Production scheduling with history‐dependent setup times

We consider a parallel‐machine scheduling problem with jobs that require setups. The duration of a setup does not depend only on the job just completed but on a number of preceding jobs. These setup times are referred to as history‐dependent. Such a scheduling problem is often encountered in the food processing industry as well as in other process industries. In our model, we consider two types of setup times—a regular setup time and a major setup time that becomes necessary after several “hard‐to‐clean” jobs have been processed on the same machine. We consider multiple objectives, including facility utilization, flexibility, number of major setups, and tardiness. We solve several special cases assuming predetermined job sequences and propose strongly polynomial time algorithms to determine the optimal timing of the major setups for given job sequences. We also extend our analysis to develop pseudopolynomial time algorithms for cases with additional objectives, including the total weighted completion time, the total weighted tardiness, and the weighted number of tardy jobs. © 2012 Wiley Periodicals, Inc. Naval Research Logistics, 2012     

Server scheduling on parallel dedicated machines with fixed job sequences

We consider server scheduling on parallel dedicated machines to minimize the makespan. Each job has a loading operation and a processing operation. The loading operation requires a server that serves all the jobs. Each machine has a given set of jobs to process, and the processing sequence is known and fixed. We design a polynomial‐time algorithm to solve the two‐machine case of the problem. When the number of machines is arbitrary, the problem becomes strongly NP‐hard even if all the jobs have the same processing length or all the loading operations require a unit time. We design two heuristic algorithms to treat the case where all the loading times are unit and analyze their performance.     

Capacity allocation with machine duplication in semiconductor manufacturing

The manufacturing process for a computer chip is complex in that it involves a large number of distinct operations requiring a substantial lead‐time for completion. Our observations of such a manufacturing process at a large plant in the United States led us to identify several tactical and operational problems that were being addressed by the production planners on a recurring basis. This paper focuses on one such problem. At a tactical level, given a demand forecast of wafers to be manufactured, one specific problem deals with specifying which machine or machine groups will process different batches of wafers. We address this problem by recognizing the capacity limitations of the individual machines as well as the requirement for reducing operating and investment costs related to the machines. A mathematical model, which is a variation of the well‐known capacitated facility location problem, is proposed to solve this problem. Given the intractability of the model, we first develop problem specific lower bounding procedures based on Lagrangean relaxation. We also propose a heuristic method to obtain “good” solutions with reasonable computational effort. Computational tests, using hypothetical and industry‐based data, indicate that our heuristic approach provides optimal/near optimal solutions fairly quickly. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Scheduling with tool changes to minimize total completion time: A study of heuristics and their performance

The machine scheduling literature does not consider the issue of tool change. The parallel literature on tool management addresses this issue but assumes that the change is due only to part mix. In practice, however, a tool change is caused most frequently by tool wear. That is why we consider here the problem of scheduling a set of jobs on a single CNC machine where the cutting tool is subject to wear; our objective is to minimize the total completion time. We first describe the problem and discuss its peculiarities. After briefly reviewing available theoretical results, we then go on to provide a mixed 0–1 linear programming model for the exact solution of the problem; this is useful in solving problem instances with up to 20 jobs and has been used in our computational study. As our main contribution, we next propose a number of heuristic algorithms based on simple dispatch rules and generic search. We then discuss the results of a computational study where the performance of the various heuristics is tested; we note that the well‐known SPT rule remains good when the tool change time is small but deteriorates as this time increases and further that the proposed algorithms promise significant improvement over the SPT rule. © 2002 Wiley Periodicals, Inc. Naval Research Logistics, 2003     

Flow‐shop batch scheduling with identical processing‐time jobs

In many practical situations of production scheduling, it is either necessary or recommended to group a large number of jobs into a relatively small number of batches. A decision needs to be made regarding both the batching (i.e., determining the number and the size of the batches) and the sequencing (of batches and of jobs within batches). A setup cost is incurred whenever a batch begins processing on a given machine. This paper focuses on batch scheduling of identical processing‐time jobs, and machine‐ and sequence‐independent setup times on an m‐machine flow‐shop. The objective is to find an allocation to batches and their schedule in order to minimize flow‐time. We introduce a surprising and nonintuitive solution for the problem. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004     

Allocation of resources of modular sizes with an application to Internet Protocol (IP) address allocation

We consider a resource allocation problem, where resources of different capacities must satisfy multiple demands. The demand sizes and the resource capacities are limited to sizes that are power‐of‐two integers (i.e., 1, 2, 4, 8, …). The cost of the resources exhibit economies‐of‐scale savings, i.e., the cost per capacity unit is smaller for resources with larger capacity. The problem is to select the minimum‐cost set of resources that satisfies the demands, while each of the demands must be assigned to a single resource and the number of selected resources does not exceed a specified upper bound. We present algorithms that take advantage of the special structure of the problem and provide optimal solutions in a negligible computing effort. This problem is important for the allocation of blocks of Internet Protocol (IP) addresses, referred to as subnets. In typical IP networks, subnets are allocated at a large number of nodes. An effective allocation attempts to balance the volume of excess addresses that are not used versus fragmentation of addresses at nodes to too many subnets with a discontinuous range of addresses. Due to the efficiency of the algorithms, they can readily be used as valuable modules in IP address management systems. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

