The equipment maintenance scheduling problem in a coal production system

This paper addresses an equipment maintenance scheduling problem in a coal production system which includes three consecutive stages: the coal mining stage, the coal washing stage and the coal loading stage. Each stage is composed of different equipment that needs maintenance each day. There exists intermediate storage with finite capacities and the finished products are transported by train. Moreover, some equipment has a different preference for (aversion to) the start time of maintenance (STOM). The objective is to minimise the weighted sum of aversion about STOM, changeover times and train waiting time. We first formulate this problem into a mixed integer linear programming (MILP) model, then a hybrid genetic algorithm (HGA) is proposed to solve it. The proposed method has been tested on a practical coal enterprise in China and some randomly generated instances. Computational results indicate that our algorithm can produce near-optimal solutions efficiently.     

Mathematical models and a hunting search algorithm for the no-wait flowshop scheduling with parallel machines

Majority of researches in no-wait flowshop scheduling assume that there is only one machine at each stage. But, factories commonly duplicate machines in parallel for each operation. In this case, they balance the speed of the stages, increase the throughput of the shop floor and reduce the impact of bottleneck stages. Despite their importance, there is no paper to study the general no-wait flowshop with parallel machines. This paper studies this problem where the objective is to minimise makespan. Since there is no mathematical model for the problem, we first mathematically formulate it in form of two mixed integer linear programming models. By the models, the small instances are optimally solved. We then propose a novel hunting search metaheuristic algorithm (HSA) to solve large instances of the problem. HSA is derived based on a model of group hunting of animals when searching for food. A set of experimental instances are carried out to evaluate the algorithm. The algorithm is carefully evaluated for its performance against an available algorithm by means of statistical tools. The related results show that the proposed HSA provides sound performance comparing with other algorithms.     

Comparisons of bi-objective genetic algorithms for hybrid flowshop scheduling with sequence-dependent setup times

This paper addresses the scheduling problems in a hybrid flowshop with two objectives of minimising the makespan and total tardiness. Since this problem is NP-hard, evolutionary algorithms based on the genetic algorithm (GA) namely; BOGAW, BOGAC, BOGAT, and BOGAS are proposed for searching the Pareto-optimal frontier. In these algorithms, we propose to generate a section of solutions for the next generation using a neighbourhood search structure on the best individual in each generation. The selection procedure selects the best chromosome based on an evaluation mechanism used in the algorithm (i.e., weighted sum, crowding distance, TOPSIS and single-objective). The aim of this paper is to clarify that the cited characteristic is efficient and it enhances the efficiency of algorithms. Therefore, we perform a comparison between the proposed algorithms to find the best alternative. Data envelopment analysis is used to evaluate the performance of approximation methods. The obtained result from the comparison shows that, BOGAC is the more efficient. To continue, since the efficiency of our idea is not clear, we compare our efficient algorithm with other efficient algorithms in the literature (namely PGA-ALS and MOGLS). The final persuasive results support the idea that BOGAC in comparison with PGA-ALS and MOGLS is more effective and efficient.     

Mathematical modelling and optimisation of energy-conscious hybrid flow shop scheduling problem with unrelated parallel machines

This paper investigates an energy-conscious hybrid flow shop scheduling problem with unrelated parallel machines (HFSP-UPM) with the energy-saving strategy of turning off and on. We first analyse the energy consumption of HFSP-UPM and formulate five mixed integer linear programming (MILP) models based on two different modelling ideas namely idle time and idle energy. All the models are compared both in size and computational complexities. The results show that MILP models based on different modelling ideas vary dramatically in both size and computational complexities. HFSP-UPM is NP-Hard, thus, an improved genetic algorithm (IGA) is proposed. Specifically, a new energy-conscious decoding method is designed in IGA. To evaluate the proposed IGA, comparative experiments of different-sized instances are conducted. The results demonstrate that the IGA is more effective than the genetic algorithm (GA), simulating annealing algorithm (SA) and migrating birds optimisation algorithm (MBO). Compared with the best MILP model, the IGA can get the solution that is close to an optimal solution with the gap of no more than 2.17% for small-scale instances. For large-scale instances, the IGA can get a better solution than the best MILP model within no more than 10% of the running time of the best MILP model.     

