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.     

Scheduling algorithms for computer-aided line balancing in printed circuit board assembly

Generalized flexible flow line (GFFL) is a scheduling environment comprising several machine banks which the products visit in the same order but can skip some machine banks. The type of machines in a bank can differ but they are suitable for performing the same manufacturing tasks. To change one product to another demands a set-up operation of the machine. This paper describes several scheduling algorithms for the GFFL problem. The overall structure of these algorithms is similar, consisting of machine allocation and sequencing phases. The algorithms have been integrated into an interactive production scheduling system for electronics assembly. Sample cases are used to illustrate the operation of the system in practice.     

Supporting Quick Response Through Scheduling of Make-to-Stock Production/Inventory Systems*

Scheduling of traditional job shops in make-to-order systems has seen extensive research over the past three decades. In such systems, performance is often related to various job completion metrics such as average flow time, average lateness, etc. This paper examines a scheduling problem in a make-to-stock environment where individual job completion measures are irrelevant. In this case, customer orders are satisfied through on-hand inventory where customer service is more closely related to the manufacturer's ability to quickly satisfy demand. We consider the role of scheduling in reducing inventories and improving customer service in the context of a manufacturer who assembles several different products on a single assembly line. We develop scheduling rules for such a system and experimentally compare their performance to those typically used in such environments. Our results indicate that rules which consider the inventory position and demand forecast outperform traditional fixed cycle rules.     

面向并行制造的多生产单元协同调度研究

为提升多生产单元制造系统整体效率，在其系统内开展面向并行制造的协同调度研究，在考虑运输、换线等时间的基础上，构建多生产单元并行协同调度模型，采用并行分段协同遗传算法求解；在此基础上，将所研究协同调度方法应用于某复杂机电产品多生产单元制造车间，并与变批量调度与等批量调度比较。研究表明，所提的并行协同调度方法可以显著提升生产单元效率，提高生产单元设备和人员利用率。     

Dynamic scheduling of manufacturing job shops using extreme value theory

Most job shop scheduling approaches reported in the literature assume that the scheduling problem is static (i.e. job arrivals and the breakdowns of machines are neglected) and in addition, these scheduling approaches may not address multiple criteria scheduling or accommodate alternate resources to process a job operation. In this paper, a scheduling method based on extreme value theory (SEVAT) is developed and addresses all the shortcomings mentioned above. The SEVAT approach creates a statistical profile of schedules through random sampling, and predicts the quality or 'potential' of a feasible schedule. A dynamic scheduling problem was designed to reflect a real job shop scheduling environment closely. Two performance measures, viz. mean job tardiness and mean job cost, were used to demonstrate multiple criteria scheduling. Three factors were identified, and varied between two levels each, thereby spanning a varied job shop environment. The results of this extensive simulation study show that the SEVAT scheduling approach produces a better performance compared to several common dispatching rules.     

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.     

Hospital resident scheduling problem

This paper addresses the resident scheduling problem (RSP) at hospitals concerned with prescribing work-nights for residents while considering departmental staffing and skill requirements as well as residents' preferences. Three scenarios that represent most situations and account for various departmental requirements and needs are described. Although similar scheduling problems are considered in the literature, no analysis exists that adequately deals with the speciffic nature of this problem. The problem is modeled as a mixed-integer program and heuristic solution procedures are developed for the different identified scheduling scenarios. These procedures exploit the inherent network structure of the problem which is an important feature that enhances problem solvability. For the sake of comparison, the problem is also solved exactly via the CPLEX-MIP (version 6.0) package. The contribution of this work is important since many hospitals are still utilizing manual techniques in preparing their own schedules, expending considerable effort and time and yet contending with limited scheduling flexibility.     

REQUIREMENTS PLANNING FOR CONTROL OF INFORMATION RESOURCES

Producing reports assembled from files, records, and raw data is a major function of the computer in modern organizations. Transaction processing, records management, file organization, and data-base management are aspects of the information production function that have received a good deal of attention. But planning, scheduling, and controlling the production of information products have been neglected. For complex applications involving assembly of reports from multilevel information sources, the requirements planning model is suggested as an effective alternative to present methods. Thus, our suggestion is that the computer be used to plan, schedule, and control computer production of information products. Presently available material requirements planning software may be employed with minor modifications that depend on the given information system characteristics. In this paper an example of requirements planning as applied to production of information in a satellite control system is presented.     

