A new MRP/GT lot sizing heuristic: A simulation study

This paper studies the lot-sizing problem in Material Requirements Planning/Group Technology (MRP/GT) systems. A GT production cell is designed to produce many families of components. A major setup is required when switching from manufacturing one family of components to another family, and a minor setup is needed when switching from manufacturing a component type to another component type within the same family. Inventory holding cost is incurred if inventory level is positive, and inventory shortage cost is incurred if inventory level is negative, that is, backordering. The objective of the proposed lot-sizing problem is to minimize the sum of major and minor setup costs, holding and shortage costs, and regular production cost, and to meet simultaneously the demand requirements. The proposed problem is modelled into a linear integer program, a heuristic method to solve the problem is proposed, and a simulation experiment conducted to evaluate the performance of the proposed heuristic and some existing heuristics. The computational results show that the proposed heuristic is useful to reduce the total cost significantly over a wide variety of simulated environments.     

Organization theory and group technology manufacturing systems

A survey has been made of the manufacturing characteristics and performance of 35 engineering companies which are using Group Technology (GT) methods in production. Data have been collected from these companies on a “before” and “after” GT basis. This study investigates the changes in staffing levels brought about by introducing GT, and the findings reported here are compared with those of other researchers. In this paper we argue that it is doubtful whether the extensive research work carried out on the relationship between the “technology” of organizations and structures can be used to extrapolate the changes which might take place in staffing levels when a GT system is introduced into a firm.     

Multi-objective machine-component grouping in cellular manufacturing: A genetic algorithm

The cellular manufacturing system (CMS) is an important group technology (GT) application. The first step of CMS design is cell formation, generally known as machinecell formation (MCF) or machine-component (MCG). A genetic algorithm (GA) is a robust adaptive optimization method based on principles of natural evolution and is appropriate for the MCG problem, which is an NP complete complex problem. In this study, we propose a GA-based procedure to solve the MCG problem. More specifically, this study aims to minimize (1) total cost, which includes intercell and intracell part transportation costs and machines investment cots; (2) intracell machine loading imbalance; and (3) intercell machine loading imbalance under many realistic considerations. An illustrative example and comparisons demonstrate the effectiveness of this procedure. The proposed procedure is extremely adaptive, flexible, efficient and can be used to solve real MCG problems in factories by providing robust manufacturing cell formation in a short execution time.     

Solving the part families problem in discrete-parts manufacture by simulated annealing

In the production planning and control of discrete-parts manufacture, aggregation of parts into families, on the basis of similarity, is carried out to ease both long-horizon planning and short-horizon scheduling. Additional advantages are related to those of group technology (GT), such as simplifying the flow of parts and tools and reducing both set-up and production costs. The problem of formally forming part families is presented and discussed. Previous work is reviewed and assessed. Two solution approaches, one based on a location model, the other on simulated annealing, are presented and compared along with test results. The location formulation, which results in an integer programming model solved by Lagrangian relaxation, proved capable of producing solutions of excellent quality, but only for relatively small problem instances. In contrast, simulated annealing, which is a general heuristic approach to combinatorial optimization, produced solutions of comparable quality and could handle realistically large problem instances. However, careful design of the simulated annealing algorithm is crucially important. An effective design is presented.     

Lot-sizing decisions under limited-time price incentives: A review

The problem of determining the optimal order quantities for an inventoried item, when the vendor offers a limited-time price reduction is both interesting and important. It is interesting in that it has received continued attention of academic researchers for over four decades and it is important given its economic implication in a variety of practical settings. The extensive literature on this problem represents a fascinating confluence of: (1) economic significance and relevance to managerial practice, (2) continuing academic research interest directed at precise mathematical analysis leading to the development of rigorous and complex models and policies, and (3) elegance and adequacy of simple models and heuristic policies which are validated by the results of rigorous models and computational analysis. In this paper, we survey this literature using simple classification frameworks and then review some of the key studies. We highlight their key assumptions and findings, bring across key implications for policy implementation and academic research and identify avenues for further research.     

