Multi‐item capacitated lot‐sizing problems with setup times and pricing decisions

We study a multi‐item capacitated lot‐sizing problem with setup times and pricing (CLSTP) over a finite and discrete planning horizon. In this class of problems, the demand for each independent item in each time period is affected by pricing decisions. The corresponding demands are then satisfied through production in a single capacitated facility or from inventory, and the goal is to set prices and determine a production plan that maximizes total profit. In contrast with many traditional lot‐sizing problems with fixed demands, we cannot, without loss of generality, restrict ourselves to instances without initial inventories, which greatly complicates the analysis of the CLSTP. We develop two alternative Dantzig–Wolfe decomposition formulations of the problem, and propose to solve their relaxations using column generation and the overall problem using branch‐and‐price. The associated pricing problem is studied under both dynamic and static pricing strategies. Through a computational study, we analyze both the efficacy of our algorithms and the benefits of allowing item prices to vary over time. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

Batch scheduling with step‐deteriorating processing times to minimize flowtime

Both topics of batch scheduling and of scheduling deteriorating jobs have been very popular among researchers in the last two decades. In this article, we study a model combining these two topics. We consider a classical batch scheduling model with unit‐jobs and batch‐independent setup times, and a model of step‐deterioration of processing times. The objective function is minimum flowtime. The optimal solution of the relaxed version (allowing non‐integer batch sizes) is shown to have a unique structure consisting of two consecutive decreasing arithmetic sequences of batch sizes. We also introduce a simple and efficient rounding procedure that guarantees integer batch sizes. The entire solution procedure requires an effort of O(n) (where nis the number of jobs.) © 2012 Wiley Periodicals, Inc. Naval Research Logistics, 2012     

The one‐warehouse multiretailer problem with an order‐up‐to level inventory policy

We consider a two‐level system in which a warehouse manages the inventories of multiple retailers. Each retailer employs an order‐up‐to level inventory policy over T periods and faces an external demand which is dynamic and known. A retailer's inventory should be raised to its maximum limit when replenished. The problem is to jointly decide on replenishment times and quantities of warehouse and retailers so as to minimize the total costs in the system. Unlike the case in the single level lot‐sizing problem, we cannot assume that the initial inventory will be zero without loss of generality. We propose a strong mixed integer program formulation for the problem with zero and nonzero initial inventories at the warehouse. The strong formulation for the zero initial inventory case has only T binary variables and represents the convex hull of the feasible region of the problem when there is only one retailer. Computational results with a state‐of‐the art solver reveal that our formulations are very effective in solving large‐size instances to optimality. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

An exact branch‐and‐price algorithm for multitasking scheduling on unrelated parallel machines

We consider the multitasking scheduling problem on unrelated parallel machines to minimize the total weighted completion time. In this problem, each machine processes a set of jobs, while the processing of a selected job on a machine may be interrupted by other available jobs scheduled on the same machine but unfinished. To solve this problem, we propose an exact branch‐and‐price algorithm, where the master problem at each search node is solved by a novel column generation scheme, called in‐out column generation, to maintain the stability of the dual variables. We use a greedy heuristic to obtain a set of initial columns to start the in‐out column generation, and a hybrid strategy combining a genetic algorithm and an exact dynamic programming algorithm to solve the pricing subproblems approximately and exactly, respectively. Using randomly generated data, we conduct numerical studies to evaluate the performance of the proposed solution approach. We also examine the effects of multitasking on the scheduling outcomes, with which the decision maker can justify making investments to adopt or avoid multitasking.     

Integrated scheduling of loading and transportation with tractors and semitrailers separated

Motivated by some practical applications, we study a new integrated loading and transportation scheduling problem. Given a set of jobs, a single crane is available to load jobs, one by one, onto semitrailers with a given capacity. Loaded semitrailers are assigned to tractors for transportation tasks. Subject to limited resources (crane, semitrailers, and tractors), the problem is to determine (1) an assignment of jobs to semitrailers for loading tasks, (2) a sequence for the crane to load jobs onto semitrailers, (3) an assignment of loaded semitrailers to tractors for transportation tasks, and (4) a transportation schedule of assigned tractors such that the completion time of the last transportation task is minimized. We first formulate the problem as a mixed integer linear programming model (MILPM) and prove that the problem is strongly NP‐hard. Then, optimality properties are provided which are useful in establishing an improved MILPM and designing solution algorithms. We develop a constructive heuristic, two LP‐based heuristics, and a recovering beam search heuristic to solve this problem. An improved procedure for solutions by heuristics is also presented. Furthermore, two branch‐and‐bound (B&B) algorithms with two different lower bounds are developed to solve the problem to optimality. Finally, computational experiments using both real data and randomly generated data demonstrate that our heuristics are highly efficient and effective. In terms of computational time and the number of instances solved to optimality in a time limit, the B&B algorithms are better than solving the MILPM. © 2015 Wiley Periodicals, Inc. Naval Research Logistics 62: 416–433, 2015     

