Pattern-based ILP models for the one-dimensional cutting stock problem with setup cost

Journal of Combinatorial Optimization - The one-dimensional cutting stock problem with setup cost (CSP-S) is a cutting problem that seeks a cutting plan with a minimum number of objects and a...     

Optimal wafer cutting in shuttle layout problems

A major cost in semiconductor manufacturing is the generation of photo masks which are used to produce the dies. When producing smaller series of chips it can be advantageous to build a shuttle mask (or multi-project wafer) to share the startup costs by placing different dies on the same mask. The shuttle layout problem is frequently solved in two phases: first, a floorplan of the shuttle is generated. Then, a cutting plan is found which minimizes the overall number of wafers needed to satisfy the demand of each die type. Since some die types require special production technologies, only compatible dies can be cut from a given wafer, and each cutting plan must respect various constraints on where the cuts may be placed. We present an exact algorithm for solving the minimum cutting plan problem, given a floorplan of the dies. The algorithm is based on delayed column generation, where the pricing problem becomes a maximum vertex-weighted clique problem in which each clique consists of cutting compatible dies. The resulting branch-and-price algorithm is able to solve realistic cutting problems to optimality in a couple of seconds.     

A Semidefinite Programming Approach to the Quadratic Knapsack Problem

In order to gain insight into the quality of semidefinite relaxations of constrained quadratic 0/1 programming problems we study the quadratic knapsack problem. We investigate several basic semidefinite relaxations of this problem and compare their strength in theory and in practice. Various possibilities to improve these basic relaxations by cutting planes are discussed. The cutting planes either arise from quadratic representations of linear inequalities or from linear inequalities in the quadratic model. In particular, a large family of combinatorial cuts is introduced for the linear formulation of the knapsack problem in quadratic space. Computational results on a small class of practical problems illustrate the quality of these relaxations and cutting planes.     

Approximate and Exact Algorithms for Constrained (Un) Weighted Two-dimensional Two-staged Cutting Stock Problems

In this paper we propose two algorithms for solving both unweighted and weighted constrained two-dimensional two-staged cutting stock problems. The problem is called two-staged cutting problem because each produced (sub)optimal cutting pattern is realized by using two cut-phases. In the first cut-phase, the current stock rectangle is slit down its width (resp. length) into a set of vertical (resp. horizontal) strips and, in the second cut-phase, each of these strips is taken individually and chopped across its length (resp. width).First, we develop an approximate algorithm for the problem. The original problem is reduced to a series of single bounded knapsack problems and solved by applying a dynamic programming procedure. Second, we propose an exact algorithm tailored especially for the constrained two-staged cutting problem. The algorithm starts with an initial (feasible) lower bound computed by applying the proposed approximate algorithm. Then, by exploiting dynamic programming properties, we obtain good lower and upper bounds which lead to significant branching cuts. Extensive computational testing on problem instances from the literature shows the effectiveness of the proposed approximate and exact approaches.     

OPTIMAL DIMENSIONS OF VIRGIN STOCK IN CUTTING GLASS TO ORDER

Glass cutting is a two-dimensional version of the cutting-stock problem. It involves two questions. One concerns the best way to cut a pane from a given plate. A less obvious question concerns selection of the plate from which the pane is cut. This leads to the question of what stock to order, before we even think of cutting it. We show that this latter question is more critical to economic cutting than the refinement of cutting procedures. We also present a method for selecting optimal stock sizes.     

Constructive procedures to solve 2-dimensional bin packing problems with irregular pieces and guillotine cuts

This paper presents an approach for solving a new real problem in cutting and packing. At its core is an innovative mixed integer programme model that places irregular pieces and defines guillotine cuts. The two-dimensional irregular shape bin packing problem with guillotine constraints arises in the glass cutting industry, for example, the cutting of glass for conservatories. Almost all cutting and packing problems that include guillotine cuts deal with rectangles only, where all cuts are orthogonal to the edges of the stock sheet and a maximum of two angles of rotation are permitted. The literature tackling packing problems with irregular shapes largely focuses on strip packing i.e. minimizing the length of a single fixed width stock sheet, and does not consider guillotine cuts. Hence, this problem combines the challenges of tackling the complexity of packing irregular pieces with free rotation, guaranteeing guillotine cuts that are not always orthogonal to the edges of the stock sheet, and allocating pieces to bins. To our knowledge only one other recent paper tackles this problem. We present a hybrid algorithm that is a constructive heuristic that determines the relative position of pieces in the bin and guillotine constraints via a mixed integer programme model. We investigate two approaches for allocating guillotine cuts at the same time as determining the placement of the piece, and a two phase approach that delays the allocation of cuts to provide flexibility in space usage. Finally we describe an improvement procedure that is applied to each bin before it is closed. This approach improves on the results of the only other publication on this problem, and gives competitive results for the classic rectangle bin packing problem with guillotine constraints.     

