Flowshop scheduling problem with a batching machine and task compatibilities

This paper deals with the problem of task scheduling in a flowshop with two (discrete and batching) machines. Each task has to be processed by both machines. All tasks visit the machines in the same order. The first machine is a discrete machine that can process no more than one task at a time, and the second machine is a batching machine that can process several tasks per batch with the additional feature that the tasks of the same batch have to be compatible. A compatibility relation is defined between each pair of tasks, so that an undirected compatibility graph is obtained which turns out to be an interval graph. The batch processing time is equal to the maximal processing time of the tasks in this batch and all tasks of the same batch start and finish together. The aim is to make batching and sequencing decisions and minimize the makespan.     

Makespan minimization in a no-wait flow shop problem with two batching machines

This paper deals with the problem of task scheduling in a no-wait flowshop with two batching machines. Each task has to be processed by both machines. All tasks visit the machines in the same order. Batching machines can process several tasks per batch so that all tasks of the same batch start and complete together. The batch processing time for the first machine is equal to the maximal processing time of the tasks in this batch, and for the second machine is equal to the sum of the processing times of the tasks in this batch. We assume that the capacity of any batch on the first machine is bounded, and that when a batch is completed on the first machine it is immediately transferred to the second machine. The aim is to make batching and sequencing decisions that allow the makespan to be minimized.     

Scheduling a hybrid flowshop with batch production at the last stage

In this paper, we address the problem of scheduling n$n$ jobs in an s$s$-stage hybrid flowshop with batch production at the last stage with the objective of minimizing a given criterion with respect to the completion time. The batch production at stage s$s$ is referred to as serial batches by Hopp and Spearman where the processing time of a batch is equal to the sum of the processing times of all jobs included in it. This paper establishes an integer programming model and proposes a batch decoupling based Lagrangian relaxation algorithm for this problem. In this algorithm, after capacity constraints are relaxed by Lagrangian multipliers, the relaxed problem is decomposed based on a batch, unlike the commonly used job decoupling, so that it can be decomposed into batch-level subproblems, each for a specific batch. An improved forward dynamic programming algorithm is then designed for solving these subproblems where all operations within a batch form an in-tree structure and the precedence relations exist not only between the operations of a job but between the jobs in this batch at the last stage. A computational comparison is provided for the developed algorithm and the commonly used Lagrangian relaxation algorithm which, after capacity constraints and precedence relations within a batch are relaxed, decomposes the relaxed problem into job-level subproblems and solves the subproblems by using dynamic programming. Numerical results show that the designed Lagrangian relaxation method provides much better schedules and converges faster for small to medium sized problems, especially for larger sized problems.     

Tabu search heuristic for two-machine flowshop with batch processing machines

Batch processing machines are frequently encountered in many industrial environments. A batch processing machine is one which can process several jobs simultaneously as a batch. The processing time of a batch is equal to the largest processing time of any job in the batch. This study deals with the problem of scheduling jobs in a flowshop with two batch processing machines such that the makespan is minimized. A heuristic based on Tabu search (TS) technique is proposed. The proposed heuristic is compared with a heuristic based on mixed integer linear programming (MILP). Because the complexity of the MILP-based heuristic is depended on the number of job batches, the comparison is under up-to-eight batches problem. In order to measure the proposed TS-based heuristic in larger batch problem, the relative error percentage with the lower bound (REP_LB) is used. The results show that the proposed heuristic is efficient and effective for the problems with relative large job sizes.     

Scheduling unrelated parallel batch processing machines with non-identical job sizes

Scheduling unrelated parallel batch processing machines to minimize makespan is studied in this paper. Jobs with non-identical sizes are scheduled on batch processing machines that can process several jobs as a batch as long as the machine capacity is not violated. Several heuristics based on best fit longest processing time (BFLPT) in two groups are proposed to solve the problem. A lower bound is also proved to evaluate the quality of the heuristics. Computational experiments were undertaken. These showed that J_SC-BFLPT, considering both load balance of machines and job processing times, was robust and outperformed other heuristics for most of the problem categories.     

