Skip to main content
SpringerLink
Log in

Framework for Integrating Optimization and Heuristic Models for Solving Planning and Scheduling Problem in a Resin Manufacturing Plant

  • Chapter
Book cover Intelligent Computational Optimization in Engineering

Part of the book series: Studies in Computational Intelligence ((SCI,volume 366))

  • 1178 Accesses

Abstract

This chapter introduces a three-level hierarchical production planning and scheduling approach for a multi-product batch processing resin plant in South East Asia. The approach integrates optimization and heuristic models to determine aggregate plans, master production schedule, number of batches that need to be scheduled and finally sequencing of jobs with the objective to minimize the total weighted tardiness. At the top level of the hierarchy, our approach deploys a mixed-integer linear programming model to solve the aggregate plans where setups occur. At the second level a weighted integer goal programming model is developed to disaggregate the aggregate plans and provides an optimal number of monthly batches to be sequenced in the presence of setups activities. At the third level of the hierarchy, a job-sequencing model is developed that combines two heuristics approaches that aims to minimize the total weighted tardiness. Real industrial data is used to test and validate the proposed approach. The results indicate that the approach is capable of dealing with a full range of the products produced by the resin plant.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 129.00
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 169.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 169.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. Mendez, C.A., Henning, G.P., Cerda, J.: Optimal scheduling of batches plants satisfying multiple product orders with different due-dates. Computers and Chemical Engineering 24, 2223–2245 (2000)

    Article  Google Scholar 

  2. Hax, A.C., Meal, H.C.: Hierarchical integration of production planning and scheduling. In: Geisler, M. (ed.) Logistics. TIMS Studies in Management Science, vol. 1. North-Holland, American Elsevier, New York (1975)

    Google Scholar 

  3. Gabbay, H.: A Hierarchical Approach to Production Planning. Technical Report No. 120, Operation Research Center, MIT, USA (1975)

    Google Scholar 

  4. Bitran, G.R., Tirupati, D.: Hierarchical production planning. In: Graves, S.C., Rinnooy Kan, A.H.G., Zipkin, P.H. (eds.) Logistics of Production and Inventory, pp. 523–567. North-Holland, Amsterdam (1993)

    Chapter  Google Scholar 

  5. Liberator, J.M., Miller, T.: A hierarchical production planning system. Interface 15, 1–11 (1985)

    Google Scholar 

  6. Mackulak, G.T., Moodie, C.L., Williams, J.T.: Computerized hierarchical production control in steel manufacturing. International Journal of Production Research 18, 455–465 (1980)

    Article  Google Scholar 

  7. Rutten, W.G.M.M.: Hierarchical mathematical programming for operational planning in a process industry. European Journal of Operational Research 64, 363–369 (1993)

    Article  Google Scholar 

  8. Bowers, M.R., Agarwal, A.: Hierarchical production planning: scheduling in the apparel industry. International Journal of Clothing Science and Technology 5, 36–43 (1993)

    Article  Google Scholar 

  9. Qiu, M.M., Burch, E.E.: Hierarchical production planning and scheduling in a multiproduct, multi-machine environment. International Journal of Production Research 35, 3023–3042 (1997)

    Article  MATH  Google Scholar 

  10. Venkataraman, R., Smith, S.B.: Disaggregation to a rolling horizon master production schedule with minimum batch-size production restrictions. International Journal of Production Research 6, 1517–1537 (1996)

    Article  Google Scholar 

  11. Das, B.P., Richard, J.G., Shah, N., Macchietto, S.: An investigation on integration of aggregate production planning, master production scheduling and short-term production scheduling of batch process operations through a common data model. Computers and Chemical Engineering 24, 625–1631 (2000)

    Article  Google Scholar 

  12. Omar, M.K., Teo, S.C.: Hierarchical production planning and scheduling in multiproduct, batch process environment. International Journal of Production Research 45, 1029–1047 (2007)

    Article  MATH  Google Scholar 

  13. McKay, K.N., Safayeni, F., Buzacott, J.A.: A Review of hierarchical production planning and its applicability to modern manufacturing. Production Planning and Control 6, 384–394 (1995)

    Article  Google Scholar 

  14. Okuda, K.: Hierarchical structure in manufacturing systems: a literature survey. International Journal of Manufacturing Technology Management 3, 210–224 (2001)

    Article  Google Scholar 

  15. Oliff, M.D.: Disaggregate planning for parallel processors. IIE Transactions 19, 215–221 (1987)

    Article  Google Scholar 

  16. Leong, G.K., Oliff, M.D., Markland, R.E.: Improved hierarchical production-planning model. Journal of Operations Management 8, 90–114 (1989)

    Article  Google Scholar 

  17. Toppan, S., Joanne, M.S., Parthasarati, D.: Static scheduling research to minimize weighted and unweighted tardiness: A state of-the-art survey. International Journal of Production Economics 8, 1–12 (2003)

    Google Scholar 

  18. Allahverdi, A., Ng, C.T., Cheng, T.C.E., Mikhail, Y.: A survey of scheduling problems with setup times or costs. European Journal of Operational Research 187, 985–1032 (2008)

    Article  MathSciNet  MATH  Google Scholar 

  19. Lenstra, J.K., Rinnooy Kan, A.H.G., Brucker, P.: Complexity of machine scheduling problems. Annals of Decision Mathematics 1, 342–362 (1997)