Resource-constrained materials requirements planning- MRP rc

Computerized MRP systems used in industrial practice have been criticized by researchers as well as industrial users with respect to their limited ability to generate feasible production schedules. In this paper the lot size planning stage of a typical MRP system is considered. Several modelling alternatives for multi-level lot sizing are discussed with the help of a small example. A resourceconstrained approach to lot sizing- called MRP rc- is presented that cooperates with standard production planning and control systems. In this approach the item-by-item lot size planning is substituted by the heuristic solution of a multi-level multi-item dynamic capacitated lot sizing problem with setup times for general product structures.     

A hard clustering approach to the part family formation problem

The part family problem in group technology can be stated as the problem of finding the best grouping of parts into families such that the parts within each family are as similar to each other as possible. In this paper, the part family formation problem is considered. The problem is cast into a hard clustering model, and the k-means algorithm is proposed for solving it. Preliminary computational experience on the algorithm is very encouraging and it shows that real-life problems of large sizes can efficiently be handled by this approach.     

LOT-SIZING IN CAPACITATED MULTI-STAGE SERIAL SYSTEMS

The lot-sizing problem in capacitated multi-stage systems with a serial product structure is addressed. This is a complex optimization problem that is part of the decision set in material requirements planning (MRP) systems. The mathematical model that describes the problem uses the concept of echelon stock and includes lead times. Setup times are taken into account, which implies that the problem of finding a feasible solution is NP-Complete. This paper proposes a heuristic method that provides a production plan in order to minimize inventory, production, and setup costs. The heuristic starts from a solution for the uncapacitated problem, which is given by the sequential application of the Wagner-Whitin algorithm. Feasibility is then attempted by shifting production amounts between periods. Computational tests conducted in 1,800 instances with up to 40 components and 18 periods have shown that feasible solutions were obtained in 83.7% of the instances. For the infeasible instances, on average, the heuristic is able to find solutions with very low capacity excess. The solutions' quality is evaluated through a lower bound provided by Lagrangean relaxation and on average the gap is less than 10%.     

Order Dispatching and Labor Assignment in Cellular Manufacturing Systems

Although order and labor dispatching in the job shop manufacturing setting have been investigated extensively over the last three decades, its representation of actual processes found in practice today is limited due to the move to cellular manufacturing (CM). Manufacturing cells have become an important approach to batch manufacturing in the last two decades, and their layout structure provides a dominant flow structure for the part routings. The flow shop nature of manufacturing cells adds a simplifying structure to the problem of planning worker assignments and order releases, which makes it more amenable to the use of optimization techniques. In this paper we exploit this characteristic and present two mathematical modeling approaches for making order dispatching and labor assignment/reassignment decisions in two different CM settings. The two formulations are evaluated in a dynamic simulation setting and compared to a heuristic procedure using tardiness as the primary performance measure. The formulations are superior to the heuristic approach and can be incorporated into detail scheduling systems that are being implemented by corporations employing enterprise resource planning (ERP) systems today.     

An efficient heuristic procedure for solving the layout design problem

The limited ability of schematic procedures, constraints of linear programming techniques, inflexibility of construction methods and inadequacy of dynamic programming approaches to provide acceptable solutions to realistic size layout design problems has led to an ever increasing interest in heuristic procedures. Comparative studies have shown that heuristic procedures can satisfy more desirable qualities in an ‘ideal algorithm’ to a greater extent than competitive techniques. Excessive computational effort, which has been one of the main criticisms levelled against heuristic approaches in the past, proves to be less of a problem in relation to layout design. By utilizing unique attributes associated with real-life problems and using small incisive modifications it is demonstrated how a heuristic procedure can be significantly improved.     

A SIMPLE HEURISTIC FOR DYNAMIC ORDER SIZING AND SUPPLIER SELECTION WITH TIME‐VARYING DATA

In this paper we consider the problem of supplier selection and purchase order sizing for a single item under dynamic demand conditions. Suppliers offer all‐units and/or incremental quantity discounts, which may vary over time. Although the problem refers to a typical planning task of a purchasing agent, which is often solved without algorithmic assistance, in an eBusiness (b2b) environment, the need for the integration of an automatic performance of this planning task into a web‐based procurement process becomes evident. A new model formulation for this problem is developed, and a simple but easily extendible heuristic procedure is presented and tested. The heuristic is implemented as part of the Advanced Planner and Optimizer (apo) software of SAP AG, Walldorf, Germany.     