Scheduling unrelated parallel machines with optional machines and jobs selection

In this paper we study two generalizations of the well known unrelated parallel machines scheduling problem under makespan (C_max) minimization. First, a situation in which not every available parallel machine should be used and it is desirable to employ only a subset of the parallel machines. This is referred to as “Not All Machines” or NAM in short. This environment applies frequently in production shops where capacity exceeds demand or when production capacity can be lent to third companies. Also, NAM can be used to increase production capacity and it is not clear how many additional machines should be acquired. The second studied generalization has been referred to as “Not All Jobs” or NAJ. Here, there is no obligation to process all available jobs. We propose Mixed Integer Programming mathematical formulations for both NAM and NAJ, and it is shown that the latter can be effectively solved with modern commercial solvers. We also present three algorithms to solve the NAM problem. These algorithms are compared with the proposed MIP formulation when solved with IBM ILOG CPLEX 12.1. Comprehensive computational and statistical experiments prove that our proposed algorithms significantly improve the results given by the solver.     

Modeling realistic hybrid flexible flowshop scheduling problems

This paper aims to contribute to the recent research efforts to bridge the gap between the theory and the practice of scheduling by modelizing a realistic manufacturing environment and analyzing the effect of the inclusion of several characteristics in the problem formulation. There are several constraints and characteristics that affect the scheduling operations at companies. While these constraints are many times tackled in the literature, they are seldom considered together inside the same problem formulation. We propose a formulation along with a mixed integer modelization and some heuristics for the problem of scheduling n jobs on m stages where at each stage we have a known number of unrelated machines. The jobs might skip stages and, therefore, we have what we call a hybrid flexible flowshop problem. We also consider per machine sequence-dependent setup times which can be anticipatory and non-anticipatory along with machine lags, release dates for machines, machine eligibility and precedence relationships among jobs. Manufacturing environments like this appear in sectors like food processing, ceramic tile manufacturing and several others. The optimization criterion considered is the minimization of the makespan. The MIP model and the heuristics proposed are tested against a comprehensive benchmark and the results evaluated by advanced statistical tools that make use of decision trees and experimental designs. The results allow us to identify the constraints that increase the difficulty.     

Scheduling parallel CNC machines with time/cost trade-off considerations

When the processing times of jobs are controllable, selected processing times affect both the manufacturing cost and the scheduling performance. A well-known example for such a case that this paper specifically deals with is the turning operation on a CNC machine. Manufacturing cost of a turning operation is a nonlinear convex function of its processing time. We also know that scheduling decisions are quite sensitive to the processing times. Therefore, this paper considers minimizing total manufacturing cost (_F1)$(F_1)$ and total completion time (_F2)$(F_2)$ objectives simultaneously on identical parallel CNC turning machines. Since decreasing processing time of a job increases its manufacturing cost, we cannot minimize both objectives at the same time, so the problem is to generate non-dominated solutions. We consider the problem of minimizing _F1$F_1$ subject to a given _F2$F_2$ level and give an effective formulation for the problem. For this problem, we prove some optimality properties which facilitated designing an efficient heuristic algorithm to generate approximate non-dominated solutions. Computational results show that proposed algorithm performs almost equal with the GAMS/MINOS commercial solver although it spends much less computation time.     

A genetic algorithm for minimizing maximum lateness on parallel identical batch processing machines with dynamic job arrivals and incompatible job families

We consider the problem of minimizing maximum lateness on parallel identical batch processing machines with dynamic job arrivals. We propose a family of iterative improvement heuristics based on previous work by Potts [Analysis of a heuristic for one machine sequencing with release dates and delivery times. Operations Research 1980;28:1436–41] and Uzsoy [Scheduling batch processing machines with incompatible job families. International Journal for Production Research 1995;33(10):2685–708] and combine them with a genetic algorithm (GA) based on the random keys encoding of Bean [Genetic algorithms and random keys for sequencing and optimization. ORSA Journal on Computing 1994;6(2):154–60]. Extensive computational experiments show that one of the proposed GAs runs significantly faster than the other, providing a good tradeoff between solution time and quality. The combination of iterative heuristics with GAs consistently outperforms the iterative heuristics on their own.     

