The permutation flow shop problem with just in time production considerations

This research presents a variation to the permutation flow shop problem where Just In Time (JIT) production requirements are taken into account. The model developed in this research employs dual objectives. In addition to the traditional objective of minimizing the production makespan, minimization of Miltenburg's material usage rate is also incorporated. In this model, multiple units of any product are permitted in the production sequence. However, the minimization of material usage rates attempts to prevent batch scheduling of products and allows unit flow of products as required in demand flow manufacturing. A solution method is proposed for determining an optimal production sequence via an efficient frontier approach and Simulated Annealing (SA). Test problems and specific performance criteria are used to assess the solutions generated by the proposed method. Experimental results presented in this paper show that the use of the efficient frontier and SA provide solutions that approach the optimal solution for the performance measures used in this research.     

Optimal payment time under permissible delay in payment for products with deterioration

A permissible credit period is usually allowed to a retailer to pay back the dues without paying any interest to the supplier. The retailer can pay the supplier either at the end of the credit period or later incurring interest charges on the unpaid balance for the overdue period. The retailer is expected to settle the account at a time before the end of the inventory cycle time because the payable interest rate is generally higher than the earned interest rate. A model for optimal cycle and payment times is developed here for a retailer in a deteriorating-item inventory situation where a supplier allows a specified credit period to the retailer for payment without penalty. Under these conditions, this supplier-and-retailer system is modelled as a cost minimization problem to determine the optimal payment time under various system parameters. An iterative search procedure is applied to solve the problem, and the overall findings indicate that the retailer always has an option to pay after the permissible credit period depending on unit purchase and selling price, the deterioration rate of the products and the interest rate.     

Heuristic for scheduling in a two-machine bicriteria dynamic flowshop with setup and processing times separated

This paper addresses the two-machine bicriteria dynamic flowshop problem where setup time of a job is separated from its processing time and is sequenced independently. The performance considered is the simultaneous minimization of total flowtime and makespan, which is more effective in reducing the total scheduling cost compared to the single objective. A frozen-event procedure is first proposed to transform a dynamic scheduling problem into a static one. To solve the transformed static scheduling problem, an integer programming model with N ² + 5N variables and 7N constraints is formulated. Because the problem is known to be NP-complete, a heuristic algorithm with the complexity of O (N ³) is provided. A decision index is developed as the basis for the heuristic. Experimental results show that the proposed heuristic algorithm is effective and efficient. The average solution quality of the heuristic algorithm is above 99%. A 15-job case requires only 0.0235 s, on average, to obtain a near or even optimal solution.     

A modified internal rate of return model for capital rationing in project selection

The ability of a company to finance viable projects depends on the availability of funds, and this too is a function of time, interest rate and risk factors among others. Factors such as these would lead to limited fund availability, which would necessitate capital rationing. Linear/integer programming and profitability index are often used to tackle this problem for optimal solution. A third approach utilizing a modified internal rate of return (IRR) is proposed. To overcome the difficulty usually encountered in calculating IRR, a small program coded in BASIC is presented. Even though discounting the cash outflows beyond the initial year should have been ideal in the linear programming formulation, this paper casts doubts as to the validity of the solution derived from it, as different discount rates seem to produce very conflicting results from the same set of investment options. This is also applicable to profitability index. While efforts are being made to correct these lapses, the modified IRR model has been found useful in arriving at an optimum solution both for the single-period as well as for the multi-stage situation.     

Experimental earliness/tardiness production planning with the due window system

In order to use the philosophy of JIT to improve the production planning method of MRP-II, we propose the experimental software system of the earliness/tardiness produc tion planning problem with due window. By means of the approaches and model reported in this paper, the optimal production planning can be achieved. The recommended model extends the problem of due window from the shop scheduling level into the aggregated planning level of mass manufacturing systems. Simulation results have demonstrated that the experimental software is a useful tool for the production management of repetitive manufacturing enterprises.     