    Google Scholar 

  20. Pinedo, M.: Scheduling theory, algorithms and systems, 2nd edn. Prentice Hall, New Jersey (2002)

    MATH  Google Scholar 

  21. Das, S.R., Gupta, J.N.D., Khumawala, B.M.: A saving index heuristic algorithm for flowshope scheduling with sequence dependent set-up times. Journal of the Operational Research Society 46, 1365–1373 (1995)

    MATH  Google Scholar 

  22. Gravel, M., Price, W., Gagnec, C.: Scheduling jobs in a Alcan aluminium factory using a genetic algorithm. International Journal of Production Research 38, 3031–3041 (2000)

    Article  Google Scholar 

  23. Fanti, M.P., Maione, B., Piscitelli, G., Turchiano, B.: Heuristic scheduling of jobs on a multi-product batch processing machine. International Journal of Production Research 34, 3263–3286 (1996)

    Article  Google Scholar 

  24. Dobson, G., Nambimadom, R.S.: The batch loading and scheduling problem. Operations Research 49, 52–65 (2001)

    Article  MathSciNet  MATH  Google Scholar 

  25. Azizoglu, M., Webster, S.: Scheduling a batch process machine with incompatible job families. Computers and Industrial Engineering 39, 325–335 (2001)

    Article  Google Scholar 

  26. Perez, I.C., Fowler, J.W., Carlyle, W.M.: Minimizing total weighted tardiness on a single batch process machine with incompatible job families. Computers and Operations Research 32, 327–341 (2005)

    MathSciNet  MATH  Google Scholar 

  27. Lee, Y.H., Bhaskaran, K., Pinedo, M.: A heuristic to minimize the total weighted tardiness with sequence-dependent setups. IIE Transactions 29, 45–52 (1997)

    Article  Google Scholar 

  28. Rubin, P.A., Ragatz, G.L.: Scheduling in a sequence dependent setup environment with genetic search. Computers and Operations Research 22, 85–99 (1995)

    Article  MATH  Google Scholar 

  29. Tan, K.C., Narasimhan, R.: Minimizing tardiness on a single processor with sequencedependent setup times: a simulated annealing approach. Omega 25, 619–634 (1997)

    Article  Google Scholar 

  30. Tan, K.C., Narasimhan, R., Rubin, P.A., Ragatz, G.L.: A comparison of four methods for minimizing total tardiness on a single processor with sequence-dependent setup times. Omega 28, 313–326 (2000)

    Article  Google Scholar 

  31. Cicirello, V.A.: Weighted Tardiness Scheduling with Sequence-Dependent Setups: A Benchmark Library, The Robotics Institute, Carnegie Mellon University, Pittsburgh, PA (2004), http://www.cs.drexel.edu/~cicirello/benchmarks/wtsbenchmarks.pdf

  32. Glover, F.: Tabu search-Part I. ORSA Journal on Computing 1, 190–206 (1989)

    MathSciNet  MATH  Google Scholar 

  33. Glover, F.: Tabu search-Part II. ORSA Journal on Computing 2, 4–32 (1990)

    MATH  Google Scholar 

  34. Ovacik, T.M., Uzsoy, R.: Rolling horizon algorithms for a single-machine dynamic scheduling problem with sequence-dependent setup times. International Journal of Production Research 32, 1243–1263 (1994)

    Article  MATH  Google Scholar 

  35. Xie, J., Zahao, X., Lee, T.S.: Freezing the master production schedule under single resource constrain and demand uncertainty. International Journal of Production Economics 83, 65–85 (2003)

    Article  Google Scholar 

  36. Vollmann, T.E., Berry, W.L., Whybork, D.L.: Manufacturing planning and control systems, 3rd edn. Homewood, Irwin (1992)

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Business School, Nottingham University, Jalan Broga-43500 Semenyih, Selangor Darul Ehsan, Malaysia

    Mohamed K. Omar

  2. Faculty of Engineering and Technology, Multimedia University, Melaka Campus. Jalan Ayer Keroh Lama, 75450, Melaka, Malaysia

    Yasothei Suppiah

Authors
  1. Mohamed K. Omar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yasothei Suppiah
    View author publications

    You can also search for this author in PubMed Google Scholar

Editor information

Editors and Affiliations

  1. Dept. Artificial Intelligence, Kyushu Institute of Technology, 680-4 Kawazu, 820-8502, Izuka-Shi, Fukuoka, Japan

    Mario Köppen

  2. School of Engineering and Applied Science, Aston University, Aston Triangle, B4 7ET, Birmingham, U.K.

    Gerald Schaefer

  3. Machine Intelligence Research Labs (MIR Labs), Scientific Network for Innovation and Research Excellence, P.O. Box 2259, 98071-2259, Auburn, Washington, USA

    Ajith Abraham

Rights and permissions

Reprints and permissions

Copyright information

© 2011 Springer-Verlag Berlin Heidelberg

About this chapter

Cite this chapter

Omar, M.K., Suppiah, Y. (2011). Framework for Integrating Optimization and Heuristic Models for Solving Planning and Scheduling Problem in a Resin Manufacturing Plant. In: Köppen, M., Schaefer, G., Abraham, A. (eds) Intelligent Computational Optimization in Engineering. Studies in Computational Intelligence, vol 366. Springer, Berlin, Heidelberg. https://doi.org/10.1007/978-3-642-21705-0_4

Download citation

  • DOI: https://doi.org/10.1007/978-3-642-21705-0_4

  • Publisher Name: Springer, Berlin, Heidelberg

  • Print ISBN: 978-3-642-21704-3

  • Online ISBN: 978-3-642-21705-0

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation