A new heuristic for the flowshop scheduling problem to minimize makespan and maximum tardiness

This paper presents a new heuristic for solving the flowshop scheduling problem that aims to minimize makespan and maximize tardiness. The algorithm is able to take into account the aforementioned performance measures, finding a set of non-dominated solutions representing the Pareto front. This method is based on the integration of two different techniques: a multi-criteria decision-making method and a constructive heuristic procedure developed for makespan minimization in flowshop scheduling problems. In particular, the technique for order preference by similarity of ideal solution (TOPSIS) algorithm is integrated with the Nawaz–Enscore–Ham (NEH) heuristic to generate a set of potential scheduling solutions. To assess the proposed heuristic's performance, comparison with the best performing multi-objective genetic local search (MOGLS) algorithm proposed in literature is carried out. The test is executed on a large number of random problems characterized by different numbers of machines and jobs. The results show that the new heuristic frequently exceeds the MOGLS results in terms of both non-dominated solutions, set quality and computational time. In particular, the improvement becomes more and more significant as the number of jobs in the problem increases.     

A performance evaluation of permutation vs. non-permutation schedules in a flowshop

It has been pointed out that a permutation schedule can be improved by a non-permutation schedule in a flowshop with completion-time based criteria, but there is a lack of comprehensive analyses. This paper presents an extensive computational investigation concerning the performance comparison between permutation and non-permutation schedules. The computational results indicate that in general, there is little improvement made by non-permutation schedules over permutation schedules with respect to completion-time based criteria. But the improvement is significant with respect to due-date based criteria, including total tardiness and total weighted tardiness. The results provide practitioners a guideline as to when to adopt a non-permutation schedule, which may exhibit better performance but require additional computational and control efforts.     

Fabrication and assembly scheduling in a two-machine flowshop

This paper considers a fabrication scheduling problem to minimize the makespan in a two-machine flowshop. Each job has a unique component and a common component to be processed on the first machine. On machine 1, the common components of the jobs are grouped into batches for processing with a setup cost incurred whenever a batch is formed. A job is ready for its assembly operation on the second machine if both its unique and common components are finished on machine 1. The problems with batch availability and item availability are known as NP-hard. In this paper, we give proofs for the strong NP-hardness of the two problems. The results suggest that it is very unlikely to develop polynomial- or pseudo-polynomial-time algorithm for finding exact solutions for the two problems.     

An improved branch and bound procedure for scheduling a flow line manufacturing cell

This paper presents a new branch and bound procedure for scheduling a flow-line manufacturing cell. This procedure and an existing procedure are tested on several problem sets with varying numbers of families, jobs and machines, and varying setup time distributions. The results show that the new procedure solves small problems dramatically faster than the existing procedure. Three heuristic procedures, based on the new branch and bound procedure, are developed. These heuristic procedures as well as a tabu search procedure are tested on problem sets with larger problem sizes. The results show that one of the new procedures generates solutions with improved makespans compared to the tabu search procedure.     

Minimizing the total completion time in a two-machine flowshop problem with time delays

This article proposes to solve the problem of minimizing the total completion time in a two-machine permutation flowshop environment in which time delays between the machines are considered. For this purpose, an enumeration algorithm based on the branch-and-bound framework is developed, which includes new lower and upper bounds as well as dominance rules. The computational study shows that problems with up to 40 jobs can be solved in a reasonable amount of time.     

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.     

Permutation flowshop scheduling with simple linear deterioration

This article addresses permutation flowshop scheduling problems with simple linear deterioration. The objectives are to minimize logarithm of the makespan, total logarithm of the completion time, total weighted logarithm of the completion time, and the sum of the quadratic job logarithms of the completion times. Approximation algorithms and their worst-case bounds are presented and analysed. Branch-and-bound algorithms are also proposed to solve the problems optimally. Computational experiments are performed to illustrate the algorithms.     

Production in a two-machine flowshop scheduling environment with uncertain processing and setup times to minimize makespan

A wide range of uncertainties exists in some real-world production environments which result in uncertain setup and/or processing times. Factors such as crew skills, shortages in equipment and resource breakdowns can be the sources of these uncertainties. This study considers a two-machine production flowshop scheduling problem where both setup and processing times are treated as uncertain variables. The objective is to minimise makespan which is an effective way of resource utilisation. There exists a dominance relation in the literature for the two-machine flowshop scheduling problem with uncertain setup and processing times. However, the dominance relation has not been evaluated. In this study, we evaluate the existing dominance relation. Moreover, a new dominance relation is established and shown to be more effective than the existing one. Furthermore, twenty-five implementations of a polynomial time algorithm are developed. Extensive computational experiments are conducted to evaluate the performance of the implementations of the algorithm. The computational experiments indicate that the overall gap (error) of the best implementation of the algorithm is less than 0.3% when compared to the optimal solution. Moreover, the performance of this implementation of the algorithm is the best one when compared to the remaining implementations for all the considered experimental environments. Additionally, the performance of this implementation of the algorithm is shown to be insensitive to the uncertainty in setup times.     

