Optimization models for the tool change scheduling problem

Traditional machine scheduling literature generally assumes that a machine is available at all times. Yet this assumption may not be accurate in real manufacturing systems. In many cases, a machine's tool must be changed after it has continuously worked for a period of time. This paper deals with a single machine scheduling problem subject to tool wear, given the allowed maximum continuous working time of the machine is _TL$T_{\mathrm{L}}$ (tool life) and the tool change time is _TC$T_{\mathrm{C}}$. Job processing and tool changes are scheduled simultaneously. In this paper, we examine this problem to minimize the total tardiness of jobs. Two mixed binary integer programming models are developed to optimally solve this problem. Computational experiments are performed to evaluate the models’ efficiency.     

A column generation heuristic for dynamic capacitated lot sizing with random demand under a fill rate constraint

This paper deals with the dynamic multi-item capacitated lot-sizing problem under random period demands (SCLSP). Unfilled demands are backordered and a fill rate constraint is in effect. It is assumed that, according to the static-uncertainty strategy of Bookbinder and Tan [1], all decisions concerning the time and the production quantities are made in advance for the entire planning horizon regardless of the realization of the demands. The problem is approximated with the set partitioning model and a heuristic solution procedure that combines column generation and the recently developed _ABCβ${\mathit{ABC}}_{\beta }$ heuristic is proposed.     

Critical acceptance values and sample sizes of a variables sampling plan for very low fraction of defectives

Acceptance sampling plans are practical tools for quality control applications, which involve quality contracting on product orders between the vendor and the buyer. Those sampling plans provide the vendor and the buyer rules for lot sentencing while meeting their preset requirements on product quality. In this paper, we introduce a variables sampling plan for unilateral processes based on the one-sided process capability indices _CPU$C_{\mathrm{PU}}$ (or _CPL)$C_{\mathrm{PL}})$, to deal with lot sentencing problem with very low fraction of defectives. The proposed new sampling plan is developed based on the exact sampling distribution rather than approximation. Practitioners can use the proposed sampling plan to determine accurate number of product items to be inspected and the corresponding critical acceptance value, to make reliable decisions. We also tabulate the required sample size n$n$ and the corresponding critical acceptance value _C0$C_0$ for various α$\alpha$-risks, β$\beta$-risks, and the levels of lot or process fraction of defectives that correspond to acceptable and rejecting quality levels.     

Two new robust genetic algorithms for the flowshop scheduling problem

The flowshop scheduling problem (FSP) has been widely studied in the literature and many techniques for its solution have been proposed. Some authors have concluded that genetic algorithms are not suitable for this hard, combinatorial problem unless hybridization is used. This work proposes new genetic algorithms for solving the permutation FSP that prove to be competitive when compared to many other well known algorithms. The optimization criterion considered is the minimization of the total completion time or makespan (_Cmax$C_{\max }$). We show a robust genetic algorithm and a fast hybrid implementation. These algorithms use new genetic operators, advanced techniques like hybridization with local search and an efficient population initialization as well as a new generational scheme. A complete evaluation of the different parameters and operators of the algorithms by means of a Design of Experiments approach is also given. The algorithm's effectiveness is compared against 11 other methods, including genetic algorithms, tabu search, simulated annealing and other advanced and recent techniques. For the evaluations we use Taillard's well known standard benchmark. The results show that the proposed algorithms are very effective and at the same time are easy to implement.     

Efficient composite heuristics for total flowtime minimization in permutation flow shops

In this paper, permutation flow shops with total flowtime minimization are considered. General flowtime computing (GFC) is presented to accelerate flowtime computation. A newly generated schedule is divided into an unchanged subsequence and a changed part. GFC computes total flowtime of a schedule by inheriting temporal parameters from its parent in the unchanged part and computes only those of the changed part. Iterative methods and LR (developed by Liu J, Reeves, CR. Constructive and composite heuristic solutions to theP∥Σ_Ci$P\parallel \Sigma C_i$ scheduling problem, European Journal of Operational Research 2001; 132:439–52) are evaluated and compared as solution improvement phase and index development phase. Three composite heuristics are proposed in this paper by integrating forward pair-wise exchange-restart (FPE-R) and FPE with an effective iterative method. Computational results show that the proposed three outperform the best existing three composite heuristics in effectiveness and two of them are much faster than the existing ones.     

Improving routing and scheduling decisions at a distributor of industrial gasses

This paper investigates cyclical inventory replenishment for a company's regional distribution center that supplies, distributes, and manages inventory of carbon dioxide (_CO2)$({\mathrm{CO}}_2)$ at over 900 separate customer sites in Indiana. The company previously experienced high labor costs with excessive overtime and maintained a regular back-log of customers experiencing stockouts. To address these issues we implemented a three-phase heuristic for the cyclical inventory routing problem encountered at one of the company's distribution centers. This heuristic determines regular routes for each of three available delivery vehicles over a 12-day delivery horizon while improving four primary performance measures: delivery labor cost, stockouts, delivery regularity, and driver–customer familiarity. It does so by first determining three sets of cities (one for each delivery vehicle) that must be delivered to each day based on customer requirements. Second, the heuristic assigns the remaining customers in other cities to one of the three “backbone routes” determined in phase 1. And third, it balances customer deliveries on each daily route over the schedule horizon. Through our methodology, we were able to significantly reduce overtime, driving time, and labor costs while improving customer service.