The single-machine absolute-deviation early-tardy problem with random completion times

We consider sequencing n jobs on a single machine subject to job completion times arising from either machine breakdowns or other causes. The objective is to minimize an expected weighted combination of due dates, completion times, earliness, and tardiness penalties. The determination of optimal distinct due dates or optimal common due dates for a given schedule is investigated. The scheduling problem for a fixed common due date is considered when random completion times arise from machine breakdowns. The optimality of a V-shaped about (a point) T sequence is established when the number of machine breakdowns follows either a Poisson or a geometric distribution and the duration of a breakdown has an exponential distribution. © 1996 John Wiley & Sons, Inc.     

Scheduling on M parallel machines subject to random breakdowns to minimize expected mean flow time

The problem of scheduling n jobs on m parallel machines is considered when the machines are subject to random breakdowns and job processing times are random variables. An objective function of mean flow time is developed for a general parallel machine system, and an expression of its expected value is derived. The problem is transformed into a deterministic unrelated parallel machine scheduling model with modified processing times when the number of breakdowns is modeled as a generalized Poisson process. © 1994 John Wiley & Sons, Inc.     

Stochastic scheduling subject to machine breakdowns: The preemptive‐repeat model with discounted reward and other criteria

We consider the problem of scheduling a set of jobs on a single machine subject to random breakdowns. We focus on the preemptive‐repeat model, which addresses the situation where, if a machine breaks down during the processing of a job, the work done on the job prior to the breakdown is lost and the job will have to be started from the beginning again when the machine resumes its work. We allow that (i) the uptimes and downtimes of the machine follow general probability distributions, (ii) the breakdown process of the machine depends upon the job being processed, (iii) the processing times of the jobs are random variables following arbitrary distributions, and (iv) after a breakdown, the processing time of a job may either remain a same but unknown amount, or be resampled according to its probability distribution. We first derive the optimal policy for a class of problems under the criterion to maximize the expected discounted reward earned from completing all jobs. The result is then applied to further obtain the optimal policies for other due date‐related criteria. We also discuss a method to compute the moments and probability distributions of job completion times by using their Laplace transforms, which can convert a general stochastic scheduling problem to its deterministic equivalent. The weighted squared flowtime problem and the maintenance checkup and repair problem are analyzed as applications. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004     

Scheduling jobs with random processing times on a single machine subject to stochastic breakdowns to minimize early-tardy penalties

We examine the problem of scheduling n jobs with a common due date on a single machine. The processing time of each job is a random variable, which follows an arbitrary distribution with a known mean and a known variance. The machine is not reliable; it is subject to stochastic breakdowns. The objective is to minimize the expected sum of squared deviations of job completion times from the due date. Two versions of the problem are addressed. In the first one the due date is a given constant, whereas in the second one the due date is a decision variable. In each case, a general form of the deterministic equivalent of the stochastic scheduling problem is obtained when the counting process related to the machine uptime distribution is a generalized Poisson process. A sufficient condition is derived under which optimal sequences are V-shaped with respect to mean processing times. Other characterizations of optimal solutions are also established. Based on the optimality properties, algorithms with pseudopolynomial time complexity are proposed to solve both versions of the problem. © 1996 John Wiley & Sons, Inc.     

Scheduling jobs that are subject to failure propagation

A single machine is available to process a collection of stochastic tasks. Processing is interrupted when the machine breaks down. We introduce a new model of breakdowns that more realistically incorporates the effects that job processing may have on the machine. This failure propagation model is equivalent to a Bayesian formulation in which learning about breakdown rates occurs as jobs evolve. Optimal scheduling policies are described in terms of Gittins indices and these indices are characterised in two special cases. For example, we obtain conditions which ensure that an optimal policy will only preempt a job's processing either at its completion or at a machine breakdown. We also bound the value lost by simplistic modelling which ignores the learning phenomenon. © 1996 John Wiley & Sons, Inc.     