A bounded-search iterated greedy algorithm for the distributed permutation flowshop scheduling problem

As the interest of practitioners and researchers in scheduling in a multi-factory environment is growing, there is an increasing need to provide efficient algorithms for this type of decision problems, characterised by simultaneously addressing the assignment of jobs to different factories/workshops and their subsequent scheduling. Here we address the so-called distributed permutation flowshop scheduling problem, in which a set of jobs has to be scheduled over a number of identical factories, each one with its machines arranged as a flowshop. Several heuristics have been designed for this problem, although there is no direct comparison among them. In this paper, we propose a new heuristic which exploits the specific structure of the problem. The computational experience carried out on a well-known testbed shows that the proposed heuristic outperforms existing state-of-the-art heuristics, being able to obtain better upper bounds for more than one quarter of the problems in the testbed.     

A differential evolution algorithm for the no-idle flowshop scheduling problem with total tardiness criterion

In this paper, we investigate the use of a continuous algorithm for the no-idle permutation flowshop scheduling (NIPFS) problem with tardiness criterion. For this purpose, a differential evolution algorithm with variable parameter search (vpsDE) is developed to be compared to a well-known random key genetic algorithm (RKGA) from the literature. The motivation is due to the fact that a continuous DE can be very competitive for the problems where RKGAs are well suited. As an application area, we choose the NIPFS problem with the total tardiness criterion in which there is no literature on it to the best of our knowledge. The NIPFS problem is a variant of the well-known permutation flowshop (PFSP) scheduling problem where idle time is not allowed on machines. In other words, the start time of processing the first job on a given machine must be delayed in order to satisfy the no-idle constraint. The paper presents the following contributions. First of all, a continuous optimisation algorithm is used to solve a combinatorial optimisation problem where some efficient methods of converting a continuous vector to a discrete job permutation and vice versa are presented. These methods are not problem specific and can be employed in any continuous algorithm to tackle the permutation type of optimisation problems. Secondly, a variable parameter search is introduced for the differential evolution algorithm which significantly accelerates the search process for global optimisation and enhances the solution quality. Thirdly, some novel ways of calculating the total tardiness from makespan are introduced for the NIPFS problem. The performance of vpsDE is evaluated against a well-known RKGA from the literature. The computational results show its highly competitive performance when compared to RKGA. It is shown in this paper that the vpsDE performs better than the RKGA, thus providing an alternative solution approach to the literature that the RKGA can be well suited.     

Fuzzy-metaheuristic methods to solve a hybrid flow shop scheduling problem with pre-assignment

This paper deals with a particular version of the hybrid flow shop scheduling problem inspired from a real application in the automotive industry. Specific constraints such as pre-assigned jobs, non-identical parallel machines and non-compatibility between certain jobs and machines are considered in order to minimise the total tardiness time. A mixed-integer programming model that incorporates these aspects is developed and solved using ILOG Cplex software. Thus, because of the computation time constraint, we propose approximate resolution methods based on genetic and particle swarm optimisation algorithms coupled or not with fuzzy logic control. The effectiveness of these methods is investigated via computational experiments based on theoretical and real case instances. The obtained results show that fuzzy logic control improves the performances of both genetic and particle swarm optimisation algorithms significantly.     

Synchronisation of production scheduling and shipment in an assembly flowshop

This paper studies a synchronised scheduling problem of production simultaneity and shipment punctuality in a two-stage assembly flowshop system. Production simultaneity seeks to ensure all products belonging to a same customer order are simultaneously completed (at least as close as possible). Shipment punctuality attempts to satisfy orders’ individual shipment due dates. We provide two criteria, i.e. mean longest waiting duration and mean earliness and tardiness, for measuring production simultaneity and shipment punctuality, respectively. A synchronised scheduling model is developed by balancing the two criteria using linear weighted sum method. A modified genetic algorithm (GA) is then proposed for solving this model. Numerical studies demonstrate the effectiveness of the proposed approach. The results indicate that considering production simultaneity can remarkably reduce finished products inventory. A prioritised weight combination interval for production simultaneity and shipment punctuality has been suggested. Production simultaneity is affected by the production system configuration, especially in peak seasons.     

