Robust capacity planning in semiconductor manufacturing

We present a stochastic programming approach to capacity planning under demand uncertainty in semiconductor manufacturing. Given multiple demand scenarios together with associated probabilities, our aim is to identify a set of tools that is a good compromise for all these scenarios. More precisely, we formulate a mixed‐integer program in which expected value of the unmet demand is minimized subject to capacity and budget constraints. This is a difficult two‐stage stochastic mixed‐integer program which cannot be solved to optimality in a reasonable amount of time. We instead propose a heuristic that can produce near‐optimal solutions. Our heuristic strengthens the linear programming relaxation of the formulation with cutting planes and performs limited enumeration. Analyses of the results in some real‐life situations are also presented. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

A heuristic with tie breaking for certain 0–1 integer programming models

A heuristic for 0–1 integer programming is proposed that features a specific rule for breaking ties that occur when attempting to determine a variable to set to 1 during a given iteration. It is tested on a large number of small- to moderate-sized randomly generated generalized set-packing models. Solutions are compared to those obtained using an existing well-regarded heuristic and to solutions to the linear programming relaxations. Results indicate that the proposed heuristic outperforms the existing heuristic except for models in which the number of constraints is large relative to the number of variables. In this case, it performs on par with the existing heuristic. Results also indicate that use of a specific rule for tie breaking can be very effective, especially for low-density models in which the number of variables is large relative to the number of constraints.     

An integer programming model for the weekly tour scheduling problem

We study a workforce planning and scheduling problem in which weekly tours of agents must be designed. Our motivation for this study comes from a call center application where agents serve customers in response to incoming phone calls. Similar to many other applications in the services industry, the demand for service in call centers varies significantly within a day and among days of the week. In our model, a weekly tour of an agent consists of five daily shifts and two days off, where daily shifts within a tour may be different from each other. The starting times of any two consecutive shifts, however, may not differ by more than a specified bound. Furthermore, a tour must also satisfy constraints regarding the days off, for example, it may be required that one of the days off is on a weekend day. The objective is to determine a collection of weekly tours that satisfy the demand for agents' services, while minimizing the total labor cost of the workforce. We describe an integer programming model where a weekly tour is obtained by combining seven daily shift scheduling models and days‐off constraints in a network flow framework. The model is flexible and can accommodate different daily models with varying levels of detail. It readily handles different days‐off rules and constraints regarding start time differentials in consecutive days. Computational results are also presented. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48: 607–624, 2001.     

Lagrangian relaxation approach to the targeting problem

In this paper, we consider a new weapon–target allocation problem with the objective of minimizing the overall firing cost. The problem is formulated as a nonlinear integer programming model. We applied Lagrangian relaxation and a branch‐and‐bound method to the problem after transforming the nonlinear constraints into linear ones. An efficient primal heuristic is developed to find a feasible solution to the problem to facilitate the procedure. In the branch‐and‐bound method, three different branching rules are considered and the performances are evaluated. Computational results using randomly generated data are presented. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 640–653, 1999     

Capacitated lot‐sizing and scheduling with parallel machines,back‐orders,and setup carry‐over

We address the capacitated lot‐sizing and scheduling problem with setup times, setup carry‐over, back‐orders, and parallel machines as it appears in a semiconductor assembly facility. The problem can be formulated as an extension of the capacitated lot‐sizing problem with linked lot‐sizes (CLSPL). We present a mixed integer (MIP) formulation of the problem and a new solution procedure. The solution procedure is based on a novel “aggregate model,” which uses integer instead of binary variables. The model is embedded in a period‐by‐period heuristic and is solved to optimality or near‐optimality in each iteration using standard procedures (CPLEX). A subsequent scheduling routine loads and sequences the products on the parallel machines. Six variants of the heuristic are presented and tested in an extensive computational study. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