Constraint-based model for the cyclic multi-hoists scheduling problem

This article presents a method for the resolution of a material handling scheduling problem. The case studied is a real industrial problem. It consists of finding a cyclic schedule for hoist movements in a treatment surface shop. In this kind of facility, several hoists are used for all the handling operations and they have to share common zones. Then it is necessary to control that there is no collision. The mathematical formulation of the problem is based on a combination of disjunctive constraints. The constraints describe either movement schedule or collision avoidance. The resolution procedure presented identifies all the collision configurations and then uses a branch and bound-like algorithm to find the optimal solution of a given problem. The language chosen for our implementation is the constraint logic programming language: Prolog IV, which is able to solve constraints with rational variables. It actively uses the constraint propagation mechanism that can be found in several languages.     

Designing a tabu search algorithm for the two-stage flow shop problem with secondary criterion

This paper discusses the process of desigining a tabu search-based heuristic for the two-stage flow shop problem with makespan minimization as the primary criterion and the minimization of total flow time as the secondary criterion. A factorial experiment is designed to analyse thoroughly the effects of four different factors, i.e. the initial solution, type of move, size of neighbourhood and the list size, on the performance of the tabu search-based heuristic. Using the techniques of evolution curves, and response tables and response graphs, coupled with the Taguchi method, the best combination of the factors for the tabu search-based heuristic is identified, and the effectiveness of the heuristic algorithm in finding an optimal solution is evaluated by comparing its performance with the best known heuristic to solve this problem.     

An EOQ inventory model for items with Weibull distribution deterioration,ramp type demand rate and partial backlogging

In this paper, an EOQ inventory model is presented depleted not only by demand but also by Weibull distribution deterioration, in which the demand rate is assumed that with a ramp type function of time. In the model, shortages are allowed partial backlogging and the backlogging rate is variable and is dependent on waiting time for the next replenishment. The method is illustrated by three numerical examples, and sensitivity analysis of the optimal solution with respect to parameters of the system is carried out.     

The disassembly line: balancing and modeling,by S.M. McGovern and S.M. Gupta

This note addresses a problem faced by an actual firm. The problem is to decide on the optimal level of product quality. In performing the economic analysis to determine product quality level, the firm considers revenue, production costs, and research and development costs. However, this note shows that ignoring inventory costs in the analysis will lead to suboptimal product quality levels. Also, including inventory costs in the analysis will lead to reduced production lot sizes. Numerical examples are used to illustrate the results of the model.     

An optimal product-reconfiguration policy due to order changes

Abstract

It is not an uncommon problem that a finished product cannot be delivered to its customer due to order change. In many real-life applications, such as rack-mounted computer products, it is possible to reconfigure a product by altering the combination of its components. Therefore, an inventory item, resulting from a cancelled order, can be handled in one of two ways: (1) keep the product in storage for a future order; or (2) send the product back to the manufacturing Door for reconfiguration in accordance with a new order A wise decision can be made by evaluating the trade-off between the inventory cost and the conversion cost. This paper presents an optimization procedure for achieving the minimum-cost solution. The problem is formulated by a quadratic programming model. Under a fairly general condition, the problem can be converted into a standard capacitated transportation problem and, therefore, can be solved efficiently. The cost structure, problem formulation, and solution technique arc discussed.     

Survey of resource allocation methods for distributed manufacturing systems

Distributed manufacturing systems are more flexible in their arrangement and use of their resources. This permits a more dynamic and opportunistic allocation of manufacturing resources to work elements than is possible with today's centralized allocation systems. However, unlike solving the problem from a single solver view, there is no absolute control or tight coordination over how and when to decompose the problem, when to undertake a solution or the procedure for verifying consistency. Such activities will largely be left to the distributed entities to decide either individually or jointly. As a consequence the resulting allocations may suffer and induce myopic behaviour lacking in stability and regularity in the performance of the total system. Thus, the issues connected with solving the problem often move beyond the pure algorithmic focus of computation to include how the problem is decomposed, how or to whom it is assigned, and the organization for solving the subproblems, strategies used for resolving conflicts, the manner in which communication is conducted, etc. These issues, in fact, highlight the holistic nature of the solution and are used here as parameters to compare and contrast the approaches reported in the literature.     