印刷电路板组装生产线调度优化问题建模

印刷电路板(printed circuit board,PCB)组装是电子制造的基础,其核心生产过程包括电子元器件的表面贴装。分别基于典型的表面贴装机(CM402)、以及由高速贴片机(CM402)与多功能贴片机(DT401)组成的流水线的机械特征与生产特性,对上述组装机及组装流水线的调度问题建立优化模型,为进一步的算法开发以及电子制造生产调度的智能化提供理论支持。     

Some structural properties for the just-in-time level schedule problem

Just-in-time (JIT) is a pull concept applied mainly in repetitive manufacturing systems, and it is characterized by a scenario where only the required units are produced in the required quantities at the required times. It particularly aims at eliminating wastes associated with inventories in the system. A level schedule is desirable for a JIT assembly system, as it serves as an approximation for all forms of smoothing. The min-sum formulation of the assembly line level schedule problem is one of those that has been mainly used in the literature. Using this formulation as a base, we develop some useful structural properties for the problem. Among other things, it is shown that a level schedule would tend to be more difficult to achieve for products (models) with comparatively fewer units in the products composition structure.     

Implementation of continuous flow manufacturing (CFM) system

In a world of global competition and demanding customers, putting production requirements ahead of customer's needs inevitably leads to manufacturing inefficiencies, higher inventories, and poor quality goods and services. In continuous flow manufacturing (CFM) system, the manufacturer makes how much and what is needed, and also when it is needed. A leading multinational company in oral care products produces toothbrushes through contract manufacturers (CMs). The contract manufacturer makes different stock-keeping units (SKUs) under two options: (i) the contract manufacturing option, in which CM supplies the finished products; (ii) the labour contract, in which CM is responsible only for conversion. Competitive pressure in the market pressures the company to change the operating system from the push system to CFM for CMs also. Moving from the push system with its high level of inventories to continuous flow manufacturing system enables the achievement of improved customer responsiveness, greater efficiencies, lower inventories and lower operating costs. This paper describes the way in which one such contract manufacturer was moved towards the CFM system and the benefits achieved through it.     

Simulation-based production schedule generation

Abstract

While simulation has been used in manufacturing for many years, predominantly for facility design, it is within the last few years, that simulation languages have been developed to a point where they can be used on a day-to-day basis to generate schedules and predict their performance. This paper describes our use of different modelling techniques to develop a production schedule generation system. An example describing a system for a small- to medium-sized order producing company using SIMAN/CINEMA is included. While addressing the shortcomings of existing scheduling systems it is shown how the approach taken is a feasible way of creating a dynamic goal-driven simulation-based production scheduler. The paper does not aim to describe an ‘off the shelf’ scheduling system product, but rather to give an overview to methods, techniques and experiences which enable us rapidly to tailor a simulation-based scheduling system to the specific needs of a company.     

A closed loop automatic scheduling system (CLASS)

Abstract

CLASS is a production scheduling system, that is designed to function in either a stand-alone manner, or in conjunction with an MRP system. MRP systems innately do not have 'closed loop’ capability in the sense of being able to produce master schedules and order releases that are consistent and that respect capacity constraints. True closed loop performance requires detailed scheduling. In addition to interfacing with MRP systems, CLASS is designed to produce schedules that can be used in conventional shops or can be downloaded to automated facilities. The design goals for the system, its internal architecture, and its role in manufacturing control systems are described. The modelling and decision capabilities     

An efficient scheduling algorithm for the hot coil making in the steel mini-mill

This paper investigates and suggests an efficient solution to the problem of scheduling the steel making line in the Mini Steel Mill, which consists of three major processes: molten steel making, continuous slab casting, and hot charged rolling. Careful synchronization of these processes is a key productivity factor, since a very limited amount of work-in-process inventory is allowed. Since each process must run in batch, the schedule for the Mini-Mill consists of grouping and sequencing of lots for each process. However, each process has its own criteria for judging the quality of its lot grouping, which often conflicts with other processes. An efficient scheduling algorithm for the Mini-Mill is proposed. Numerical experiments with real world data suggest that the proposed algorithm yield satisfactory schedules very efficiently. The algorithm is currently used for the actual scheduling of a Mini-Mill in Korea.     