A general strategic capacity planning model under demand uncertainty

Capacity planning decisions affect a significant portion of future revenue. In equipment intensive industries, these decisions usually need to be made in the presence of both highly volatile demand and long capacity installation lead times. For a multiple product case, we present a continuous‐time capacity planning model that addresses problems of realistic size and complexity found in current practice. Each product requires specific operations that can be performed by one or more tool groups. We consider a number of capacity allocation policies. We allow tool retirements in addition to purchases because the stochastic demand forecast for each product can be decreasing. We present a cluster‐based heuristic algorithm that can incorporate both variance reduction techniques from the simulation literature and the principles of a generalized maximum flow algorithm from the network optimization literature. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

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     

Batch scheduling on a two‐machine jobshop with machine‐dependent setup times

The problem of minimum makespan on an m machine jobshop with unit execution time (UET) jobs (m ≥ 3) is known to be strongly NP‐hard even with no setup times. We focus in this article on the two‐machine case. We assume UET jobs and consider batching with batch availability and machine‐dependent setup times. We introduce an efficient \begin{align*}(O(\sqrt{n}))\end{align*} algorithm, where n is the number of jobs. We then introduce a heuristic for the multimachine case and demonstrate its efficiency for two interesting instances. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

Polynomial‐time approximation schemes for two‐machine open shop scheduling with nonavailability constraints

This paper addresses a two‐machine open shop scheduling problem, in which the machines are not continuously available for processing. The processing of an operation affected by a non‐availability interval can be interrupted and resumed later. The objective is to minimize the makespan. We present two polynomial‐time approximation schemes, one of which handles the problem with one non‐availability interval on each machine and the other for the problem with several non‐availability intervals on one of the machines. Problems with a more general structure of the non‐availability intervals are not approximable in polynomial time within a constant factor, unless . © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

Scheduling and lot streaming in two‐machine open shops with no‐wait in process

We study the problem of minimizing the makespan in no‐wait two‐machine open shops producing multiple products using lot streaming. In no‐wait open shop scheduling, sublot sizes are necessarily consistent; i.e., they remain the same over all machines. This intractable problem requires finding sublot sizes, a product sequence for each machine, and a machine sequence for each product. We develop a dynamic programming algorithm to generate all the dominant schedule profiles for each product that are required to formulate the open shop problem as a generalized traveling salesman problem. This problem is equivalent to a classical traveling salesman problem with a pseudopolynomial number of cities. We develop and test a computationally efficient heuristic for the open shop problem. Our results indicate that solutions can quickly be found for two machine open shops with up to 50 products. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Approximation schemes for single‐machine scheduling with a fixed maintenance activity to minimize the total amount of late work

We consider the problem of scheduling n independent and simultaneously available jobs without preemption on a single machine, where the machine has a fixed maintenance activity. The objective is to find the optimal job sequence to minimize the total amount of late work, where the late work of a job is the amount of processing of the job that is performed after its due date. We first discuss the approximability of the problem. We then develop two pseudo‐polynomial dynamic programming algorithms and a fully polynomial‐time approximation scheme for the problem. Finally, we conduct extensive numerical studies to evaluate the performance of the proposed algorithms. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 172–183, 2016     

Predicting intensive care unit bed occupancy for integrated operating room scheduling via neural networks

In a master surgery scheduling (MSS) problem, a hospital's operating room (OR) capacity is assigned to different medical specialties. This task is critical since the risk of assigning too much or too little OR time to a specialty is associated with overtime or deficit hours of the staff, deferral or delay of surgeries, and unsatisfied—or even endangered—patients. Most MSS approaches in the literature focus only on the OR while neglecting the impact on downstream units or reflect a simplified version of the real‐world situation. We present the first prediction model for the integrated OR scheduling problem based on machine learning. Our three‐step approach focuses on the intensive care unit (ICU) and reflects elective and urgent patients, inpatients and outpatients, and all possible paths through the hospital. We provide an empirical evaluation of our method with surgery data for Universitätsklinikum Augsburg, a German tertiary care hospital with 1700 beds. We show that our model outperforms a state‐of‐the‐art model by 43% in number of predicted beds. Our model can be used as supporting tool for hospital managers or incorporated in an optimization model. Eventually, we provide guidance to support hospital managers in scheduling surgeries more efficiently.     