Exact and heuristic algorithms for the circle cutting problem in the manufacturing industry of electric motors

Circular blanks are often cut from silicon steel plates to make stators and rotors of electric motors. The shearing and punching processes are often used to cut the blanks. First a guillotine shear cuts the plate into strips, and then a stamping press cuts the blanks from the strips. The unconstrained circle cutting problem discussed is the problem of cutting from a rectangular plate a number of circular blanks of given diameters and values, so as to maximize the value of blanks cut, where the shearing and punching processes are applied. Two algorithms based on dynamic programming are presented for generating cutting patterns, one is an exact algorithm and the other is a heuristic one. The computational results indicate that the exact algorithm is adequate for small and middle scale problems, the heuristic algorithm is much more time efficient, and can generate cutting patterns close to optimal.     

Simplest optimal guillotine cutting patterns for strips of identical circles

The manufacturing industry often uses the cutting and stamping process to divide stock plates into circles. A guillotine machine cuts the plate into strips for stamping at the cutting stage, and then a stamping press punches out the circles from the strips at the stamping stage. The problem discussed is to cut a plate into strips of identical circles such that the number of circles is maximized. A dynamic programming algorithm is presented for generating the simplest optimal cutting patterns of the strips. The computational results indicate that the algorithm is much efficient in simplifying the cutting process.     

Energy-oriented bi-objective optimization for the tempered glass scheduling

This paper investigates a real life bi-objective hybrid flow shop scheduling problem in an energy-intensive manufacturing system, in which glass is produced successively in cutting, printing and tempering stages. The problem aims to simultaneously optimize makespan and the total electricity cost under a time-of-use electricity pricing policy. The glass production has to respect the following environments: (i) the cutting and printing operations are processed in parallel machine environments; (ii) the tempering operation is processed on a batch machine; (iii) machine eligibility and setup time have to be considered in the cutting and printing stages; (iv) the whole manufacturing system is under a time-of-use electricity pricing policy. For the problem, an integer programming model is firstly proposed and shown to be strongly NP-hard. Then a model-based heuristic is adopted and a bi-objective differential evolution algorithm (BODE) is devised based on problem features. Computational experiments on randomly generated instances demonstrated that the BODE outperforms the model-based heuristic in terms of computation time and solution quality. Moreover, with mild increase on computation burden, the BODE significantly outperforms the classic NSGA II in terms of solution quality.     

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。     

Approaches to real world two-dimensional cutting problems

We consider a real world generalization of the 2-Dimensional Guillotine Cutting Stock Problem arising in the wooden board cutting industry. A set of rectangular items has to be cut from rectangular stock boards, available in multiple formats. In addition to the classical objective of trim loss minimization, the problem also asks for the maximization of the cutting equipment productivity, which can be obtained by cutting identical boards in parallel. We present several heuristic algorithms for the problem, explicitly considering the optimization of both objectives. The proposed methods, including fast heuristic algorithms, Integer Linear Programming models and a truncated Branch and Price algorithm, have increasing complexity and require increasing computational effort. Extensive computational experiments on a set of realistic instances from the industry show that high productivity of the cutting equipment can be obtained with a minimal increase in the total area of used boards. The experiments also show that the proposed algorithms perform extremely well when compared with four commercial software tools available for the solution of the problem.     

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.     

An exact semidefinite programming approach for the max-mean dispersion problem

This paper proposes an exact algorithm for the Max-Mean dispersion problem (\(Max-Mean DP\)), an NP-Hard combinatorial optimization problem whose aim is to select the subset of a set such that the average distance between elements is maximized. The problem admits a natural non-convex quadratic fractional formulation from which a semidefinite programming (SDP) relaxation can be derived. This relaxation can be tightened by means of a cutting plane algorithm which iteratively adds the most violated triangular inequalities. The proposed approach embeds the SDP relaxation and the cutting plane algorithm into a branch and bound framework to solve \(Max-Mean DP\) instances to optimality. Computational experiments show that the proposed method is able to solve to optimality in reasonable time instances with up to 100 elements, outperforming other alternative approaches.     

Dynamic Programming and Hill-Climbing Techniques for Constrained Two-Dimensional Cutting Stock Problems

In this paper we propose an algorithm for the constrained two-dimensional cutting stock problem (TDC) in which a single stock sheet has to be cut into a set of small pieces, while maximizing the value of the pieces cut. The TDC problem is NP-hard in the strong sense and finds many practical applications in the cutting and packing area. The proposed algorithm is a hybrid approach in which a depth-first search using hill-climbing strategies and dynamic programming techniques are combined. The algorithm starts with an initial (feasible) lower bound computed by solving a series of single bounded knapsack problems. In order to enhance the first-level lower bound, we introduce an incremental procedure which is used within a top-down branch-and-bound procedure. We also propose some hill-climbing strategies in order to produce a good trade-off between the computational time and the solution quality. Extensive computational testing on problem instances from the literature shows the effectiveness of the proposed approach. The obtained results are compared to the results published by Alvarez-Valdés et al. (2002).     