A two‐echelon inventory‐location problem with service considerations

We study the problem of designing a two‐echelon spare parts inventory system consisting of a central plant and a number of service centers each serving a set of customers with stochastic demand. Processing and storage capacities at both levels of facilities are limited. The manufacturing process is modeled as a queuing system at the plant. The goal is to optimize the base‐stock levels at both echelons, the location of service centers, and the allocation of customers to centers simultaneously, subject to service constraints. A mixed integer nonlinear programming model (MINLP) is formulated to minimize the total expected cost of the system. The problem is NP‐hard and a Lagrangian heuristic is proposed. We present computational results and discuss the trade‐off between cost and service. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

A parallel machine replacement model

This paper considers a finite horizon parallel machine replacement problem where a fixed number of machines is in operation at all times. The operating cost for a machine goes up as the machine gets older. An older machine may have to be replaced by a new one when its operating cost becomes too high. There is a fixed order cost associated with the purchase of new machines. Machine purchase prices and salvage values may depend on the period in which they were purchased. The objective is to find a replacement plan that minimizes the total discounted cost over the problem horizon. We believe that the costs in our model are more commonly observed in practice than those previously used in the literature. The paper develops properties of optimal solutions and an efficient forward‐time algorithm to find an optimal replacement plan. A dominance property is developed that further limits the options to be considered, and a simple forecast horizon result is also presented. Future research possibilities are mentioned. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 275–287, 2002; Published online in Wiley InterScience (http://www.interscience.wiley.com). DOI 10.1002/nav.10012     

Dynamic programming approaches to the multiple criteria knapsack problem

We study the integer multiple criteria knapsack problem and propose dynamic‐programming‐based approaches to finding all the nondominated solutions. Different and more complex models are discussed, including the binary multiple criteria knapsack problem, problems with more than one constraint, and multiperiod as well as time‐dependent models. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 57–76, 2000     

Parallel machine scheduling with batch deliveries to minimize total flow time and delivery cost

Motivated by the flow of products in the iron and steel industry, we study an identical and parallel machine scheduling problem with batch deliveries, where jobs finished on the parallel machines are delivered to customers in batches. Each delivery batch has a capacity and incurs a cost. The objective is to find a coordinated production and delivery schedule that minimizes the total flow time of jobs plus the total delivery cost. This problem is an extension of the problem considered by Hall and Potts, Ann Oper Res 135 (2005) 41–64, who studied a two‐machine problem with an unbounded number of transporters and unbounded delivery capacity. We first provide a dynamic programming algorithm to solve a special case with a given job assignment to the machines. A heuristic algorithm is then presented for the general problem, and its worst‐case performance ratio is analyzed. The computational results show that the heuristic algorithm can generate near‐optimal solutions. Finally, we offer a fully polynomial‐time approximation scheme for a fixed number of machines. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 492–502, 2016     

Coordinated replenishments from multiple suppliers with price discounts

In this study we present an integer programming model for determining an optimal inbound consolidation strategy for a purchasing manager who receives items from several suppliers. The model considers multiple suppliers with limited capacity, transportation economies, and quantity discounts. We propose an integrated branch and bound procedure for solving the model. This procedure, applied to a Lagrangean dual at every node of the search tree, combines the subgradient method with a primal heuristic that interact to change the Lagrangean multipliers and tighten the upper and lower bounds. An enhancement to the branch and bound procedure is developed using surrogate constraints, which is found to be beneficial for solving large problems. We report computational results for a variety of problems, with as many as 70,200 variables and 3665 constraints. Computational testing indicates that our procedure is significantly faster than the general purpose integer programming code OSL. A regression analysis is performed to determine the most significant parameters of our model. © 1998 John Wiley & Sons, Inc. Naval Research Logistics 45: 579–598, 1998     

An integer programming algorithm for portfolio selection with fixed charges

A mean-variance portfolio selection model with limited diversification is formulated in which transaction and management costs are incorporated as the sum of a linear cost and a fixed cost. The problem is a fixed charge integer programming problem solved by hypersurface search using dynamic programming. Fathoming is performed in the forward pass of dynamic programming so that values of the state variable which correspond to infeasible solutions are eliminated from the tables. This logic permits the solution of problems with 20–30 possible investments.     

