Optimization-based manufacturing scheduling with multiple resources and setup requirements

摘要

Abstract: The increasing demand for on-time delivery and low price forces manufacturer to seek effective schedules to improve coordination of multiple resources and to reduce product internal costs associated with labor, setup and inventory. This study describes the design and implementation of a scheduling system for J. M. Product Inc. whose manufacturing is characterized by the need to simultaneously consider machines and operators while an operator may attend several operations at the same time, and the presence of machines requiring significant setup times. The scheduling problem with these characteristics are typical for many manufacturers, very difficult to be handled, and have not been adequately addressed in the literature. In this study, both machine and operators are modeled as resources with finite capacities to obtain efficient coordination between them, and an operator's time can be shared by several operations at the same time to make full use of the operator. Setups are explicitly modeled following our previous work, with additional penalties on excessive setups to reduce setup costs and avoid possible scraps. An integer formulation with a separable structure is developed to maximize on-time delivery of products, low inventory and small number of setups. Within the Lagrangian relaxation framework, the problem is decomposed into individual subproblems that are effectively solved by using dynamic programming with additional penalties embedded in state transitions. Heuristics is then developed to obtain a feasible schedule following on our previous work with new mechanism to satisfy operator capacity constraints. The method has been implemented using the object-oriented programming language C$PLU$PLU with a user-friendly interface, and numerical testing shows that the method generates high quality schedules in a timely fashion. Through simultaneous consideration of machines and operators, machines and operators are well coordinated to facilitate the smooth flow of parts through the system. The explicit modeling of setups and the associated penalties let parts with same setup requirements clustered together to avoid excessive setups.!14