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.     

Assessing scheduling policies in a permutation flowshop with common due dates

This paper focuses onto a situation arising in most real-life manufacturing environments when scheduling has to be performed periodically. In such a scenario, different scheduling policies can be adopted, being perhaps the most common to assume that, once a set of jobs has been scheduled, their schedule cannot be modified (‘frozen’ schedule). This implies that, when the next set of jobs is to be scheduled, the resources may not be fully available. Another option is assuming that the schedule of the previously scheduled jobs can be modified as long as it does not violate their due date, which has been already possibly committed to the customer. This policy leads to a so-called multi-agent scheduling problem. The goal of this paper is to discern when each policy is more suitable for the case of a permutation flowshop with common due dates. To do so, we carry out an extensive computational study in a test bed specifically designed to control the main factors affecting the policies, so we analyse the solution space of the underlying scheduling problems. The results indicate that, when the due date of the committed jobs is tight, the multi-agent approach does not pay off in view of the difficulty of finding feasible solutions. Moreover, in such cases, the policy of ‘freezing’ the schedule of the jobs leads to a very simple scheduling problem with many good/acceptable solutions. In contrast, when the due date has a medium/high slack, the multi-agent approach is substantially better. Nevertheless, in this latter case, in order to perceive the full advantage of this policy, powerful solution procedures have to be designed, as the structure of the solution space of the latter problem makes extremely hard to find optimal/good solutions.     

Minimizing the makespan for the two-machine scheduling problem with a single server: Two algorithms for very large instances

This article considers the problem of scheduling a given set of n jobs on two identical parallel machines with a single server. Each job must be processed on one of the machines. Before processing, the server has to set up the relevant machine. The objective is to minimize the makespan. For this unary NP-hard problem, two fast constructive algorithms with a complexity of O(n²) are presented. The performance of these algorithms is evaluated for instances with up to 10,000 jobs. Computational results indicate that the algorithms have an excellent performance for very large instances so that the obtained objective function values are very close to a lower bound, and in many cases even an optimal solution is achieved. Superiority over all existing algorithms is obtained by sequencing the jobs on the two machines so that the machine idle time and the server waiting time are minimized. In doing so, the characteristics of an optimal solution resulting from its relevant lower bound are taken into account.     

Green permutation flowshop scheduling problem with sequence-dependent setup times: a case study

Increasing global energy consumption, large variations in its cost and the environmental degradation effects are good reasons for the manufacturing industries to become greener. Green shop floor scheduling is increasingly becoming a vital factor in the sustainable manufacturing. In this paper, a green permutation flowshop scheduling problem with sequence-dependent setup times is studied. Two objectives are considered including minimisation of makespan as a measure of service level and minimisation of total energy consumption as a measure of environmental sustainability. We extend a bi-objective mixed-integer linear programming model to formulate the stated problem. We develop a constructive heuristic algorithm to solve the model. The constructive heuristic algorithm includes iterated greedy (CHIG) and local search (CHLS) algorithms. We develop an efficient energy-saving method which decreases energy consumption, on average, by about 15%. To evaluate the effectiveness of the constructive heuristic algorithm, we compare it with the famous augmented ?-constraint method using various small-sized and large-sized problems. The results confirm that the heuristic algorithm obtains high-quality non-dominated solutions in comparison with the augmented ?-constraint method. Also, they show that the CHIG outperforms the CHLS. Finally, this paper follows a case-study, with in-depth analysis of the model and the constructive heuristic algorithm.     

A note on minimising total absolute deviation of job completion times on a two-machine no-wait proportionate flowshop

A popular measure used in service systems is that of total absolute deviation of job completion times (TADC). It is relevant to settings where the objective is to balance the level of service provided to different customers. During the last decade, TADC has been studied in various machine settings, and under various assumptions on the job processing times. In this note, we study TADC on a two-machine no-wait proportionate flow shop, i.e. a flow shop with machine-independent processing times, and with no buffer between the machines. A very surprising and unique result is introduced: a simple index policy (the well-known largest processing time (LPT) first sequence) is shown to be optimal for instances of no more than seven jobs. This property does not hold for larger instances. We show that for instances of eight and nine jobs, there are exactly two schedules which are candidates for optimality. For the 10-job instance, the number of candidates increases. This uncommon behaviour of the optimal solution and, consequently, the complexity of the problem studied here, remain open questions, and are challenging topics for future research.     