A specially structured nonlinear integer resource allocation problem

We present an algorithm for solving a specially structured nonlinear integer resource allocation problem. This problem was motivated by a capacity planning study done at a large Health Maintenance Organization in Texas. Specifically, we focus on a class of nonlinear resource allocation problems that involve the minimization of a convex function over one general convex constraint, a set of block diagonal convex constraints, and bounds on the integer variables. The continuous variable problem is also considered. The continuous problem is solved by taking advantage of the structure of the Karush‐Kuhn‐Tucker (KKT) conditions. This method for solving the continuous problem is then incorporated in a branch and bound algorithm to solve the integer problem. Various reoptimization results, multiplier bounding results, and heuristics are used to improve the efficiency of the algorithms. We show how the algorithms can be extended to obtain a globally optimal solution to the nonconvex version of the problem. We further show that the methods can be applied to problems in production planning and financial optimization. Extensive computational testing of the algorithms is reported for a variety of applications on continuous problems with up to 1,000,000 variables and integer problems with up to 1000 variables. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 770–792, 2003.     

A novel modeling approach for express package carrier planning

Express package carrier networks have large numbers of heavily‐interconnected and tightly‐constrained resources, making the planning process difficult. A decision made in one area of the network can impact virtually any other area as well. Mathematical programming therefore seems like a logical approach to solving such problems, taking into account all of these interactions. The tight time windows and nonlinear cost functions of these systems, however, often make traditional approaches such as multicommodity flow formulations intractable. This is due to both the large number of constraints and the weakness of the linear programming (LP) relaxations arising in these formulations. To overcome these obstacles, we propose a model in which variables represent combinations of loads and their corresponding routings, rather than assigning individual loads to individual arcs in the network. In doing so, we incorporate much of the problem complexity implicitly within the variable definition, rather than explicitly within the constraints. This approach enables us to linearize the cost structure, strengthen the LP relaxation of the formulation, and drastically reduce the number of constraints. In addition, it greatly facilitates the inclusion of other stages of the (typically decomposed) planning process. We show how the use of templates, in place of traditional delayed column generation, allows us to identify promising candidate variables, ensuring high‐quality solutions in reasonable run times while also enabling the inclusion of additional operational considerations that would be difficult if not impossible to capture in a traditional approach. Computational results are presented using data from a major international package carrier. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

Cyclic preference scheduling for nurses using branch and price

This paper presents a new methodology to solve the cyclic preference scheduling problem for hourly workers. The focus is on nurse rostering but is applicable to any organization in which the midterm scheduling decision must take into account a complex of legal, institutional, and preferential constraints. The objective is to strike a balance between satisfying individual preferences and minimizing personnel costs. The common practice is to consider each planning period independently and to generate new rosters at the beginning of each. To reduce some of the instability in the process, there is a growing trend toward cyclic schedules, which are easier to manage and are generally perceived to be more equitable. To address this problem, a new integer programming model is presented that combines the elements of both cyclic and preference scheduling. To find solutions, a branch‐and‐price algorithm is developed that makes use of several branching rules and an extremely effective rounding heuristic. A unique feature of the formulation is that the master problem contains integer rather than binary variables. Computational results are reported for problem instances with up to 200 nurses. Most were solved within 10 minutes and many within 3 minutes when a double aggregation approach was applicable. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2007.     

Cyclic best first search: Using contours to guide branch‐and‐bound algorithms

The cyclic best‐first search (CBFS) strategy is a recent search strategy that has been successfully applied to branch‐and‐bound algorithms in a number of different settings. CBFS is a modification of best‐first search (BFS) that places search tree subproblems into contours which are collections of subproblems grouped in some way, and repeatedly cycles through all non‐empty contours, selecting one subproblem to explore from each. In this article, the theoretical properties of CBFS are analyzed for the first time. CBFS is proved to be a generalization of all other search strategies by using a contour definition that explores the same sequence of subproblems as any other search strategy. Further, a bound is proved between the number of subproblems explored by BFS and the number of children generated by CBFS, given a fixed branching strategy and set of pruning rules. Finally, a discussion of heuristic contour‐labeling functions is provided, and proof‐of‐concept computational results for mixed‐integer programming problems from the MIPLIB 2010 database are shown. © 2017 Wiley Periodicals, Inc. Naval Research Logistics, 64: 64–82, 2017     