An FPTAS for scheduling a two‐machine flowshop with one unavailability interval

We study a deterministic two‐machine flowshop scheduling problem with an assumption that one of the two machines is not available in a specified time period. This period can be due to a breakdown, preventive maintenance, or processing unfinished jobs from a previous planning horizon. The problem is known to be NP‐hard. Pseudopolynomial dynamic programming algorithms and heuristics with worst case error bounds are given in the literature to solve the problem. They are different for the cases when the unavailability interval is for the first or second machine. The existence of a fully polynomial time approximation scheme (FPTAS) was formulated as an open conjecture in the literature. In this paper, we show that the two cases of the problem under study are equivalent to similar partition type problems. Then we derive a generic FPTAS for the latter problems with O(n⁵/ε⁴) time complexity. © 2003 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

Optimization of schedule stability and efficiency under processing time variability and random machine breakdowns in a job shop environment

The ability to cope with uncertainty in dynamic scheduling environments is becoming an increasingly important issue. In such environments, any disruption in the production schedule will translate into a disturbance of the plans for several external activities as well. Hence, from a practical point of view, deviations between the planned and realized schedules are to be avoided as much as possible. The term stability refers to this concern. We propose a proactive approach to generate efficient and stable schedules for a job shop subject to processing time variability and random machine breakdowns. In our approach, efficiency is measured by the makespan, and the stability measure is the sum of the variances of the realized completion times. Because the calculation of the original measure is mathematically intractable, we develop a surrogate stability measure. The version of the problem with the surrogate stability measure is proven to be NP‐hard, even without machine breakdowns; a branch‐and‐bound algorithm is developed for this problem variant. A tabu search algorithm is proposed to handle larger instances of the problem with machine breakdowns. The results of extensive computational experiments indicate that the proposed algorithms are quite promising in performance. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

The effect of correlated exponential service times on single server tandem queues

An investigation via simulation of system performance of two stage queues in series (single server, first-come, first-served) under the assumption of correlated exponential service times indicates that the system's behavior is quite sensitive to departures from the traditional assumption of mutually independent service times, especially at higher utilizations. That service times at the various stages of a tandem queueing system for a given customer should be correlated is intuitively appealing and apparently not at all atypical. Since tandem queues occur frequently, e.g. production lines and the logistics therewith associated, it is incumbent on both the practitioner and the theoretician that they be aware of the marked effects that may be induced by correlated service times. For the case of infinite interstage storage, system performance is improved by positive correlation and impaired by negative correlation. This change in system performance is reversed however for zero interstage storage and depends on the value of the utilization rate for the case where interstage storage equals unity. The effect due to correlation is shown to be statistically significant using spectral analytic techniques. For correlation equal unity and infinite interstage storage, results are provided for two through twenty-five stages in series to suggest how adding stages affects system performance for ρ>0. In this extreme case of correlation, adding stages has an effect on system performance which depends markedly on the utilization rate. Recursive formulae for the waiting time per customer for the cases of zero, one, and infinite interstage storage are derived.     

A note on minimizing the expected makespan in flowshops subject to breakdowns

Consider a two machine flow shop and n jobs. The processing time of job j on machine i is equal to the random variable X_ij One of the two machines is subject to breakdown and repair. The objective is to find the schedule that minimizes the expected makespan. Two results are shown. First, ifP(X_2j ≧ X_1j) = 1 for all j and the random variables X₁₁, X₁₂,…, X_1n are likelihood ratio ordered, then the SEPT sequence minimizes the expected makespan when machine 2 is subject to an arbitrary breakdown process; if P(X_1j≧X_2j) = 1 and X₂₁, X₂₂,….,X_2n are likelihood ratio ordered, then the LEPT sequence minimizes the expected makespan when machine 1 is subject to an arbitrary breakdown process. A generalization is presented for flow shops with m machines. Second, consider the case where X_1j and X_2j are i.i.d. exponentially distributed with rate λ_j. The SEPT sequence minimizes the expected makespan when machine 2 is subject to an arbitrary breakdown process and the LEPT sequence is optimal when machine 1 is subject to an arbitrary breakdown process. © 1995 John Wiley & Sons, Inc.     