On the asymptotic optimality of algorithms for the flow shop problem with release dates

We consider the nonpermutation flow shop problem with release dates, with the objective of minimizing the sum of the weighted completion times on the final machine. Since the problem is NP‐hard, we focus on the analysis of the performance of several approximation algorithms, all of which are related to the classical Weighted Shortest Processing Time Among Available Jobs heuristic. In particular, we perform a probabilistic analysis and prove that two online heuristics and one offline heuristic are asymptotically optimal. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Bicriteria scheduling on a single batching machine with job transportation and deterioration considerations

We study a single batching machine scheduling problem with transportation and deterioration considerations arising from steel production. A set of jobs are transported, one at a time, by a vehicle from a holding area to the single batching machine. The machine can process several jobs simultaneously as a batch. The processing time of a job will increase if the duration from the time leaving the holding area to the start of its processing exceeds a given threshold. The time needed to process a batch is the longest of the job processing times in the batch. The problem is to determine the job sequence for transportation and the job batching for processing so as to minimize the makespan and the number of batches. We study four variations (P1, P2, P3, P4) of the problem with different treatments of the two criteria. We prove that all the four variations are strongly NP‐hard and further develop polynomial time algorithms for their special cases. For each of the first three variations, we propose a heuristic algorithm and analyze its worst‐case performance. For P4, which is to find the Pareto frontier, we provide a heuristic algorithm and an exact algorithm based on branch and bound. Computational experiments show that all the heuristic algorithms perform well on randomly generated problem instances, and the exact algorithm for P4 can obtain Pareto optimal schedules for small‐scale instances. © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 269–285, 2014     

Approximation algorithms for minimizing total weighted completion time of orders on identical machines in parallel

We consider the problem of scheduling orders on identical machines in parallel. Each order consists of one or more individual jobs. A job that belongs to an order can be processed by any one of the machines. Multiple machines can process the jobs of an order concurrently. No setup is required if a machine switches over from one job to another. Each order is released at time zero and has a positive weight. Preemptions are not allowed. The completion time of an order is the time at which all jobs of that order have been completed. The objective is to minimize the total weighted completion time of the orders. The problem is NP‐hard for any fixed number (≥2) of machines. Because of this, we focus our attention on two classes of heuristics, which we refer to as sequential two‐phase heuristics and dynamic two‐phase heuristics. We perform a worst case analysis as well as an empirical analysis of nine heuristics. Our analyses enable us to rank these heuristics according to their effectiveness, taking solution quality as well as running time into account. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

On‐line algorithms for minimizing makespan on batch processing machines

We consider problem of scheduling jobs on‐line on batch processing machines with dynamic job arrivals to minimize makespan. A batch machine can handle up to B jobs simultaneously. The jobs that are processed together from a batch, and all jobs in a batch start and complete at the same time. The processing time of a batch is given by the longest processing time of any job in the batch. Each job becomes available at its arrival time, which is unknown in advance, and its processing time becomes known upon its arrival. In the first part of this paper, we address the single batch processing machine scheduling problem. First we deal with two variants: the unbounded model where B is sufficiently large and the bounded model where jobs have two distinct arrival times. For both variants, we provide on‐line algorithms with worst‐case ratio (the inverse of the Golden ratio) and prove that these results are the best possible. Furthermore, we generalize our algorithms to the general case and show a worst‐case ratio of 2. We then consider the unbounded case for parallel batch processing machine scheduling. Lower bound are given, and two on‐line algorithms are presented. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48: 241–258, 2001     

Machine scheduling with pickup and delivery

The coordination of production, supply, and distribution is an important issue in logistics and operations management. This paper develops and analyzes a single‐machine scheduling model that incorporates the scheduling of jobs and the pickup and delivery arrangements of the materials and finished jobs. In this model, there is a capacitated pickup and delivery vehicle that travels between the machine and the storage area, and the objective is to minimize the makespan of the schedule. The problem is strongly NP‐hard in general but is solvable in polynomial time when the job processing sequence is predetermined. An efficient heuristic is developed for the general problem. The effectiveness of the heuristic is studied both analytically and computationally. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Scheduling with centralized and decentralized batching policies in concurrent open shops

This article considers batch scheduling with centralized and decentralized decisions. The context of our study is concurrent open shop scheduling where the jobs are to be processed on a set of independent dedicated machines, which process designated operations of the jobs in batches. The batching policy across the machines can be centralized or decentralized. We study such scheduling problems with the objectives of minimizing the maximum lateness, weighted number of tardy jobs, and total weighted completion time, when the job sequence is determined in advance. We present polynomial time dynamic programming algorithms for some cases of these problems and pseudo‐polynomial time algorithms for some problems that are NP‐hard in the ordinary sense. © 2010 Wiley Periodicals, Inc. Naval Research Logistics 58: 17–27, 2011     

Dynamic server assignment policies for assembly‐type queues with flexible servers

We seek dynamic server assignment policies in finite‐capacity queueing systems with flexible and collaborative servers, which involve an assembly and/or a disassembly operation. The objective is to maximize the steady‐state throughput. We completely characterize the optimal policy for a Markovian system with two servers, two feeder stations, and instantaneous assembly and disassembly operations. This optimal policy allocates one server per station unless one of the stations is blocked, in which case both servers work at the unblocked station. For Markovian systems with three stations and instantaneous assembly and/or disassembly operations, we consider similar policies that move a server away from his/her “primary” station only when that station is blocked or starving. We determine the optimal assignment of each server whose primary station is blocked or starving in systems with three stations and zero buffers, by formulating the problem as a Markov decision process. Using this optimal assignment, we develop heuristic policies for systems with three or more stations and positive buffers, and show by means of a numerical study that these policies provide near‐optimal throughput. Furthermore, our numerical study shows that these policies developed for assembly‐type systems also work well in tandem systems. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008