Flow shop scheduling with earliness,tardiness, and intermediate inventory holding costs

We consider the problem of scheduling customer orders in a flow shop with the objective of minimizing the sum of tardiness, earliness (finished goods inventory holding), and intermediate (work‐in‐process) inventory holding costs. We formulate this problem as an integer program, and based on approximate solutions to two different, but closely related, Dantzig‐Wolfe reformulations, we develop heuristics to minimize the total cost. We exploit the duality between Dantzig‐Wolfe reformulation and Lagrangian relaxation to enhance our heuristics. This combined approach enables us to develop two different lower bounds on the optimal integer solution, together with intuitive approaches for obtaining near‐optimal feasible integer solutions. To the best of our knowledge, this is the first paper that applies column generation to a scheduling problem with different types of strongly ????‐hard pricing problems which are solved heuristically. The computational study demonstrates that our algorithms have a significant speed advantage over alternate methods, yield good lower bounds, and generate near‐optimal feasible integer solutions for problem instances with many machines and a realistically large number of jobs. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

Resource allocation with lumpy demand: To speed or not to speed?

In the classical EPQ model with continuous and constant demand, holding and setup costs are minimized when the production rate is no larger than the demand rate. However, the situation may change when demand is lumpy. We consider a firm that produces multiple products, each having a unique lumpy demand pattern. The decision involves determining both the lot size for each product and the allocation of resources for production rate improvements among the products. We find that each product's optimal production policy will take on only one of two forms: either continuous production or lot‐for‐lot production. The problem is then formulated as a nonlinear nonsmooth knapsack problem among products determined to be candidates for resource allocation. A heuristic procedure is developed to determine allocation amounts. The procedure decomposes the problem into a mixed integer program and a nonlinear convex resource allocation problem. Numerical tests suggest that the heuristic performs very well on average compared to the optimal solution. Both the model and the heuristic procedure can be extended to allow the company to simultaneously alter both the production rates and the incoming demand lot sizes through quantity discounts. Extensions can also be made to address the case where a single investment increases the production rate of multiple products. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

Preemptive parallel‐machine scheduling with a common server to minimize makespan

We consider parallel‐machine scheduling with a common server and job preemption to minimize the makespan. While the non‐preemptive version of the problem is strongly NP‐hard, the complexity status of the preemptive version has remained open. We show that the preemptive version is NP‐hard even if there is a fixed number of machines. We give a pseudo‐polynomial time algorithm to solve the case with two machines. We show that the case with an arbitrary number of machines is unary NP‐hard, analyze the performance ratios of some natural heuristic algorithms, and present several solvable special cases. © 2017 Wiley Periodicals, Inc. Naval Research Logistics 64: 388–398, 2017     

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     

Scheduling a maintenance activity on parallel identical machines

We study a problem of scheduling a maintenance activity on parallel identical machines, under the assumption that all the machines must be maintained simultaneously. One example for this setting is a situation where the entire system must be stopped for maintenance because of a required electricity shut‐down. The objective is minimum flow‐time. The problem is shown to be NP‐hard, and moreover impossible to approximate unless P = NP. We introduce a pseudo‐polynomial dynamic programming algorithm, and show how to convert it into a bicriteria FPTAS for this problem. We also present an efficient heuristic and a lower bound. Our numerical tests indicate that the heuristic provides in most cases very close‐to‐optimal schedules. © 2008 Wiley Periodicals, Inc. Naval Research Logistics 2009     

New heuristic methods for the capacitated multi‐facility Weber problem

In this paper we consider the capacitated multi‐facility Weber problem with the Euclidean, squared Euclidean, and ?_p‐distances. This problem is concerned with locating m capacitated facilities in the Euclidean plane to satisfy the demand of n customers with the minimum total transportation cost. The demand and location of each customer are known a priori and the transportation cost between customers and facilities is proportional to the distance between them. We first present a mixed integer linear programming approximation of the problem. We then propose new heuristic solution methods based on this approximation. Computational results on benchmark instances indicate that the new methods are both accurate and efficient. © 2006 Wiley Periodicals, Inc. Naval Research Logistics 2006     

