一类新型批处理机调度问题的理论分析

钢卷在冷轧生产中,为了改进其性能,需要在罩式炉进行退火,退火过程由加热、保温和降温三段组成,而这三段处理时间由于工艺上的要求不能归结为一个时间,这与传统批处理机调度有明显的差别.对新型批处理机的总加权完成时间最小化问题建立了非线性整数规划模型,开发了基于动态规划的启发式算法.通过理论分析,获得该算法的误差性能比为3.对于三段中的某一段板卷的处理时间相同的情况,证明了启发式算法的误差性能比是2,而且证明是紧界.对于三段中的某二段板卷的处理时间相同的情况,证明了启发式算法是最优算法.对启发式算法扩展到带有任意段的加工时间的一般情况进行了性能分析.     

Heuristic for the cutting and purchasing decisions of multiple metal coils

This paper presents a heuristic algorithm for the rectangular two-dimensional cutting stock problem, where metal coils of multiple widths are divided into rectangular items with guillotine cuts. The cutting process contains two phases. Coils are cut into segments at the first phase and the segments into items at the second phase. A subset of three-staged patterns is considered in generating the cutting plan. The algorithm is used to accomplish the following tasks: (1) Generating cutting plans for the cutting process; (2) Selecting the coil widths to purchase; (3) Optimizing the segment lengths to order. Benchmark instances are used to demonstrate the effectiveness of the algorithm in improving material utilization, and examples are used to illustrate the decision methods for different tasks.     

Makespan and workstation utilization minimization in a flowshop with operations flexibility

Production environments where there are more tasks than workstations and any task can be assigned to any workstation are examples of operations flexibility. This paper investigates the benefits of operations flexibility in a flowshop when the goals are to minimize the makespan and workstation utilization. Furthermore, machine dominance principles are extended to the case of a flowshop with operations flexibility. The proposed heuristic framework comprises of two phases, allocation of operations to workstations and generation of job sequencing. In addition, an improvement procedure based on simulated annealing is implemented for this problem. The experimental results identify the effects of the experimental factors; show the significance of the heuristic factor; and demonstrate the tradeoff between the two performance criteria.     

Improving throughput for an electronic assembly line using a constraint analysis methodology

Electronic assembly operations are vital to industries such as telecommunications, computers and consumer electronics. This paper presents a constraint analysis methodology for planning and improving electronic assembly operations that draws on concepts from queueing theory, simulation and production planning. The proposed methodology identifies the operational bottleneck and predicts the utilization, throughput and lead time of the assembly line. It also quantifies the relationship between yields and utilization for the assembly operations. A case study is presented that applies the methodology at an Ericsson, Inc., telecommunications equipment assembly facility. The constraint analysis methodology provided valuable decision support as the managers of Ericsson evaluated the costs and benefits of additional production capacity. Although the focus of this paper is electronic assembly operations, the methodology can be applied to general flow line assembly systems with feedback loops for test and rework under dedicated high-volume production.     

A solution framework for the multi-mode resource-constrained cross-dock scheduling problem

In this paper we propose a framework for shift-level container scheduling and resource allocation decisions at a cross-dock facility. The Multi-Mode Resource-Constrained Cross-Dock Scheduling Problem (MRCDSP) approach minimizes material flow and schedules inbound and outbound containers to dock-doors such that the total processing time is minimized subject to the resource constraints at the cross-dock. While container scheduling and resource allocation problems at cross-dock facilities have been studied previously in isolation, our work is the first to consider a complete view of cross-dock operations providing optimal container to dock-door allocation, and a makespan minimizing schedule of containers to the cross-dock. We present a comprehensive framework that includes identification of container clusters to reduce the problem size, a container-to-dock-door assignment algorithm, and a container clusters scheduling model that is solvable for practically sized problems. In a comparative numeric study based on data simulating a cross-dock facility, our approach is shown to outperform current practice, reducing the average time required for processing a set of containers by 37% and reducing the weighted-distance material traveled within the cross-dock by 45%.     

The importance of operations management problems in service organizations

This article reports on the research to empirically determine which operations management problems are the most important to small service organizations. The authors asked managers of service organizations to rank a set of operations problems according to their relative importance using Q methodology. In this article, Q method is explained, significant factors are analyzed, and explanations are offered for the ranking of the operations problems. The results indicate that forecasting, quality management, and resource utilization are important operational issues for service organizations. However, the results also indicate that facility location and layout, waiting line systems, and distribution requirements planning were for the most part unimportant to the respondent service organizations. In addition, Schmenner's service typology does not provide an explanatory basis for the variations in the factor results. Lastly, the results are used to suggest operations management techniques that should be taught to students who are expected to work in service organizations upon graduation.     