Online batch scheduling on parallel machines with delivery times

We study the online batch scheduling problem on parallel machines with delivery times. Online algorithms are designed on m parallel batch machines to minimize the time by which all jobs have been delivered. When all jobs have identical processing times, we provide the optimal online algorithms for both bounded and unbounded versions of this problem. For the general case of processing time on unbounded batch machines, an online algorithm with a competitive ratio of 2 is given when the number of machines m=2 or m=3, respectively. When m≥4, we present an online algorithm with a competitive ratio of 1.5+o(1).     

Hybrid flowshop with unrelated machines, sequence-dependent setup time, availability constraints and limited buffers

This paper presents a genetic algorithm for an important production scheduling problem. Since the problem is NP-hard, we focus on suboptimal scheduling solutions for the hybrid flowshop with unrelated machines, sequence-dependent setup time, availability constraints, and limited buffers. The production environment of a television assembly line for inserting electronic components is considered. The proposed genetic algorithm is a modified and extended version of the algorithm for a problem without limited buffers. It takes into account additional limited buffer constraints and uses a new crossover operator and stopping criteria. Experimental results carried out on real production settings show an improvement in scheduling when the proposed algorithm is used.     

A tabu search heuristic for the hybrid flowshop scheduling with finite intermediate buffers

This paper investigates the hybrid flowshop scheduling with finite intermediate buffers, whose objective is to minimize the sum of weighted completion time of all jobs. Since this problem is very complex and has been proven strongly NP-hard, a tabu search heuristic is proposed. In this heuristic there are two main features. One is that a scatter search mechanism is incorporated to improve the diversity of the search procedure. And the other is that a permutation of N jobs representing their processing order in the first stage instead of a complex complete schedule is used to denote a solution. Computational experiments on randomly generated instances with different structures show that the proposed tabu search heuristic can provide good solutions compared to both the lower bounds and the algorithm proposed for this problem in a lately published literature.     

A hybrid flowshop scheduling model considering dedicated machines and lot-splitting for the solar cell industry

This paper studies a solar cell industry scheduling problem, which is similar to traditional hybrid flowshop scheduling (HFS). In a typical HFS problem, the allocation of machine resources for each order should be scheduled in advance. However, the challenge in solar cell manufacturing is the number of machines that can be adjusted dynamically to complete the job. An optimal production scheduling model is developed to explore these issues, considering the practical characteristics, such as hybrid flowshop, parallel machine system, dedicated machines, sequence independent job setup times and sequence dependent job setup times. The objective of this model is to minimise the makespan and to decide the processing sequence of the orders/lots in each stage, lot-splitting decisions for the orders and the number of machines used to satisfy the demands in each stage. From the experimental results, lot-splitting has significant effect on shortening the makespan, and the improvement effect is influenced by the processing time and the setup time of orders. Therefore, the threshold point to improve the makespan can be identified. In addition, the model also indicates that more lot-splitting approaches, that is, the flexibility of allocating orders/lots to machines is larger, will result in a better scheduling performance.     

A hybrid genetic heuristic for scheduling parallel batch processing machines with arbitrary job sizes

This paper investigates the scheduling problem of parallel identical batch processing machines in which each machine can process a group of jobs simultaneously as a batch. Each job is characterized by its size and processing time. The processing time of a batch is given by the longest processing time among all jobs in the batch. Based on developing heuristic approaches, we proposed a hybrid genetic heuristic (HGH) to minimize makespan objective. To verify the performance of our algorithm, comparisons are made through using a simulated annealing (SA) approach addressed in the literature as a comparator algorithm. Computational experiments reveal that affording the knowledge of problem through using heuristic procedures, gives HGH the ability of finding optimal or near optimal solutions in a reasonable time.     

Lagrangian relaxation with cut generation for hybrid flowshop scheduling problems to minimize the total weighted tardiness

In this paper, we address a new Lagrangian relaxation (LR) method for solving the hybrid flowshop scheduling problem to minimize the total weighted tardiness. For the conventional LR, the problem relaxing machine capacity constraints can be decomposed into individual job-level subproblems which can be solved by dynamic programming. The Lagrangian dual problem is solved by the subgradient method. In this paper, a Lagrangian relaxation with cut generation is proposed to improve the Lagrangian bounds for the conventional LR. The lower bound is strengthened by imposing additional constraints for the relaxed problem. The state space reductions for dynamic programming for subproblems are also incorporated. Computational results demonstrate that the proposed method outperforms the conventional LR method without significantly increasing the total computing time.     