Formulations for dynamic lot sizing with service levels

In this article, we study deterministic dynamic lot‐sizing problems with a service‐level constraint on the total number of periods in which backlogs can occur over a finite planning horizon. We give a natural mixed integer programming formulation for the single item problem (LS‐SL‐I) and study the structure of its solution. We show that an optimal solution to this problem can be found in \begin{align*}\mathcal O(n^2\kappa)\end{align*} time, where n is the planning horizon and \begin{align*}\kappa=\mathcal O(n)\end{align*} is the maximum number of periods in which demand can be backlogged. Using the proposed shortest path algorithms, we develop alternative tight extended formulations for LS‐SL‐I and one of its relaxations, which we refer to as uncapacitated lot sizing with setups for stocks and backlogs. {We show that this relaxation also appears as a substructure in a lot‐sizing problem which limits the total amount of a period's demand met from a later period, across all periods.} We report computational results that compare the natural and extended formulations on multi‐item service‐level constrained instances. © 2013 Wiley Periodicals, Inc. Naval Research Logistics, 2013     

Short‐term capacity allocation problem with tool and setup constraints

We consider a short‐term capacity allocation problem with tool and setup constraints that arises in the context of operational planning in a semiconductor wafer fabrication facility. The problem is that of allocating the available capacity of parallel nonidentical machines to available work‐in‐process (WIP) inventory of operations. Each machine can process a subset of the operations and a tool setup is required on a machine to change processing from one operation to another. Both the number of tools available for an operation and the number of setups that can be performed on a machine during a specified time horizon are limited. We formulate this problem as a degree‐constrained network flow problem on a bipartite graph, show that the problem is NP‐hard, and propose constant factor approximation algorithms. We also develop constructive heuristics and a greedy randomized adaptive search procedure for the problem. Our computational experiments demonstrate that our solution procedures solve the problem efficiently, rendering the use of our algorithms in real environment feasible. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

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     

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     

Priority and dynamic scheduling in a make‐to‐stock queue with hyperexponential demand

We consider the scheduling problem in a make‐to‐stock queue with two demand classes that can be differentiated based on their variability. One class experiences Poisson arrivals and the other class experiences hyperexponential renewal arrivals. We provide an exact analysis of the case where the demand class with higher variability is given non‐preemptive priority. The results are then used to compare the inventory cost performance of three scheduling disciplines, first‐come first‐serve and priority to either class. We then build on an existing dynamic scheduling heuristic to propose a modification that works well for our system. Extensions of the heuristic to more than two classes and to the case where demand state is known are also discussed. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2006.     

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.     

Non‐greedy heuristics and augmented neural networks for the open‐shop scheduling problem

In this paper we propose some non‐greedy heuristics and develop an Augmented‐Neural‐Network (AugNN) formulation for solving the classical open‐shop scheduling problem (OSSP). AugNN is a neural network based meta‐heuristic approach that allows integration of domain‐specific knowledge. The OSSP is framed as a neural network with multiple layers of jobs and machines. Input, output and activation functions are designed to enforce the problem constraints and embed known heuristics to generate a good feasible solution fast. Suitable learning strategies are applied to obtain better neighborhood solutions iteratively. The new heuristics and the AugNN formulation are tested on several benchmark problem instances in the literature and on some new problem instances generated in this study. The results are very competitive with other meta‐heuristic approaches, both in terms of solution quality and computational times. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Scheduling for parallel dedicated machines with a single server

This paper examines scheduling problems in which the setup phase of each operation needs to be attended by a single server, common for all jobs and different from the processing machines. The objective in each situation is to minimize the makespan. For the processing system consisting of two parallel dedicated machines we prove that the problem of finding an optimal schedule is N P‐hard in the strong sense even if all setup times are equal or if all processing times are equal. For the case of m parallel dedicated machines, a simple greedy algorithm is shown to create a schedule with the makespan that is at most twice the optimum value. For the two machine case, an improved heuristic guarantees a tight worst‐case ratio of 3/2. We also describe several polynomially solvable cases of the later problem. The two‐machine flow shop and the open shop problems with a single server are also shown to be N P‐hard in the strong sense. However, we reduce the two‐machine flow shop no‐wait problem with a single server to the Gilmore—Gomory traveling salesman problem and solve it in polynomial time. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 304–328, 2000