Scheduling a single semi-continuous batching machine

This paper addresses a new problem, called semi-continuous batch scheduling, which arises in the heating-operation of tube-billets in the steel industry. Each heating furnace can be regarded as a semi-continuous batching machine, which can handle up to C jobs simultaneously. The jobs in the same batch enter and leave the machine semi-continuously, which differs from the traditional batching machine scheduling where the jobs in same batch have a starting time and a finishing time. In this paper the processing time of a batch depends on the capacity of the semi-continuous batching machine, the longest processing time of jobs in the batch and its size. The objectives are to schedule jobs on the machine so that the makespan and the total completion time are minimized. A schedule for a semi-continuous batching machine consists of a batching and sequencing for the batches. We propose the optimal properties of two different objective functions and present the different dynamic programming algorithms with a running time of O(n²), respectively.     

The project of a new of neural networks products line: An application

The aim of this paper is to propose a new approach to the issue ofpositioning and pricing a firm's new products line; it is shown here how to conceive an artificial neural system able to find the optimal solution. The formulation of the problem follows the model proposed by Dobson and Kalish, while the implementation is based on the Hopfield Neural Network, thus used here for a new class of problems. The model shows a capacity to converge to the optimal solution; besides its effectiveness, this technique appears to also be efficient if applied to such a production problem.     

DYNAMIC COURSE SCHEDULING FOR COLLEGE FACULTY VIA ZERO-ONE PROGRAMMING*

This paper formulates a multi-period course scheduling problem as a zero-one programming model. Under various constraints, and for a planning horizon of several terms, the model seeks to maximize: (1) the faculty course preferences in assigning faculty members to courses, and (2) the faculty time preferences in allocating courses to time blocks, via a two-stage optimization procedure. The multi-period structure of the model, strengthened by the explicit inclusion of a wide-range of constraints designed to represent various special requirements has enabled the model to capture the many dynamic features of the course scheduling problem at the college level. As such, it can be used not only for long-range or short-range departmental planning, but also as a suitable framework toward the development of a larger, and all-inclusive course scheduling decision system. The paper begins with a brief review of several related studies and then presents a multi-period scheduling model and its extensions. Some numerical examples are used to test the model, and the authors' experience, resulting from such tests with several computer codes, is reported. The possible directions for future research are also suggested.     

Business drivers not sector membership determine the most effective production planning and control; a novel approach to a perennial problem

This paper outlines research aimed at developing novel planning and scheduling reference models for industrial sectors where the MRPII paradigm is not appropriate. It outlines the process mapping approach adopted, the data capture method developed for the case study companies, the use of ARIS (Scheer's) enterprise modelling tool, and the first stages in the production of sector reference models.     

大规模集成电路预烧作业中分批排序问题的数学模型

分批排序(Batch Scheduling)是在半导体生产过程的最后阶段提炼出来的一类重要的排序问题。单机分批排序问题就是n个工件在一台机器上加工,要将工件分批,每批最多可以同时加工B个工件,每批的加工时间等于此批工件中的最大的加工时间。Skutella^[8]1998年把平行机排序的P｜｜∑ω_jC_j和R｜｜∑ω_jC_j表述成二次的0-1整数规划,得到一些令人满意的结果;国内罗守成等^[9]、张倩^[10]给出了单机排序问题1｜｜∑ω_jC_j的数学规划表示,对于用数学规划来研究排序问题是一个很有意义的进展。本文首先介绍总完工时间和最小的带权单机分批排序问题1｜B｜∑ω_jC_j,然后将1｜B｜∑ω_jC_j表示成数学规划的形式,并且用数学规划中的对偶理论证明了SPT序是其特殊情况1｜B=1｜∑C_j的最优解。