Optimal dispatching control of an AGV in a JIT production system

This paper deals with an FMS (Flexible Manufacturing System) in a JIT (Just-In-Time) production system. The FMS consists of m workstations, one dispatching station and a single AGV (Automated Guided Vehicle). Each workstation has an input buffer of limited capacity and its processing times are distributed stochastically. When the processing of a new component starts at the workstation, a withdrawal Kanban attached to it is sent to the dispatching station. The AGV chooses one from workstations whose withdrawal Kanbans are accumulated at the dispatching station, and conveys a component with a withdrawal Kanban from the dispatching station to the workstation. The main purpose of this paper is to find an optimal dispatching policy of the AGV that maximizes the long-run expected average reward per unit time. The problem is formulated as a semi-Markov decision process and an optimal dispatching policy is computed. Numerical experiments are performed to make several comparisons.     

Note on inventory models with Weibull distribution deterioration

This article explores the inventory model with a general demand rate function in which both the Weibull distributed deterioration and partial backlogging are considered. The inventory model discussed here is based on the important finding by Wu [Wu, K.S., 2001. An EOQ inventory model for items with Weibull distribution deterioration, ramp type demand rate and partial backlogging. Production Planning and Control, 12, 787–793]. There are four parts in our research. First, we derive the analytical framework of the inventory model for a general demand rate function1 1.?Based on detailed suggestions of Professor Wafik H. Iskander, Email: whiskander@mail.wvu.edu . Second, for the ramp type demand, we improve Wu's model to find the criterion to guarantee the existence and uniqueness of the optimal solution. Third, we develop a new model to compensate for the missing case in Wu's article. Fourth, we combine our results to show that our findings are applicable to the ramp type demand inventory model, so that the optimal solution is independent of the demand function. Finally, some numerical examples and graphs are provided to illustrate our discovery and demonstrate the application of our analytical framework.     

An optimal replenishment model for inventory items with normally distributed deterioration

This paper deals with the inventory replenishment problem for deteriorating items with normally distributed shelf life, continuous time-varying demand, and shortages under the inflationary and time discounting environment. The reasons of choosing normal are twofold: it is one of the most important probability phenomena in the real world due to the classical central limit theorem, and it is also one of the most commonly used lifetime distributions in reliability contexts. The problem is formulated as a dynamic programming model and solved by numerical search techniques. The solutions of the model determine the optimal replenishment schedule over a finite planning horizon so that the present worth of the future costs associated with the system is minimized. In the extensive experiments, we validate the model, demonstrate the optimal replenishment schedule and lot-size, and carry out a comparative study to ascertain its contribution. In addition, sensitivity analysis was provided to help identify the most crucial factors that affect system performance. The experimental result shows that the deteriorating problem solved by an appropriate model (i.e. the proposed normal model) can save the total cost up to 2% approximately. It also identifies that the magnitudes of purchase cost per unit and demand rate are the most significant parameters that affect the replenishment decisions and cost.     

Locations and vehicle routing designs of physical distribution systems

The design of a physical distribution system (PDS) involves the determination of the number and locations of distribution centres, estimation of required vehicle numbers and design of vehicle routings. Due to the enormous numbers of possible combinatorial designs of the system, it is difficult to obtain an optimal design in acceptable computation effort on many occasions. In this paper, a new solution framework for the design of PDS by implementing the genetic algorithm (GA) is presented. With the characteristic of simultaneous optimization of a large population of configuration, the proposed methodology has been proved to be an extremely efficient optimizer. In the experimental simulation conducted in this paper, it also indicates this approach can provide a near-optimal solution to the design of PDS. To analyse the growth and decay of many schemas contained in the population, the effects of the operation of reproduction, crossover and mutation on the schema are studied. The simulation evaluation about the system performance and genetic parameters is presented along with the discussions at the end of this paper.     

Multiple criteria approach for solving feeder assignment and assembly sequence problem in PCB assembly

The feeder assignment and assembly sequence problem in printed circuit board (PCB) assembly with the twin objectives of minimizing magazine travel time and minimizing board travel time is presented in this study. The problem uses Dynamic Pick-and-Place (DPP) model where robot arm, board and magazine move together with different speeds based on relative coordinates between consecutive assembled points. The difficulty of the problem is that the feeder assignment depends on assembly sequence and vice versa. A new approach is proposed to improve the existing approaches. The trade-off between two strategies, assembly by area and assembly by component types, can give better results. The numerical experiments proved the efficiency of the new algorithm.     

