A heuristic approach to minimize the number of saw cycles in small-scale furniture factories

Toscano, Alyne; Rangel, Socorro; Yanasse, Horácio Hideki

doi:10.1007/s10479-015-1955-9

Cited by 18 publications

(7 citation statements)

References 39 publications

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“…Therefore, a multi-period cutting stock problem with a capacity constraint as addressed at level 2 in the G3ILSCS model is not fully explored in the literature to model cutting processes and provides an interesting and relevant avenue for future research. The capacity constraint may not only be related to the production time of the cutting process, but may be related to other aspects, such as saw cycles ( Toscano, Rangel, & Yanasse, 2017;Vanzela et al, 2017 ). In some industrial applications, delivering the orders on time can be far more important than reducing the resulting waste and the cost of cut objects.…”

Section: Further Research Opportunitiesmentioning

confidence: 99%

Classification and literature review of integrated lot-sizing and cutting stock problems

Melega

Araújo

Jans

2018

European Journal of Operational Research

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a b s t r a c tThe aim of this paper is to classify the literature related to the integration between the lot-sizing and cutting stock problem. A deterministic mathematical model, that considers multiple dimensions of integration and comprises several aspects found in practice, is proposed. This model is used as a framework to classify the current literature in this field. The main classification of the literature is organized around two types of integration. In a planning horizon which consists of multiple periods, the inventory provides a link between the periods. This integration across time periods constitutes the first type of integration. The proposed model also considers the production of different types of items at three different levels: objects are fabricated or purchased and next cut into pieces which are then assembled into final products. The integration between these three production levels constitutes the second type of integration. The classification indicates that, even though many papers in the current literature analyze an integrated lot-sizing and cutting stock problem, they vary widely with respect to the level of integration on the time and production level dimensions. Furthermore, our analysis indicates that the current models also consider varying assumptions with respect to the inventory, the production capacities and the setups. Finally, we point out some possible interesting areas for future research. (R. Jans). that might correspond to customer requests, and a decision related to the cutting stock problem is needed. Part of the smaller reels can be cut again into paper sheets, according to some decision related to the lot size for the papers sheets. In the furniture industry, wooden plates are produced or purchased from different suppliers, and a decision about the size of the lots to be produced or purchased from each supplier must be taken. Then, these wooden plates are cut into several wooden parts (in a two-dimensional cutting stock process) to be assembled into the final products. A decision about the size of the lots of final products is also needed, and consequently there are three levels of decisions. Other examples can be found in the fiberglass industry, where fiberglass plates are cut to manufacture printed circuit boards and in the aluminium industry, where aluminium profiles are cut to make several window types. The basic idea of the integrated lot-sizing and cutting stock problem is to consider, simultaneously, the decisions related to both problems so as to capture the interdependency between these decisions in order to obtain a better global solution. Several papers from the literature present computational results showing the benefits of considering an integrated approach instead of taking decisions separately

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Section: Further Research Opportunitiesmentioning

confidence: 99%

Classification and literature review of integrated lot-sizing and cutting stock problems

Melega

Araújo

Jans

2018

European Journal of Operational Research

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“…The total number of plates that can be stacked depends on the machine maximum load and on the thickness of the plates. The time necessary to adjust the cutting machine and to cut a stack of objects according to a given cutting pattern is named saw cycle [39,34]. So, the total number of saw cycles is an important aspect to be considered when solving the cutting stock problem.…”

Section: Review Of Related Papersmentioning

confidence: 99%

“…Silva et al [32] do not consider capacity constraints. Furthermore, Toscano et al [34] focus specifically on the optimization of the cutting sector of Factory L, which shows the relevance of the cutting sector in furniture industries and that this is a realistic simplification. 2.…”

Section: Mathematical Model For the Integrated Lot Sizing And Cuttingmentioning

confidence: 99%

The integrated lot sizing and cutting stock problem with saw cycle constraints applied to furniture production

Vanzela

Melega

Rangel

et al. 2017

Computers & Operations Research

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The integrated lot sizing and cutting stock problem is studied in the context of furniture production. The goal is to capture the interdependencies between the determination of the lot size and of the cutting process in order to reduce raw material waste and production and inventory costs. An integrated mathematical model is proposed that includes lot sizing decisions with safety stock level constraints and saw capacity constraints taking into account saw cycles. The model solution is compared to a simulation of the common practice of taking the lot size and the cutting stock decisions separately and sequentially. Given the large number of variables in the model, a column-generation solution method is proposed to solve the problem. An extensive computational study is conducted using instances generated based on data collected at a typical small scale Brazilian factory. It includes an analysis of the performance of the integrated approach against sequential approaches, when varying the costs in the objective function. The integrated approach performs well, both in terms of reducing the total cost of raw materials as well as the inventory costs of pieces. They also indicate that the model can support the main decisions taken and can bring improvements to the factory's production planning.