An improved memetic algorithm based on a dynamic neighbourhood for the permutation flowshop scheduling problem

The permutation flowshop scheduling problem (PFSP) has been extensively studied in the scheduling literature. In this paper, we present an improved memetic algorithm (MA) to solve the PFSP to minimise the total flowtime. In the proposed MA, we develop a stochastic local search based on a dynamic neighbourhood derived from the NEH method. During the evolution process, the size of the neighbourhood is dynamically adjusted to change the search focus from exploration to exploitation. In addition, we introduce a new population generation mechanism to guarantee both the quality and diversity of the new populations. We also design a diversity index for the population to monitor the diversity of the current population. If the diversity index is less than a given threshold value, the current population will be replaced by a new one with good diversity so that the proposed MA has good ability to overcome local optima. We conduct computational experiments to test the effectiveness of the proposed algorithm. The computational results on randomly generated problem instances and benchmark problem instances show that the proposed MA is effective and superior or comparable to other algorithms in the literature.     

Permutation flow-shop scheduling problem to optimize a quadratic objective function

A flow-shop scheduling model enables appropriate sequencing for each job and for processing on a set of machines in compliance with identical processing orders. The objective is to achieve a feasible schedule for optimizing a given criterion. Permutation is a special setting of the model in which the processing order of the jobs on the machines is identical for each subsequent step of processing. This article addresses the permutation flow-shop scheduling problem to minimize the criterion of total weighted quadratic completion time. With a probability hypothesis, the asymptotic optimality of the weighted shortest processing time schedule under a consistency condition (WSPT-CC) is proven for sufficiently large-scale problems. However, the worst case performance ratio of the WSPT-CC schedule is the square of the number of machines in certain situations. A discrete differential evolution algorithm, where a new crossover method with multiple-point insertion is used to improve the final outcome, is presented to obtain high-quality solutions for moderate-scale problems. A sequence-independent lower bound is designed for pruning in a branch-and-bound algorithm for small-scale problems. A set of random experiments demonstrates the performance of the lower bound and the effectiveness of the proposed algorithms.     

A heuristic model for dynamic flexible job shop scheduling problem considering variable processing times

In real scheduling problems, unexpected changes may occur frequently such as changes in task features. These changes cause deviation from primary scheduling. In this article, a heuristic model, inspired from Artificial Bee Colony algorithm, is proposed for a dynamic flexible job-shop scheduling (DFJSP) problem. This problem consists of n jobs that should be processed by m machines and the processing time of jobs deviates from estimated times. The objective is near-optimal scheduling after any change in tasks in order to minimise the maximal completion time (Makespan). In the proposed model, first, scheduling is done according to the estimated processing times and then re-scheduling is performed after determining the exact ones considering machine set-up. In order to evaluate the performance of the proposed model, some numerical experiments are designed in small, medium and large sizes in different levels of changes in processing times and statistical results illustrate the efficiency of the proposed algorithm.     

A hybrid flowshop scheduling problem for a cold treating process in seamless steel tube production

Seamless steel tubes often have various categories and specifications, which further require complicated operations in production, especially in the cold treating process (CTP). This paper investigates the scheduling problem using the seamless tube plant of Baoshan Iron and Steel Complex as a study background. By considering the practical production constraints such as sequence-dependent setup times, maintenance schedule, intermediate material buffers, job-machine matches, we formulate the hybrid flowshop scheduling problem with a non-linear mixed integer programming model (NMIP). In addition, our model provides a flexibility to remove the permutation assumption, which is often a limitation in early studies. In order to obtain the solution of the above NMIP problem, a two-stage heuristic algorithm is proposed and it combines a modified genetic algorithm and a local search method. With real production instances, our computation experiments indicate that the proposed algorithm is efficient and it outperforms several other approaches. Industrial implementation also shows that such a scheduling tool brings a cost saving of more than 10% and it substantially reduces the computation time. Our study also illustrates the need of relaxing permutation assumption in such a scheduling problem with complicated operation sequences.     

No-wait scheduling of a two-machine flow-shop to minimise the makespan under non-availability constraints and different release dates

In this paper, we consider the two-machine no-wait flow-shop scheduling problem, when every machine is subject to one non-availability constraint and jobs have different release dates. The non-availability intervals of the machines overlap and they are known in advance. We aim to find a non-resumable schedule that minimises the makespan. We propose several lower bounds and upper bounds. These bounding procedures are used in a branch-and-bound algorithm. Computational experiments are carried out on a large set of instances and the obtained results show the effectiveness of our method.     

A genetic algorithm based approach for scheduling of jobs containing multiple orders in a three-machine flowshop

This paper investigates a new scheduling problem of multiple orders per job (MOJ) in a three-machine flowshop consisting of an item-processing machine, a lot-processing machine and a batch-processing machine, for a semiconductor manufacturing operation that must form a layer on the wafers. The three-machine flowshop MOJ scheduling problem deals with sequencing customer orders, assigning orders to jobs, and then combining the formed jobs into batches. Genetic algorithms are presented for this scheduling problem to minimise the total weighted tardiness (TWT), in the presence of non-zero order ready times, different order due dates, different order weights and unequal order sizes. Extensive experiments were performed to compare the proposed genetic algorithm (GA)-based approach with the benchmark heuristics presented in previous studies. The experiments led to the conclusions that the GA-based approach is significantly superior over other heuristics in terms of TWT and can find near-optimal solutions in an acceptable amount of computation time.