Balancing Production and Distribution in Paper Manufacturing

A paper manufacturing plant minimizes its production cost by using long production runs that combine the demands from its various customers. As jobs are completed, they are released to distribution for delivery. Deliveries are made by railcars, each of which is dedicated to one customer. Long production runs imply that maximizing railcar utilization requires holding the cars over several days or holding completed jobs within the loading facility. Each of these methods imposes a cost onto the distribution function. We find how distribution can minimize its cost, given production's schedule. We then consider the problem of minimizing the company's overall cost of both production and distribution. A computational study using general data illustrates that the distribution cost is reduced by 25.80% through our proposed scheme, and that the overall cost is reduced an additional 4.40% through our coordination mechanism. An optimal algorithm is derived for a specific plant's operations.     

一种差异工件单机批调度问题的蚁群优化算法

由于在利用蚁群算法构建差异工件(即工件有尺寸差异)单机批调度问题的解时,批的加工时间是不确定的.从而不能类似于经典调度问题的蚁群算法把批加工时间的倒数作为蚁群算法中的启发式信息,引入批的利用率和批的负载均衡率作为蚁群算法中的启发式信息,提出了JACO(ant colony optimization based a job sequence)和BACO(ant colony optimization based a batch sequence)两种蚁群优化算法.在算法JACO中,解的编码为工件序列,它对应着用BF(best fit)分批规则生成的调度方案,信息素代表工件间的排列顺序;在算法BACO中,解的编码为批序列,信息素代表工件间的批相关性,由此信息素通过中间信息素量来构造相应的解,并引入特定的局部优化策略,提高了算法的搜索效率.实验表明,与以往文献中的SA(simula-ted annealing)、GA(genetic algorithm)算法以及FFLPT(first-fit longest processing time)、BFLPT (best-fit longest processing time)启发式规则相比,算法JACO和BACO明显优于它们,且BACO算法比JACO算法效果更好.     

Event-driven production scheduling in SME

One common problem among Small and Medium Enterprises (SME) is to don’t have at disposal formal and simple approaches for production scheduling, especially in case of an event that introduces the requirement of a re-planning. The paper approaches this kind of event-driven re-scheduling problems at the arrival of a new order, when some jobs are under processing, some operation have already finished and other jobs are waiting to be loaded on a machine. For a simple application in a SME, to the operations already started and completed for a job a processing time equal to zero is assigned; the operations already started but not yet completed are interrupted and considered as operations that must be executed for the remaining part of their processing time; all the other jobs are considered for the event-driven job-shop re-scheduling problem. A validation of the procedure in a realistic application is presented.     

Sequencing heuristics for dependent setups in a continuous process industry

In this paper we address the scheduling of Biaxially Oriented Polypropylene (BOPP) film production, which belongs to the plastics industry and is a continuous process. Scheduling problems in BOPP film production involve processing different thickness settings of films on a common facility. Customer orders of the same thickness setting are usually grouped together as a production batch and a setup time is incurred whenever the batch is switched. However, there is usually more than one batch for the same thickness setting because of the due date constraints of the orders. Therefore, there is a need to develop a batching and sequencing scheme that minimizes the total setup time, or equivalently the makespan, under the due date constraint. In this paper heuristics are developed to generate a near-optimal solution for the problem. The heuristics are evaluated by an optimal solution procedure and are tested by using the actual data from a plant making the BOPP film. Comparison of the heuristics with the results of the current system has demonstrated a significant reduction in total setup time.     

INSTRUCTING OPERATIONS DESIGN: AN EXPERIENTIAL APPROACH

Teaching an operations design course has major pedagogical challenges. (1) The design topics—output, process, facility, and work design—are necessarily taught sequentially, yet the decisions are integrative. (2) Instruction must be generic to service or product producers. (3) Discussing output design is difficult since students typically have had no exposure to the “product language” of engineering graphics. (4) No text is available which examines in sufficient depth all the operations design decisions. (5) Cases necessarily depict historical situations—process technologies and economic data—while operations managers must plan future directions for their productive systems. (6) While the commercial world contains fresh information and data, students are inexperienced in obtaining knowledge from the real world. (7) While the course presents an operations management perspective, students must recognize the information, data, and cooperation necessary from the other functional areas to successfully complete the operations design. To help overcome these seven pedagogical challenges, the students in the undergraduate and graduate operation design courses complete a comprehensive feasibility study for a new product or service and the entire productive system.     