MRP Planned Orders in a Multiple‐Supplier Environment with Differing Lead Times

This study examines a deterministic material requirements planning (MRP) problem where lead times at subsequent ordering moments differ. Adequate replenishment methods that can cope with lead time differences are lacking because of the order crossover phenomenon, that is, replenishment orders are not received in the sequence they are ordered. This study specifies how to handle order crossovers and recalculate planned order releases after an update of gross requirements. The optimal (s, S) policy is based on dynamic programing. The state space is kept to a minimum due to three fundamental insights. The performance of the optimal solution approach is compared with two heuristics based on relaxations and a benchmark approach in which order crossovers are ignored. A numerical analysis reveals that average cost savings up to 25% are possible if the optimal policy is used instead of the benchmark approach. The contribution of this study is threefold: (1) it generalizes theory on MRP ordering, allowing for lead time differences and order crossovers; (2) it develops new fundamental insights and an optimal solution procedure, leading to substantial cost saving; and (3) it provides good‐performing heuristics for a general and realistic replenishment problem that can replace the current replenishment methods within MRP.     

O(m2) ALGORITHMS FOR THE TWO AND THREE SUBLOT LOT STREAMING PROBLEM

Lot streaming is the process of splitting a job or lot into sublots to reduce its makespan on a sequence of machines. The goal in the lot streaming problem is to find the optimal size of each sublot that will minimize the makespan. The makespan is defined as the time the last sublot completes its processing on the last machine. If the sizes of these sublots are restricted to remain the same on all machines, the solution is called a consistent sublot solution. However, if the sizes of the sublots are allowed to vary, the solution is referred to as a nonconsistent or variable sublot solution. Also, if the machines must be in operation continuously from the first to the last sublot, the solution is a no idling solution. When setups are explicitly considered in the problem, there will be two cases. If setups on each machine require some portion of the first sublot be present by the machine, the problem is referred to as the attached setup time problem. If setups can be performed ahead of time before the first sublot reaches the particular machine, the corresponding problem is referred to as the detached setup problem. Finally, if the machines are allowed to be idle between the processing of sublots, the resultant solution is an intermittent idling solution. In this paper, the consistent sublot lot streaming problem with intermittent idling and no setups is discussed. The models developed also assume that the number of sublots are fixed and known. The m machine two sublot lot streaming problem is reviewed. An algorithm for the three sublot, m machine problem is derived using a network representation of the problem. The complexity of the algorithm is O (m²). Finally, using the insights from three sublot problem, a heuristic algorithm is provided for the m machine, n sublot problems. The results on the proposed heuristic are very encouraging; average percent deviation from optimal makespan is approximately at 0.76% on 155 randomly generated problems with different m and n values.     

Some inverse min-max network problems under weighted l1 and l∞ norms with bound constraints on changes

We consider some inverse min-max (or max-min) network problems. Such an inverse problem is to modify the weights with bound constraints so that a given feasible solution becomes an optimal solution of a min-max (or max-min) network problem, and the deviation of the weights, measured by the weighted l ₁ norm or weighted l _∞ norm, is minimum. In this paper, we present strongly polynomial time algorithms to solve the inverse min-max spanning tree problem and the inverse maximum capacity path problem.     

Distributed Decision‐Making in Supply Chains and Private E‐Marketplaces

This paper develops a distributed decision‐making framework for the players in a supply chain or a private e‐marketplace to collaboratively arrive at a global Pareto‐optimal solution. In this model, no player has complete knowledge about all the costs and constraints of the other players. The decision‐making framework employs an iterative procedure, based on the Integer L‐shaped method, in which a master problem is solved to propose global solutions, and each player uses his local problems to construct feasibility and optimality cuts on the master problem. The master problem is modeled as a mixed‐integer program, and the players' local problems are formulated as linear programs. Collaborative planning scenarios in private e‐marketplaces and in supply chains were formulated and solved for test data. The results show that this distributed model is able to achieve near‐optimal solutions considerably faster than the traditional centralized approach.