Lot-Sizing and Scheduling for Flexible Flow Lines

ISBN-13: 9783540223252 / Angielski / Miękka / 2004 / 227 str.

Daniel Quadt

Opis

The book considers the lot-sizing and scheduling problem for flexible flow line production facilities. Flexible flow lines are flow lines with parallel machines on some or all production stages. They can be found in a vast number of industries. A three-phased solution approach is presented that solves the integrated lot-sizing and scheduling problem in a hierarchical manner. The approach is able to handle several important features relevant in industrial practice, such as back-orders and setup carry-over. The developed solution procedures solve practically sized problems in a relatively short amount of time. One of the procedures is based on a novel mixed integer programming (MIP) model, which employs integer variables instead of binary variables. This makes it possible to find (near-)optimal solutions using standard algorithms such as CPLEX. Another procedure uses two nested Genetic Algorithms. An application of the framework in the semiconductor industry is given.

Spis treści

1 Introduction.- 1.1 Lot-Sizing and Scheduling.- 1.2 Flexible Flow Lines.- 1.3 Characteristics of the Problem.- 1.4 Scope and Outline of the Study.- 2 Lack of Solution Procedures in the Literature.- 2.1 Lot-Sizing Problems.- 2.2 Scheduling Problems.- 2.2.1 Branch & Bound Procedures.- 2.2.2 Local Search and Metaheuristics.- 2.2.3 Stage Decomposition Approaches.- 2.2.4 Job-Oriented Procedures.- 2.2.5 (Sequential) Loading and Sequencing Algorithms.- 2.3 Summary and Conclusion.- 3 An Integrative Solution Approach.- 4 Phase I: Bottleneck Planning.- 4.1 Lot-sizing and Scheduling on Parallel Machines.- 4.2 Literature Review.- 4.2.1 Back-Order Literature.- 4.2.2 Setup Carry-Over Literature.- 4.2.3 Parallel Machines Literature.- 4.3 Standard Models with Extensions.- 4.3.1 Capacitated Lot-Sizing Problem with Linked Lot-Sizes (CLSPL).- 4.3.2 CLSPL with Back-Orders and Parallel Machines (CLSPL-BOPM).- 4.3.3 Capacitated Lot-Sizing Problem with Sequence-Dependent Setups, Back-Orders and Parallel Machines (CLSD-BOPM).- 4.4 Solution Approach.- 4.4.1 A Novel Heuristic Model.- 4.4.2 Solution Procedure.- 4.4.3 Rolling Planning Horizon.- 4.5 Computational Results.- 4.5.1 Effect of Problem Characteristics.- 4.5.2 Effect of Capacity Adjustment and Time Limit.- 4.5.3 Effect of Problem Size.- 4.6 Summary.- 5 Phase II: Schedule Roll-Out.- 5.1 Premises and Scope.- 5.2 Scheduling Non-Bottleneck Production Stages.- 5.2.1 Step 1: Batching and Machine-Assignment.- 5.2.2 Step 2: Generation of Machine/Time Slots.- 5.3 Two Remarks on the Resulting Schedule.- 5.4 Summary.- 6 Phase III: Product-to-Slot Assignment.- 6.1 Goal Trade-Off.- 6.2 Genetic Algorithms.- 6.3 Solution Procedure: Two Nested Genetic Algorithms.- 6.3.1 Setting Target Values.- 6.3.2 The Inner Genetic Algorithm: Creating a Product Schedule Using the Target Values.- 6.3.3 The Outer Genetic Algorithm: Calculating New Target Values.- 6.4 Computational Results.- 6.4.1 Parameter Optimization.- 6.4.2 Effect of Problem Characteristics.- 6.5 Summary.- 7 An Illustrative Example.- 7.1 Data of the Example.- 7.2 Solution after Phase I.- 7.3 Solution after Phase II.- 7.4 Solution after Phase III.- 8 An Application in the Semiconductor Industry.- 8.1 Semiconductor Process Flow.- 8.2 Problem Specifics and Dimensions.- 8.3 Modeling Assumptions.- 8.4 Short-Term Production Planning.- 8.5 Medium-Term Capacity Planning.- 9 Summary and Conclusions.- List of Abbreviations.- List of Symbols.- References.