Genetic algorithms for optimization of a mine system under uncertainty

The production planning of a mine system associated with mining, processing and refining stages dictates to determine optimal system parameters such as optimal production rates, location of refining facility and the best reconstruction time of production rates. This paper proposes a combination of the chance constrained programming (CCP) and the genetic algorithms (GA) to find the optimal system parameters simultaneously. In generic form the problem is expressed as the maximization of net present value of future cash flows such that the capacity constraint and predefined specifications are satisfied. The blending requirements expressed in the CCP are transformed into deterministic equivalents. A new form of the problem is solved by the GA. The approach was demonstrated on extraction, processing and refining of four iron ore mines with varying reserves, ore qualities, geological and topographic conditions, four mineral processing units and one refining facility. The results showed that the proposed algorithm could be used to determine optimal production rates, the facility location and the best reconstruction time.     

Quantitative risk assessment-epidemic curve prediction model for leafy green outbreak investigation

The objective of this study was to leverage quantitative risk assessment to investigate possible root cause(s) of foodborne illness outbreaks related to Shiga toxin-producing Escherichia coli O157:H7 (STEC O157) infections in leafy greens in the United States. To this end, we developed the FDA leafy green quantitative risk assessment epidemic curve prediction model (FDA-LG QRA-EC) that simulated the lettuce supply chain. The model was used to predict the number of reported illnesses and the epidemic curve associated with lettuce contaminated with STEC O157 for a wide range of scenarios representing various contamination conditions and facility processing/sanitation practices. Model predictions were generated for fresh-cut and whole lettuce, quantifying the differing impacts of facility processing and home preparation on predicted illnesses. Our model revealed that the timespan (i.e., number of days with at least one reported illness) and the peak (i.e., day with the most predicted number of reported illnesses) of the epidemic curve of a STEC O157-lettuce outbreak were not strongly influenced by facility processing/sanitation practices and were indications of contamination pattern among incoming lettuce batches received by the facility or distribution center. Through comparisons with observed number of illnesses from recent STEC O157-lettuce outbreaks, the model identified contamination conditions on incoming lettuce heads that could result in an outbreak of similar size, which can be used to narrow down potential root cause hypotheses.     

Minimizing tardiness on a single processor with sequence-dependent setup times: a simulated annealing approach

In today's fast-paced Just-In-Time and mass customization manufacturing in a sequence-dependent setup environment, the challenge of making production schedules to meet due-date requirements is becoming a more complex problem. Unfortunately, much of the research on operations scheduling problems has either ignored setup times or assumed that setup times on each machine are independent of the job sequence. This paper considers the problem of minimizing tardiness, a common measure of due-date performance, in a sequence-dependent setup environment. Simulated annealing was used to solve the sequencing problem, and its performance was compared with random search. Our experimental results show that the algorithm can find a good solution fairly quickly, and thus can rework schedules frequently to react to variations in the schedule. The algorithm is invaluable for ‘on-line’ production scheduling and ‘last-minute’ changes to production schedule. The results of this research also suggest ways in which more complex and realistic job shop environments, such as multiple machines with a higher number of jobs in the sequence, and other scheduling objectives can be modeled. This research also investigates computational aspects of simulated annealing in solving complex scheduling problems.     

The impact of random machine unavailability on inventory policies in a continuous improvement environment

There are production situations where a production facility (e.g. a machine) is used intermittently to produce lot sizes of certain products. Upon completion of production run, the facility may not be available for a random amount of time due to several reasons, such as: the facility needs to be maintained and the maintenance time is random due to unforeseen circumstances; or that the facility is leased by different manufacturers and the demand for the facility is random. As a result of machine unavailability, stock-out situations might arise. This paper extends the work of Abboud et al . (2000, Computers and Operations Research , 27 , 335-351) by assuming learning and forgetting in production. A new mathematical model is developed with numerical examples and sensitivity analysis provided. Furthermore, this paper determines how the overall inventory cost is influenced by the nature of the random variable that represents the unavailability time of the production facility.     