Transforming an MRP plan into a short-term schedule

A new approach for transforming MRP orders, planned periodically, e.g. on a weekly base, into a detailed sequence of jobs is presented. In this model for a single machine environment, the jobs are partitioned into families and a family specific set-up time is required at the start of each period and of each batch, where a batch is a maximal set of jobs in the same family, that are processed consecutively. An integer program is formulated for both the problem of minimizing the number of overloaded periods and the problem of minimizing the total overtime. These programs generate benchmark results for the heuristic approach. A heuristic model is developed that constructs a schedule in which overloaded periods are relieved and set-up time is saved. In this approach, the job sequence is constructed by repeatedly solving a knapsack problem. The weights used in this knapsack problem relate to the preferred priorities of the jobs not yet scheduled and determine the quality of the final sequence. The different features of the heuristic model are compared using a large set of test problems. The results show that the quality of the final sequence depends on an appropriate choice for the weights.     

A REVIEW OF HEURISTIC PROGRAMMING

This article presents some of the basic concepts and definitions of the technique of heuristic programming. An analysis and criticism of the heuristic programming methodology is made. A survey of the existing literature demonstrates the power and the generality possible of heuristic programming. Furthermore, a look forward reveals likely future developments of teh technique. For several years now, impressive and extensive applications of heuristic programming have been made of various decision situations. Yet, seminars and discussions of heuristic programming continue to find the heuristic programming experts fielding basic questions such as the following: Where did heuristic programming originate? Does heuristic programming have a lexicon? What are some examples of heuristics? What is the heuristic approach? Hasn't the validity of heuristic programming been questioned? What progress has been made in using heuristic programming? What basic approaches have evolved in using heuristic programming? Is heuristic programming compatible with other research now being carried out? And what is the future of heuristic programming? This article brings the answers to these questions together for easy reference for researchers in the decision sciences of all areas.     

Computational risk management techniques for fixed charge network flow problems with uncertain arc failures

We consider a formulation for the fixed charge network flow (FCNF) problem subject to multiple uncertain arc failures, which aims to provide a robust optimal flow assignment in the sense of restricting potential losses using Conditional Value-at-Risk (CVaR). We show that a heuristic algorithm referred to as Adaptive Dynamic Cost Updating Procedure (ADCUP) previously developed for the deterministic FCNF problem can be extended to the considered problem under uncertainty and produce high-quality heuristic solutions for large problem instances. The reported computational experiments demonstrate that the described procedure can successfully tackle both the uncertainty considerations and the large size of the networks. High-quality heuristic solutions for problem instances with up to approximately 200,000 arcs have been identified in a reasonable time.     

下料问题与运输问题联合优化建模

本文研究了考虑子材运输的标准一维下料问题。建立了由生产商负责运输时,标准一维下料与运输协调优化整数规划模型,最小化母材使用成本,子材库存成本及子材运输成本。采用拉格朗日松弛技术对有关约束进行松弛和模型分解,设计基于序列规则和FFD规则的混合启发式算法求解模型。该算法由两部分组成,分别用于求解标准一维下料子问题和卖方运输子问题。通过随机产生的1800个算例,验证模型合理性与算法的有效性。与基于列生成法的两阶段算法解进行比较,平均总成本降低了17.57%,表明集成算法优于两阶段算法。     

INTEGRATED COMPONENT AND SUPPLIER SELECTION FOR A PRODUCT FAMILY

This paper examines the reduction in complexity of a product family through product design. By leveraging the commonalities among products in a family, the decision support methodology presented in the paper helps choose components and suppliers that minimize the sum of design, procurement, and usage costs. The problem of integrated component and supplier selection is conceptualized and formulated as an integer-programming model. Analysis of the model yields two properties, complete and continuous replacement, which form the basis of a heuristic procedure. Computational tests show that the heuristic provides results close to the optimal solution and can be used for selecting components and suppliers. Application of the model to an industrial problem is discussed.     