Scheduling jobs on parallel machines with setup times and ready times

In this research we are interested in scheduling jobs with ready times on identical parallel machines with sequence dependent setups. Our objective is to minimize the total weighted tardiness. As this problem is NP-Hard, we develop a heuristic to solve this problem in reasonable time. Our approach is an extension of the apparent tardiness cost with setups (ATCS) approach by [Lee, Y. H., Pinedo, M. (1997). Scheduling jobs on parallel machines with sequence dependent setup times. European Journal of Operational Research, 100, 464–474.] to allow non-ready jobs to be scheduled – meaning we allow a machine to remain idle for a high priority job arriving at a later time. To determine the scaling parameters for our composite dispatching rule (called ATCSR), we first develop a ‘grid approach’ that considers multiple values for the scaling parameters, generates multiple schedules, and chooses the best schedule for the solution. This experimentation was then used to develop regression equations to predict the values of the scaling parameters that would yield the highest quality solution. The grid and regression versions of ATCSR provide better performance than grid and empirically based formula versions of ATCS, BATCS, and X-RM which are the prominent algorithms in the literature.     

Scheduling on parallel machines with preemption and transportation delays

This paper deals with an identical parallel machines scheduling problem, where independent jobs can be preempted and transported from one machine to another. The transportation of a preempted job requires a time called the transportation delay. The goal is to find a solution that minimizes the total completion time (makespan). We first study the case of equal-size jobs where new complexity results are given. Then, to solve the problem with two identical machines, we present a dynamic programming algorithm and a fully polynomial time approximation scheme (FPTAS). Experimental results show the efficiency of the FPTAS compared to a previously published heuristic.     

Scheduling two parallel machines with a single server: the general case

This paper considers the problem of scheduling two-operation non-preemptable jobs on two identical semi-automatic machines. A single server is available to carry out the first (or setup) operation. The second operation is executed automatically, without the server. The general problem of makespan minimization is NP-hard in the strong sense. In earlier work, we showed that the equal total length problem is polynomial time and we also provided efficient and effective solutions for the special cases of equal setup and equal processing times. Most of the cases analyzed thus far have fallen into the category of regular problems. In this paper we build on this earlier work to deal with the general case. Various approaches will be considered. One may reduce the problem to a regular one by amalgamating jobs, or we may apply the earlier heuristics to (possibly regular) job clusters. Alternately we may apply a greedy heuristic, a metaheuristic such as a genetic algorithm or the well known Gilmore–Gomory algorithm to solve the general problem. We report on the performance of these various methods.     

Scheduling reentrant jobs on parallel machines with a remote server

This paper explores a specific combinatorial problem relating to reentrant jobs on parallel primary machines, with a remote server machine. A middle operation is required by each job on the server before it returns to its primary processing machine. The problem, which is new to the literature, is inspired by the logistics of a semi-automated microbiology laboratory. We establish the NP-hard nature of the problem, and demonstrate various structural properties. A heuristic is developed and tested on randomly generated benchmark data. No alternative heuristics are available in the literature for comparison, but results indicate solutions reliably within 1.5% of optimum. Moreover, tests of our heuristic on real-life data from the microbiology laboratory provide a 20% improvement in throughput relative to current practice.     

Scheduling unrelated parallel batch processing machines with non-identical job sizes and unequal ready times

This research analyzes the problem of scheduling a set of n jobs with arbitrary job sizes and non-zero ready times on a set of m unrelated parallel batch processing machines so as to minimize the makespan. Unrelated parallel machine is a generalization of the identical parallel processing machines and is closer to real-world production systems. Each machine can accommodate and process several jobs simultaneously as a batch as long as the machine capacity is not exceeded. The batch processing time and the batch ready time are respectively equal to the largest processing time and the largest ready time among all the jobs in the batch. Motivated by the computational complexity and the practical relevance of the problem, we present several heuristics based on first-fit and best-fit earliest job ready time rules. We also present a mixed integer programming model for the problem and a lower bound to evaluate the quality of the heuristics. The small computational effort of deterministic heuristics, which is valuable in some practical applications, is also one of the reasons that motivates this study. The results show that the heuristic proposed in this paper has a superior performance compared to the heuristics based on ideas proposed in the literature.