HOPS – Hamming-Oriented Partition Search for production planning in the spinning industry

Camargo, Victor Claudio Bento de; Toledo, Franklina Maria Bragion de; Almada-Lobo, Bernardo

doi:10.1016/j.ejor.2013.10.017

Cited by 31 publications

(14 citation statements)

References 34 publications

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“…The LBBD method has been implemented to solve many different kinds of combinatorial problems (Camargo et al. , Cambazard et al. , Coban and Hooker , Fazel‐Zarandi and Beck , Heinz and Beck , Hooker , , Tran and Beck , Xiaolu et al.…”

Section: Literature Reviewmentioning

confidence: 99%

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Scheduling Methods for Efficient Stamping Operations at an Automotive Company

Gençosman

Begen

Özmutlu

et al. 2016

Production and Operations Management

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We consider scheduling issues at Beyçelik, a Turkish automotive stamping company that uses presses to give shape to metal sheets in order to produce auto parts. The problem concerns the minimization of the total completion time of job orders (i.e., makespan) during a planning horizon. This problem may be classified as a combined generalized flowshop and flexible flowshop problem with special characteristics. We show that the Stamping Scheduling Problem is NP‐Hard. We develop an integer programming‐based method to build realistic and usable schedules. Our results show that the proposed method is able to find higher quality schedules (i.e., shorter makespan values) than both the company's current process and a model from the literature. However, the proposed method has a relatively long run time, which is not practical for the company in situations when a (new) schedule is needed quickly (e.g., when there is a machine breakdown or a rush order). To improve the solution time, we develop a second method that is inspired by decomposition. We show that the second method provides higher‐quality solutions—and in most cases optimal solutions—in a shorter time. We compare the performance of all three methods with the company's schedules. The second method finds a solution in minutes compared to Beyçelik's current process, which takes 28 hours. Further, the makespan values of the second method are about 6.1% shorter than the company's schedules. We estimate that the company can save over €187,000 annually by using the second method. We believe that the models and methods developed in this study can be used in similar companies and industries.

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Section: Literature Reviewmentioning

confidence: 99%

“…These studies may be strengthened with the help of meta‐heuristics and exact methods (Camargo et al. ). The papers referenced in this paragraph show that various decomposition approaches can be developed by using the exact methods and heuristics in LBBD.…”

Section: Literature Reviewmentioning

confidence: 99%

Scheduling Methods for Efficient Stamping Operations at an Automotive Company

Gençosman

Begen

Özmutlu

et al. 2016

Production and Operations Management

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“…Equivalent to the CLSD, the objective function (10) of the GLSP aims at minimizing holding and setup costs. Demand in a given period is to be met from initial inventory or production within the current period, as stated by constraints (11). The production amounts of each product in a given period are derived from production in the different micro-periods/slots.…”

Section: The General Lotsizing and Scheduling Problemmentioning

confidence: 99%

Industrial Insights Into Lot Sizing and Scheduling Modeling

et al. 2015

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Lot sizing and scheduling by mixed integer programming has been a hot research topic in the last 20 years. Researchers have been trying to develop stronger formulations, as well as to incorporate real-world requirements from different applications. This paper illustrates some of these requirements and demonstrates how small-and big-bucket models have been adapted and extended. Motivation comes from different industries, especially from process and fast-moving consumer goods industries.

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“…There is also a two-stage production process with soft drinks (Ferreira et al, 2009), where the syrup is prepared in tanks in the first stage, and then distributed to parallel bottling machines in the second stage. The production system of the spinning industry processes fibres (of different fibre blends) in the first stage, which are then used to produce different types of yarn on parallel machines in the second stage (Camargo et al, 2014). In these examples, the twostage manufacturing structure must be addressed within the production-distribution planning procedure, which may eventually alter the quantities of the production lot, as well as the timing and magnitude of the distribution.…”

Section: Introductionmentioning

confidence: 99%

Tactical production and distribution planning with dependency issues on the production process

Wei

Guimarães

Amorim

et al. 2017

Omega

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Tactical production-distribution planning models have attracted a great deal of attention in the past decades. In these models, production and distribution decisions are considered simultaneously such that the combined plans are more advantageous than the plans resolved in a hierarchical planning process. We consider a two-stage production process, where in the first stage raw materials are transformed into continuous resources that feed the discrete production of end products in the second stage. Moreover, the setup times and costs of resources depend on the sequence in which they are processed in the first stage. The minimum scheduling unit is the product family which consists of products sharing common resources and manufacturing processes. Based on different mathematical modelling approaches to the production in the first stage, we develop a sequence-oriented formulation and a product-oriented formulation, and propose decompositionbased heuristics to solve this problem efficiently. By considering these dependencies arising in practical production processes, our model can be applied to various industrial cases, such as the beverage industry or the steel industry. Computation tests on instances from an industrial application are provided at the end of the paper.

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HOPS – Hamming-Oriented Partition Search for production planning in the spinning industry

Cited by 31 publications

References 34 publications

Scheduling Methods for Efficient Stamping Operations at an Automotive Company

Scheduling Methods for Efficient Stamping Operations at an Automotive Company

Industrial Insights Into Lot Sizing and Scheduling Modeling

Tactical production and distribution planning with dependency issues on the production process

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