Campaign planning for multi-stage batch processes in the chemical industry |
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Authors: | Martin Grunow Hans-Otto Günther Matthias Lehmann |
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Affiliation: | 1.Deptartment of Production Management, Technical University Berlin, Wilmersdorfer Stra?e 148, 10585 Berlin, Germany (e-mail:{m.grunow, ho.guenther, m.lehmann}@pm-berlin.net)
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Abstract: | Inspired by a case study from industry, the production of special chemical products is considered. In this industrial environment,
multi-purpose equipment is operated in batch mode to carry out the diverse processing tasks. Often, extensive set-up and cleaning
of the equipment are required when production switches between different types of products. Hence, processes are scheduled
in campaign mode, i.e. a number of batches of the same type are processed in sequence. The production of chem ical products
usually involves various stages with significant cumulative lead times. Typically, these production stages are assigned to
different plants. A hierarchical modelling approach is presented which co-ordinates the various plant operations within the
entire supply network. In the first stage, the length of the campaigns, their timing, the corresponding material flows, and
equipment requirements have to be determined. At this stage, an aggregation scheme based on feasibility constraints is employed
in order to reflect the limited availability of the various types of production equipment. The second stage consists of an
assignment model, which allocates the available equipment units between the production campaigns determined in the first stage
of the solution procedure. In the third stage, resource conflicts are resolved, which may occur if clean-out operations and
minimal campaign lengths have to be considered. The proposed hierarchical approach allows a more compact model formulation
compared to ot her approaches known from the literature. As a result, a very efficient and flexible solution approach is obtained.
In particular, commercially available standard solvers can be used to solve a wide range of campaign planning problems arising
in the chemical industry. |
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Keywords: | : Campaign planning – Supply networks – Chemical industry – Linear optimization model – Hierarchical production planning |
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