) considers machine flexibility but not worker flexibility. Given the influence and potential of human factors in improving production efficiency and decreasing the cost in practical production systems, we propose a mathematical model of an extended FJSP with worker flexibility (FJSPW). A hybrid artificial bee colony algorithm (HABCA) is presented to solve the proposed FJSPW. For the HABCA, effective encoding, decoding, crossover and mutation operators are designed, and a new effective local search method is developed to improve the speed and exploitation ability of the algorithm. The Taguchi method of Design of Experiments is used to obtain the best combination of key parameters of the HABCA. Extensive computational experiments carried out to compare the HABCA with some well-performing algorithms from the literature confirm that the proposed HABCA is more effective than these algorithms, especially on large-scale FJSPW instances.