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“…(Toscano et al, 2013): O número mínimo de ciclos da serra, necessários para cortar y e j objetos de espessura e, de acordo com um determinado padrão de corte j e com a capacidade da serraé calculado de acordo com: y e j cap e j = 1, . .…”

Section: Proposta De Reformulaçãounclassified

Problema Integrado De Dimensionamento De Lotes E Corte De Estoque Com Restrição De Ciclos Da Serra

Melega¹,

Vanzela²,

Araújo³

et al. 2015

Anais Do Congresso Nacional De Matemática Aplicada À Indústria

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Resumo. Neste trabalho aborda-se o problema integrado de dimensionamento de lotes e corte de estoque. O objetivo do problema integradoé capturar a interdependência entre as decisões destes problemas, possibilitando economia de matéria prima e diminuição dos gastos no processo de produção. Um modelo da literaturaé discutido, no qual os autores realizam um estudo de caso em uma fábrica de móveis de pequeno porte e consideram em seu modelo, restrições para o controle do número de ciclos da serra. Propomos uma extensão deste conjunto de restrições que resulta em um modelo não linear. Uma estratégia de linearizaçãoé aplicada a estas restrições, obtendo assim um modelo linear. Pretende-se com este novo modelo, estender a técnica de geração de colunas a qual foi aplicada ao modelo original e discutir os resultados obtidos.Palavras-chave: Problema de Dimensionamento de Lotes, Problema de Corte de Estoque, Problema Integrado, Ciclos da Serra. INTRODUÇÃOEstudar o problema de dimensionamento de lotes (PDL) de forma integrada ao problema de corte de estoque (PCE) constitui umaárea de relevância na literatura devido a sua grande aplicabilidade no setor industrial. O objetivo do problema integradoé capturar a interdependência entre as decisões, de modo a possibilitar economia de matéria-prima e diminuição dos custos globais no processo de produção. Assim, o problema integrado de dimensionamento de lotes e corte de estoque consiste em decidir, em cada período do horizonte de planejamento a quantidade de produtos finais (itens) a serem produzidos, de maneira a minimizar o custo total. No custo total são incluídos custos de preparo e estocagem referentes ao problemas de dimensionamento de lotes e a quantidade de objetos a serem cortados, esteúltimo, objetivo do problema de corte de estoque.Diversos trabalhos da literatura tratam o PDL e o PCE de maneira integrada em diferentes setores industriais, entre eles Farley (1988) em uma fábrica de roupas (corte bidimensional), Hendry et al. (1996) Em Vanzela et al. (2013), o problema integradoé estudado no contexto do processo produtivo de uma fábrica de móveis de pequeno porte. Um aspecto importante no modelo apresentado,é a restrição de capacidade da máquina de corte (serra), em que se possibilita o corte simultâneo de vários objetos. O conjunto de todas as operações necessárias para cortar um, ou mais objetos simultaneamente, de acordo com um determinado padrão de corteé definido como ciclo da serra (Yanasse et al., 1991). No entanto, Vanzela et al. (2013) consideraram na restrição de ciclos da serra que padrões de corte diferentes podem compartilhar o mesmo ciclo da serra, o que consiste em uma relaxação para situações encontradas na prática de um ambiente industrial.Como objetivo deste trabalho, propomos uma reformulação para a restrição referente ao ciclo da serra, na qual considera-se que cada ciclo da serra seja composto por umúnico padrão de corte. O modelo reformulado constitui um modelo de programação não linear, para o qual aplica-se uma estratégia de linearização baseada ...

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A heuristic approach to minimize the number of saw cycles in small-scale furniture factories

Cited by 18 publications

References 39 publications

Classification and literature review of integrated lot-sizing and cutting stock problems

Classification and literature review of integrated lot-sizing and cutting stock problems

The integrated lot sizing and cutting stock problem with saw cycle constraints applied to furniture production

Problema Integrado De Dimensionamento De Lotes E Corte De Estoque Com Restrição De Ciclos Da Serra

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