A joint optimization of data ferry trajectories and communication powers of ground sensors for long-term environmental monitoring

Recently, various hybrid wireless sensor networks which consist of several robotic vehicles and a number of static ground sensors have been investigated. In this kind of system, the main role of the mobile nodes is to deliver the messages produced by the sensor nodes, and naturally their trajectory control becomes a significant issue closely related to the performance of the entire system. Previously, several communication power control strategies such as topology control are investigated to improve energy-efficiency of wireless sensor networks. However, to the best of our knowledge, no communication power control strategy has been investigated in the context of the hybrid wireless sensor networks. This paper introduces a new strategy to utilize the communication power control in multiple data ferry assisted wireless sensor network for long-term environmental monitoring such that the lifetime of the sensor network is maximized. We formally define the problem of our interest and show it is NP-hard. We further prove there exists no approximation algorithm for the problem which can produce a feasible solution for every possible problem instance even though there is a feasible solution. Then, we propose heuristic algorithms along with rigorous theoretical performance analysis for both the single data ferry case and the multiple data ferry case under certain condition.     

A Context‐sensitive Approach to Analysing Talk in Strategy Meetings

The talk of managers in meetings is central to organizational life and crucial to research in strategic management, as well as managerial and organizational cognition, sensemaking and decision‐making. To achieve full understanding, both the text and the context of discussion require systematic analysis, but most approaches treat context as everything that is known and observed beyond the immediate text. This obscures different readings of the text of meetings. To resolve this problem, the discourse historical approach (DHA) to critical discourse analysis is outlined as a framework within which researchers can analyse the text and context of talk in meetings. The primary contribution of this paper is to isolate four ‘levels of context’ as a heuristic framework within which discursive practices, strategies and texts can be located. By making explicit the levels of contextual analysis that are implicit in other methods, and illustrating the DHA using an episode of strategic discussion from a multinational company, this paper shows how researchers can use the approach to analyse the naturally occurring talk of senior managers in meetings, which is arguably the most important but yet under‐explored venue for strategizing.     

Two approaches to solving the multi-depot vehicle routing problem with time windows in a time-based logistics environment

This paper presents a two-phase heuristic method that can be used to efficiently solve the intractable multi-depot vehicle routing problem with time windows. The waiting time that was ignored by previous researchers is considered in this study. The necessity of this consideration is verified through an initial experiment. The results indicate that the waiting time has a significant impact on the total distribution time and the number of vehicles used when solving test problems with narrow time windows. In addition, to fairly evaluate the performance of the proposed heuristic method, a meta-heuristic method, which extends the unified tabu search of Cordeau et al., is proposed. The results of a second experiment reveal that the proposed heuristic method can obtain a better solution in the case of narrow time windows and a low capacity ratio, while the proposed meta-heuristic method outperforms the proposed heuristic method, provided that wide time windows and a high capacity ratio are assumed. Finally, a well-known logistics company in Taiwan is used to demonstrate the method, and a comparison is made, which shows that the proposed heuristic method is superior to the current method adopted by the case company.     

OPTIMAL AND NEAR OPTIMAL CONTROL OF A TWO-PART-TYPE STOCHASTIC MANUFACTURING SYSTEM WITH DYNAMIC SETUPS

This paper deals with a manufacturing system consisting of a single machine subject to random failures and repairs. The machine can produce two types of parts. When the production is switched from one part type to the other, a random setup time is incurred at a constant cost rate. The objective is to track the demand, while keeping the work-in-process as close as possible to zero for both products. The problem is formulated as an optimal stochastic control problem. The optimal policy is obtained numerically by discretizing the continuous time continuous state opti-mality conditions using a Markov chain approximation technique. The discretized optimality conditions are shown to correspond to an infinite horizon, discrete time, discrete state dynamic programming problem. The optimal setup policy is shown to have two different structures depending on the parameters of the system. A heuristic policy is proposed to approximate the optimal setup policy. Simulation results show that the heuristic policy is a very good approximation for sufficiently reliable systems.