Move blocking strategy applied to re-entrant manufacturing line scheduling

Model predictive control (MPC)-based approach to fab-wide scheduling has been suggested to solve constraint-aware production optimization and in-process inventory level control simultaneously at each scheduling instance. However, application of this approach to real fab suffers from computational difficulties brought by the need to solve a huge optimization problem on-line as real fab scheduling problems are characterized by long cycle times, multiple product types, hundreds of machines/processing steps and re-entrant product flows. This study explores the use of an offset-blocking strategy combined with a modified recursive least square (RLS) estimation in the fab-wide scheduler, in order to alleviate the difficulty. The strategy is tested on a modified version of published case study called Intel Mini-Fab (IMF) problem. Despite its simplicity, the blocking strategy showed excellent performance in the face of realistic demand changes and plant/model mismatch.