A modified harmony search algorithm for the multi-objective flowshop scheduling problem with due dates

This paper presents a modified harmony search optimisation algorithm (MHSO), specifically designed to solve two- and three-objective permutation flowshop scheduling problems, with due dates. To assess its capability, five sets of scheduling problems have been used to compare the MHSO with a known and highly efficient genetic algorithm (GA) chosen as the benchmark. Obtained results show that the new procedure is successful in exploring large regions of the solution space and in finding a significant number of Pareto non-dominated solutions. For those cases where the exhaustive evaluation of sequences can be applied the algorithm is able to find the whole non-dominated Pareto border, along with a considerable number of solutions that share the same optimal values for the considered optimisation parameters. To validate the algorithm, five sets of scheduling problems are investigated in-depth in comparison with the GA. Results obtained by both methods (exhaustive solutions have been provided as well for small sized problems) are fully described and discussed.     

More MILP models for hybrid flow shop scheduling problem and its extended problems

With the rapid development of computer technology and related softwares for mathematical models, mathematical modelling of scheduling problems is receiving growing attention from researchers. In this work, the hybrid flow shop scheduling problem with unrelated parallel machines (HFSP-UPM) with the objective aimed to minimise the makespan is studied. According to the characteristics of the HFSP-UPM, eight mixed integer linear programming (MILP) models are formulated in order to obtain optimal solutions based on different modelling ideas. Then, these models are extended to solve HFSP-UPM with sequence-dependent setup times (HFSP-UPM-SDST), no-wait HFSP-UPM (HFSP-UPM-NW) and HFSP-UPM with blocking (HFSP-UPM-B). All the proposed models and the existing model are detailedly compared and evaluated under three aspects namely modelling process, size complexity and computational complexity. Numerical experiments show that MILP models dependent on diverse modelling ideas perform very differently. The model developed based on stage precedence is the best one and should be given preference in future applications. In addition, the proposed models of HFSP-UPM-NW and HFSP-UPM-B improve several best known solutions for the test instances in the existing literature.     

Coordinated scheduling of production and transportation in a two-stage assembly flowshop

To enhance the overall performance of supply chains, coordination among production and distribution stages has recently received an increasing interest. This paper considers the coordinated scheduling of production and transportation in a two-stage assembly flowshop environment. In this problem, product components are first produced and assembled in a two-stage assembly flowshop, and then completed final products are delivered to a customer in batches. Considering the NP-hard nature of this scheduling problem, two fast heuristics (SPT-based heuristic and LPT-based heuristic) and a new hybrid meta-heuristic (HGA-OVNS) are presented to minimise the weighted sum of average arrival time at the customer and total delivery cost. To guide the search process to more promising areas, the proposed HGA-OVNS integrates genetic algorithm with variable neighbourhood search (VNS) to generate the offspring individuals. Furthermore, to enhance the effectiveness of VNS, the opposition-based learning (OBL) is applied to establish some novel opposite neighbourhood structures. The proposed algorithms are validated on a set of randomly generated instances, and the computation results indicate the superiority of HGA-OVNS in quality of solutions.     

A novel imperialist competitive algorithm for bi-criteria scheduling of the assembly flowshop problem

This paper deals with the two-stage assembly flowshop scheduling problem with minimisation of weighted sum of makespan and mean completion time as the objective. The problem is NP-hard, hence we proposed a meta-heuristic named imperialist competitive algorithm (ICA) to solve it. Since appropriate design of the parameters has a significant impact on the algorithm efficiency, we calibrate the parameters of this algorithm using the Taguchi method. In comparison with the best algorithm proposed previously, the ICA indicates an improvement. The results have been confirmed statistically.     