ON-LINE QUALITY MANAGEMENT: INTEGRATION OF PRODUCT INSPECTION AND PROCESS CONTROL

A growing recognition that quality management is an important factor in defining a firm's competitive position has led to renewed attention to this function and has resulted in implementation of elaborate systems for on-line quality control comprising product inspection and process control. Traditionally, these functions have been treated independently, with very little interaction. In this paper we examine, in detail, a scheme that integrates the two functions, and we demonstrate that such an approach can result in significant cost savings. The motivation for this work comes from our experience in a wafer fabrication facility that suggested that exchange of quality information between different stages of production could result in significant performance improvements. To illustrate this approach, we consider a specific environment characterized by a single-stage continuous production process whose status is monitored by an X̄ control chart. We assume that quality-related costs may be described as a function of the process output. This is analogous to Taguchi's quality loss function and may be interpreted as a generalization of conventional classification of process output as either acceptable or defective units. The integrative scheme essentially relies on utilization of the process status information (based on process control) in making product inspection decisions. For this system we derive a cost model and develop a solution procedure to determine optimal decision parameters. Limited computational results indicate that the scheme has significant potential for reducing quality-related costs.     

Benchmark Schedules for Subcontracted Operations: Decentralization Inefficiencies that Arise from Competition and First‐Come‐First‐Served Processing*

Subcontracting has become a prominent business practice across many industries. Subcontracting of industrial production is generally based on short‐term need for additional processing capacity, and is frequently employed by manufacturers to process customer orders more quickly than using only in‐house production. In this article, we study a popular business model where multiple manufacturers, each capable of processing his entire workload in‐house, have the option to subcontract some of their operations to a single third party with a flexible resource. Each manufacturer can deliver customer orders only after his entire batch of jobs, processed in‐house and at the third party, is completed. The third party facility is available to several manufacturers who compete for its use. Current business practice of First‐Come‐First‐Served (FCFS) processing of the subcontracted workloads as well as the competitive Nash equilibrium schedules developed in earlier studies result in two types of inefficiencies; the third party capacity is not maximally utilized, and the manufacturers incur decentralization cost. In this article, we develop models to assess the value created by coordinating the manufacturers' subcontracting decisions by comparing two types of centralized control against FCFS and Nash equilibrium schedules. We present optimal and/or approximate algorithms to quantify the third party underutilization and the manufacturers' decentralization cost. We find that both inefficiencies are more severe with competition than they are when the third party allocates capacity in an FCFS manner. However, in a decentralized setting, a larger percentage of the players prefer Nash equilibrium schedules to FCFS schedules. We extend our analysis to incomplete information scenarios where manufacturers reveal limited demand information, and find that more information dramatically benefits the third party and the manufacturers, however, the marginal benefit of additional information is decreasing. Finally, we discuss an extension wherein each manufacturer's objective takes into account asymmetries in subcontracting, in‐house processing, and delay costs.     

炼钢热轧一体化生产与物流计划模型及求解

合理的板坯与热轧卷库存、缩短产品的生产周期、降低能源消耗、按合同交货以提高客户满意度已成为钢铁生产管理的要求.为了降低生产与物流成本,本文针对炼钢与热轧生产及其衔接方式的特点,考虑能力和两个阶段冲突约束条件下构建生产与物流计划层次的一体化模型.分析了无能力约束和允许延迟条件下热轧批量的极点特征,对原问题采用Dantzi...     

The Impact of Variability and Patient Information on Health Care System Performance

In the delivery of health care services, variability in the patient arrival and service processes can cause excessive patient waiting times and poor utilization of facility resources. Based on data collected at a large primary care facility, this paper investigates how several sources of variability affect facility performance. These sources include ancillary tasks performed by the physician, patient punctuality, unscheduled visits to the facility's laboratory or X‐ray services, momentary interruptions of a patient's examination, and examination time variation by patient class. Our results indicate that unscheduled visits to the facility's laboratory or X‐ray services have the largest impact on a physician's idle time. The average patient wait is most affected by how the physician prioritizes completing ancillary tasks, such as telephone calls, relative to examining patients. We also investigate the improvement in system performance offered by using increasing levels of patient information when creating the appointment schedule. We find that the use of policies that sequence patients based on their classification improves system performance by up to 25.5%.     

具有遗憾值约束的鲁棒供应链网络设计模型研究

考虑不确定性环境,研究战略层次的供应链网络鲁棒设计问题,目标是设计参数发生摄动时,供应链性能能够保持稳健性。基于鲁棒解的定义,建立从上游供应商选择到下游设施选址-需求分配的供应链网络设计鲁棒优化模型;提出确定遗憾值限定系数上限和下限的方法,允许决策者调节鲁棒水平,选择多种供应链网络结构;通过模型分解与协调,设计了供应链节点配置的禁忌搜索算法。算例的计算结果表明了禁忌搜索算法具有良好的收敛特性,以及在处理大规模问题上的优越性;同时也反映了利用鲁棒优化模型进行供应链网络设计,可以有效规避投资风险。