On cutting stock with due dates

Classical stock cutting calls for fulfilling a given demand of parts, minimizing raw material needs. With the production of each part type regarded as a job due within a specific date, a problem arises of scheduling cutting operations. We here propose an exact integer linear programming formulation, and develop primal heuristics, upper bounds and an implicit enumeration scheme. A computational experience carried out for the one-dimensional problem shows that our primal heuristics outperform known ones, and that the formulation has good features for finding exact solutions of non-trivial instances.     

A PRACTICAL APPROACH TO THE LARGE-SCALE FOREST SCHEDULING PROBLEM*

A large-scale forest cutting schedule problem involving 1166 forest units to be cut over a 24–year planning period is discussed. The problem is formulated as a generalized version of the basic transportation problem. The conversion procedure for such a problem to the standard transportation format is outlined. The proposed approach is then compared with a linear programming decomposition approach on the basis of operating results obtained and computer time required by each approach. It is shown that this new approach will solve a real world problem about 40 times faster than the usual linear programming decomposition approach.     

Benders decomposition for set covering problems

This paper describes Benders decomposition approaches to optimally solve set covering problems “ almost” satisfying the consecutive ones property. The decompositions are based on the fact that set covering problems with consecutive ones property have totally unimodular coefficient matrices. Given a binary matrix, a totally unimodular matrix is enforced by filling up every row with ones between its first and its last non-zero entries. The resulting mistake is handled by introducing additional integer variables whose number depends on the reordering of the columns of the given matrix. This leads us to consider the consecutive block minimization problem. Two cutting plane algorithms are proposed and run on a large set of benchmark instances. The results obtained show that the cutting plane algorithms outperform an existing tree search method designed exclusively for such instances.     

The Ordered Cutting Stock Problem

The one‐dimensional cutting stock problem (CSP) is a classic combinatorial optimization problem in which a number of parts of various lengths must be cut from an inventory of standard‐size material. The classic CSP ensures that the total demand for a given part size is met but ignores the fact that parts produced by a given cutting pattern may be destined for different jobs. As a result, applying the classic CSP in a dynamic production environment may result in many jobs being open (or partially complete) at any point in time—requiring significant material handling or sorting operations. This paper identifies and discusses a new type of one‐dimensional CSP, called the ordered CSP, which explicitly restricts to one the number of jobs in a production process that can be open, or in process, at any given point in time. Given the growing emphasis on mass customization in the manufacturing industry, this restriction can help lead to a reduction in both in‐process inventory levels and material handling activities. A formal mathematical formulation is provided for the new CSP model, and its applicability is discussed with respect to a production problem in the custom door and window manufacturing industry. A genetic algorithm (GA) solution approach is then presented, which incorporates a customized heuristic for reducing scrap levels. Several different production scenarios are considered, and computational results are provided that illustrate the ability of the GA‐based approach to significantly decrease the amount of scrap generated in the production process.     

Energy cost saving starts on the shop floor

This paper describes how one company, the British subsidiary of an American multinational, met the problem of continually rising energy costs with a carefully co-ordinated energy conservation programme. This was linked with a pollution prevention programme and the environment and energy used an equation for cutting costs.     

Protein Threading by Linear Programming: Theoretical Analysis and Computational Results

In a previous paper (Xu, Li, Kim, and Xu, Journal of Bioinformatics and Computational Biology, vol. 1, no. 1, pp. 95–117, 2003), we have used an integer programming approach to implement a protein threading program RAPTOR for protein 3D structure prediction, based on the threading model treating pairwise contacts rigorously and allowing variable gaps. We have solved the integer program by the canonical branch-and-bound method. In this paper we present a branch-and-cut method, a careful theoretical analysis of our formulation and why our approach is so effective. The result of cutting plane analysis is that two types of well-known cuts for this problem are already implied in the constraint set, which provides us some intuition that our formulation would be very effective. Experimental results show that for about 99 percent of real threading instances, the linear relaxations of their integer programs solve to integral optimal solutions directly. For the rest one percent of real instances, the integral solutions can be obtained with only several branch nodes. Experimental results also show that no special template or sequence features result in more possibilities of fractional solutions. This indicates that extra effort to seek for cutting planes to strengthen the existing formulation is unnecessary.