Hybrid genetic algorithm for test bed scheduling problems

In this paper, we address the scheduling problem for a heavy industry company which provides ship engines for shipbuilding companies. Before being delivered to customers, ship engines are assembled, tested and disassembled on the test beds. Because of limited test bed facilities, it is impossible for the ship engine company to satisfy all customers’ orders. Therefore, they must select the orders that can be feasibly scheduled to maximise profit. An integer programming model is developed for order selection and test bed scheduling but it cannot handle large problems in a reasonable amount of time. Consequently, a hybrid genetic algorithm (GA) is suggested to solve the developed model. Several experiments have been carried out to demonstrate the performance of the proposed hybrid GA in scheduling test beds. The results show that the hybrid GA performs with an outstanding run-time and small errors in comparison with the integer programming model.     

Applying a hybrid simulated annealing and tabu search approach to non-permutation flowshop scheduling problems

Researchers have indicated that a permutation schedule can be improved by a non-permutation schedule in a flowshop with completion time-based criteria, such as makespan and total completion time. This study proposes a hybrid approach which draws on the advantages of simulated annealing and tabu search for the non-permutation flowshop scheduling problem, in which the objective function is the makespan of the schedule. To verify the effectiveness of the proposed hybrid approach, computational experiments are performed on a set of well-known non-permutation flowshop scheduling benchmark problems. The result shows that the performance of the hybrid approach is better than that of other approaches, including ant colony optimisation, simulated annealing, and tabu search. Further, the proposed approach found new upper bound values for all benchmark problems within a reasonable computational time.     

Algorithms for the joint multitasking scheduling and common due date assignment problem

In this paper, we investigate a joint multitasking scheduling and common due date assignment problem on a single machine, for which examples can be found in product delivery process in logistics. Multitasking allows the machine to perform multiple tasks. The multitasking phenomenon has been observed in various practical domains, including manufacturing and administration. In multitasking settings, each waiting job interrupts a currently in-processing job, causing an interruption time and a switching time. In common due date assignment problems, the objective is to determine the optimal value of this due date with the purpose of minimising a total penalty function, which is associated with service quality. For the problem with general interruption functions, analytical properties are obtained to reduce the search space of the optimal solutions. For the cases with linear interruption functions, we develop a polynomial-time algorithm. Numerical experiments have been conducted to validate the efficiency of our proposed algorithm. Computational results also demonstrate an interesting phenomenon that in some cases, the optimal solutions under multitasking are superior to the counterparts without multitasking. Besides, we also devise a mixed integer programme for the cases with linear interruption function.     

Lagrangian relaxation and cut generation for sequence-dependent setup time flowshop scheduling problems to minimise the total weighted tardiness

The Lagrangian relaxation and cut generation technique is applied to solve sequence-dependent setup time flowshop scheduling problems to minimise the total weighted tardiness. The original problem is decomposed into individual job-level subproblems that can be effectively solved by dynamic programming. Two types of additional constraints for the violation of sequence-dependent setup time constraints are imposed on the decomposed subproblems in order to improve the lower bound. The decomposed subproblem with the additional setup time constraints on any subset of jobs is also effectively solved by a novel dynamic programming. Computational results show that the lower bound derived by the proposed method is much better than those of CPLEX and branch and bound for problem instances with 50 jobs and five stages with less computational effort.     

Workload simulation and optimisation in multi-criteria hybrid flowshop scheduling: a case study

This paper studies a real-life multiple objective flowshop scheduling problem in a cardboard company which differs from the conventional flowshop scheduling problem in several aspects, such as multi-machine stations, sequence-dependent setup times, work calendars on resources, re-entrant flows, external operations, and transfer batches between stations. A simulation-based environment is presented in which the production sequence can be interactively chosen by the user or found by a tabu-search based heuristic algorithm while a discrete-event simulation deals with the timing aspect.     

Synchronisation of scarce resources for a parallel machine lotsizing problem

In this paper we present a novel approach to tackling the synchronisation of a secondary resource in lot-sizing and scheduling problems. This kind of problem occurs in various manufacturing processes (e.g. wafer testing in the semiconductor industry, production and bottling of soft drinks). We consider a scenario of parallel unrelated machines that have to be equipped with a tool or need a special kind of resource for processing. Our approach allows tracing the assignment of these secondary resources across different machines and synchronising their usage independently of the time period. We present extensions of the general lot-sizing and scheduling problem and of the capacitated lot-sizing problem. We prove that the latter model is a special case of the first, but it performs computationally much better.