Joint determination of preventive maintenance and safety stocks in an unreliable production environment

In this article we formulate an analytical model of preventive maintenance and safety stock strategies in a production environment subject to random machine breakdowns. Traditionally, preventive maintenance and safety stocks have been independently studied as two separate strategies for coping with machine breakdowns. Our intent is to develop a unified framework so that the two are jointly considered. We illustrate the trade-off between investing in the two options. In addition, we provide optimality conditions under which either one or both strategies should be implemented to minimize the associated cost function. Specifically, cases with deterministic and exponential repair time distributions are analyzed in detail. We include numerical examples to illustrate the determination of optimal strategies for preventive maintenance and safety stocks. © 1997 John Wiley & Sons, Inc.     

Scheduling on a single machine with a single breakdown to minimize stochastically the number of tardy jobs

Jobs with known processing times and due dates have to be processed on a machine which is subject to a single breakdown. The moment of breakdown and the repair time are independent random variables. Two cases are distinguished with reference to the processing time preempted by the breakdown (no other preemptions are allowed): (i) resumption without time losses and (ii) restart from the beginning. Under certain compatible conditions, we find the policies which minimize stochastically the number of tardy jobs.     

Proactive release procedures for just‐in‐time job shop environments,subject to machine failures

In this paper, we consider just‐in‐time job shop environments (job shop problems with an objective of minimizing the sum of tardiness and inventory costs), subject to uncertainty due to machine failures. We present techniques for proactive uncertainty management that exploit prior knowledge of uncertainty to build competitive release dates, whose execution improves performance. These techniques determine the release dates of different jobs based on measures of shop load, statistical data of machine failures, and repairs with a tradeoff between inventory and tardiness costs. Empirical results show that our methodology is very promising in comparison with simulated annealing and the best of 39 combinations of dispatch rules & release policies, under different frequencies of breakdowns. We observe that the performance of the proactive technique compared to the other two approaches improves in schedule quality (maximizing delivery performance while minimizing costs) with increase in frequency of breakdowns. The proactive technique presented here is also computationally less expensive than the other two approaches. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004     

On some sequencing problems

The (mxn) sequencing problem may be characterized as follows: There are m machines which can produce a piece consisting of n parts. Each part has a determined order in which it is processed through the machines. It is assumed that each machine cannot deal with more than one part at a time and that the processing required for each part can be accomplished only on one machine. That is, the machines are all specialized so that alternate machines for the same processing on a part is not possible. The problem is to find the best production plan consisting in sequencing the different parts so as to make the whole amount of time from the beginning of work till the piece is completed the shortest possible. Such a plan is called an optimum one. In the first 4 sections of this paper, the problem (2xn) is solved for the (2xn) case in which the order in which parts come on the machine is not constrained by further assumptions. The remainder of the paper then takes up: 1) the (3xn) problem of Bellman-Johnson (viz. the technological processing order through the machine is the same for all parts) for several new special cases; 2) the 2xn problem of sequencing when delay times must also be considered; and, 3) some properties of an approximating method for solving (mxn) problems, including a delineation of cases when the approximating method will yield optimal solutions.     

Optimal flowshop schedules with no intermediate storage space

In this paper the problem of finding an optimal schedule for the n-job, M-machine flowshop scheduling problem is considered when there is no intermediate space to hold partially completed jobs and the objective function is to minimize the weighted sum of idle times on all machines. By assuming that jobs are processed as early as possible, the problem is modeled as a traveling salesman problem and solved by known solution techniques for the traveling salesman problem. A sample problem is solved and a special case, one involving only two machines, is discussed.     