Radar pulse interleaving for multi‐target tracking

In a multifunction radar, the maximum number of targets that can be managed or tracked is an important performance measure. Interleaving algorithms developed to operate radars exploit the dead‐times between the transmitted and the received pulses to allocate new tracking tasks that might involve transmitting or receiving pulses, thus increasing the capacity of the system. The problem of interleaving N targets involves a search among N! possibilities, and suboptimal solutions are usually employed to satisfy the real‐time constraints of the radar system. In this paper, we present new tight 0–1 integer programming models for the radar pulse interleaving problem and develop effective solution methods based on Lagrangian relaxation techniques. © 2003 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

Aggregating assignment constraints

This article shows how simple systems of linear equations with {0,1} variables can be aggregated into a single linear equation whose {0,1} solutions are identical to the solutions of the original system. Structures of the original systems are exploited to keep the aggregator's integer coefficients from becoming unnecessarily large. The results have potential application in integer programming and information theory, especially for problems that contain assignment-type constraints along with other constraints. Several unresolved questions of a number-theoretic nature are mentioned at the conclusion of the article.     

Discrete equal‐capacity p‐median problem

This paper examines the discrete equal‐capacity p‐median problem that seeks to locate p new facilities (medians) on a network, each having a given uniform capacity, in order to minimize the sum of distribution costs while satisfying the demand on the network. Such problems arise, for example, in local access and transport area telecommunication network design problems where any number of a set of p facility units can be constructed at the specified candidate sites (hence, the net capacity is an integer multiple of a given unit capacity). We develop various valid inequalities, a separation routine for generating cutting planes that are specific members of such inequalities, as well as an enhanced reformulation that constructs a partial convex hull representation that subsumes an entire class of valid inequalities via its linear programming relaxation. We also propose suitable heuristic schemes for this problem, based on sequentially rounding the continuous relaxation solutions obtained for the various equivalent formulations of the problem. Extensive computational results are provided to demonstrate the effectiveness of the proposed valid inequalities, enhanced formulations, and heuristic schemes. The results indicate that the proposed schemes for tightening the underlying relaxations play a significant role in enhancing the performance of both exact and heuristic solution methods for this class of problems. © 2000 John & Sons, Inc. Naval Research Logistics 47: 166–183, 2000.     

Using Lagrangean relaxation to minimize the weighted number of late jobs on a single machine

This paper tackles the general single machine scheduling problem, where jobs have different release and due dates and the objective is to minimize the weighted number of late jobs. The notion of master sequence is first introduced, i.e., a sequence that contains at least an optimal sequence of jobs on time. This master sequence is used to derive an original mixed‐integer linear programming formulation. By relaxing some constraints, a Lagrangean relaxation algorithm is designed which gives both lower and upper bounds. The special case where jobs have equal weights is analyzed. Computational results are presented and, although the duality gap becomes larger with the number of jobs, it is possible to solve problems of more than 100 jobs. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 50: 2003     

An integer decomposition algorithm for solving a two‐stage facility location problem with second‐stage activation costs

We study a stochastic scenario‐based facility location problem arising in situations when facilities must first be located, then activated in a particular scenario before they can be used to satisfy scenario demands. Unlike typical facility location problems, fixed charges arise in the initial location of the facilities, and then in the activation of located facilities. The first‐stage variables in our problem are the traditional binary facility‐location variables, whereas the second‐stage variables involve a mix of binary facility‐activation variables and continuous flow variables. Benders decomposition is not applicable for these problems due to the presence of the second‐stage integer activation variables. Instead, we derive cutting planes tailored to the problem under investigation from recourse solution data. These cutting planes are derived by solving a series of specialized shortest path problems based on a modified residual graph from the recourse solution, and are tighter than the general cuts established by Laporte and Louveaux for two‐stage binary programming problems. We demonstrate the computational efficacy of our approach on a variety of randomly generated test problems. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010