The performance of cannibalization policies in a maintenance system with spares,repair, and resource constraints

This article presents the results of comparing the performance of several cannibalization policies using a simulation model of a maintenance system with spares, repair, and resource constraints. Although the presence of cannibalization has been incorporated into a number of maintenance system models reported in the literature, the questions of whether cannibalization should be done and what factors affect canibalization have received little attention. Policies tested include both no cannibalization and unlimited cannibalization as well as other based on the number of maintenance personnel available, the short-term machine failure rate at the time of cannibalization, and the relationship between the mean cannibalization and repair rates. The best policies found are those that allow cannibalization only when it can be done quickly relative to repair or when it can be done without delaying part repair actions. The policy of complete cannibalization (always cannibalize when it is possible) is found to perform poorly except when either average maintenance personnel utilization is very low or when mean cannibalization times are very short relative to mean repair times. The latter result casts doubts on the appropriateness of the assumption of complete cannibalization in many models in the literature.     

Minimizing flow time on a single machine with job classes and setup times

We examine the static sequencing problem of ordering the processing of jobs on a single machine so as to minimize the average weighted flow time. It is assumed that all jobs have zero ready times, and that the jobs are grouped into classes with the property that setup tasks are only required when processing switches from jobs of one class to jobs of another class. The time required for each setup task is given by the sum of a setdown time from the previous class and a setup time for the new class. We show that an algorithm presented in the literature for solving a special case of this problem gives suboptimal solutions. A number of properties of the optimal solution are derived, and their use in algorithms is evaluated. Computational results are presented for both a branch-and-bound procedure and a simpler depth-first search.     

Effect of increasing component commonality on service level and holding cost

We investigate the effect of increasing component commonality in an assemble-to-order system. Numerical investigation of two end products that share up to three components, and whose demands are identically distributed according to either the exponential or the geometric distribution, shows that increasing component commonality results in increasing marginal returns when the criteria are aggregate service level and aggregate stock requirement. For arbitrary end-product demands and general service measures, it is shown that the optimal holding cost for a given service level is concave in the level of commonality. © 1992 John Wiley & Sons, Inc.     

The stochastic U‐line balancing problem

A U‐line arranges tasks around a U‐shaped production line and organizes them into stations that can cross from one side of the line to the other. In addition to improving visibility and communication between operators on the line, which facilitates problem‐solving and quality improvement, U‐lines can reduce the total number of operators required on the line and make rebalancing the line easier compared to the traditional, straight production line. This paper studies the (type 1) U‐line balancing problem when task completion times are stochastic. Stochastic completion times occur when differences between operators cause completion times to vary somewhat and when machine processing times vary. A recursive algorithm is presented for finding the optimal solution when completion times have any distribution function. An equivalent shortest path network is also presented. An improvement for the special case of normally distributed task completion times is given. A computational study to determine the characteristics of instances that can be solved by the algorithms shows that they are able to solve instances of practical size (like the 114 Japanese and U.S. U‐lines studied in a literature review paper). © 2002 Wiley Periodicals, Inc. Naval Research Logistics, 2003     

Reliability acceptance testing for new series systems

The mean time between failures (MTBF) of a newly minted series system, all of whose components exhibit wear, will tend to be much larger than the MTBF of the same system after it has become fully aged. When fully aged systems are used for the testing, acceptance tests with a criterion regarding the MTBF of a well-aged system can be based on the assumption that times between system failures are independent, with identical exponential distributions. However, these tests are shown to offer essentially no consumer protection when applied to new systems. Tests are derived which are correct when new systems are under test but the acceptance criterion refers to the MTBF of a well-aged system. The derivation uses an approximate Poisson distribution which is valid if the total number of systems on test is sufficiently large.     

Analysis of a machine repair problem with an unreliable server and phase type repairs and services

In this paper we study a machine repair problem in which a single unreliable server maintains N identical machines. The breakdown times of the machines are assumed to follow an exponential distribution. The server is subject to failure and the failure times are exponentially distributed. The repair times of the machine and the service times of the repairman are assumed to be of phase type. Using matrix‐analytic methods, we perform steady state analysis of this model. The time spent by a failed machine in service and the total time in the repair facility are shown to be of phase type. Several performance measures are evaluated. An optimization problem to determine the number of machines to be assigned to the server that will maximize the expected total profit per unit time is discussed. An illustrative numerical example is presented. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 462–480, 2003