Advertisement

OR Spectrum

pp 1–48 | Cite as

A cyclic production scheme for the synchronized and integrated two-level lot-sizing and scheduling problem with no-wait restrictions and stochastic demand

  • Dirk Briskorn
  • Philipp ZeiseEmail author
Regular Article
  • 70 Downloads

Abstract

In this paper, we propose a production scheme for a two-step packaging system as part of a make-and-pack production process including parallel production units in all stages. In the first stage of the packaging system, flavored liquids are filled into cans of different sizes which are immediately palletized in the second stage, i.e., work-in-progress inventories do not exist. However, each filling unit can feed more than one palletizer at a time. Final products can be stored in a warehouse with limited capacity. Among others, the proposed scheme consists of a periodic production sequence, also referred to as a cycle, for each production unit and a control strategy that keeps cycle lengths close to a target length. In addition, an approach to specifying the parameters of the scheme is developed. This approach accounts for sequence-dependent setup times, downtimes of production units, capacitated storage and uncertain demand for final products that is satisfied from stock or backlogged. We evaluate our approach conducting computational experiments that are based on real-world and random data.

Keywords

Production Multi-stage Sequencing and lot sizing Cyclic patterns Stochastic demand 

Notes

References

  1. Akkerman R, van Donk DP (2007) Product prioritization in a two-stage food production system with intermediate storage. Int J Prod Econ 108:43–53CrossRefGoogle Scholar
  2. Almada-Lobo B, Oliveira JF, Carravilla MA (2008) Production planning and scheduling in the glass container industry: a VNS approach. Int J Prod Econ 114:363–375CrossRefGoogle Scholar
  3. Amin M, Altiok T (1997) Control policies for multi-product multi-stage manufacturing systems: an experimental approach. Int J Prod Res 35:201–223CrossRefGoogle Scholar
  4. Baldo TA, Santos MO, Almada-Lobo B, Morabito R (2014) An optimization approach for the lot sizing and scheduling problem in the brewery industry. Comput Ind Eng 72:58–71CrossRefGoogle Scholar
  5. Baumann P, Trautmann N (2014) A hybrid method for large-scale short-term scheduling of make-and-pack production processes. Eur J Oper Res 236:718–735CrossRefGoogle Scholar
  6. Belaid R, T’kindt V, Esswein C (2012) Scheduling batches in flowshop with limited buffers in the shampoo industry. Eur J Oper Res 223:560–572CrossRefGoogle Scholar
  7. Bourland KE, Yano CA (1994) The strategic use of capacity slack in the economic lot scheduling problem with random demand. Manag Sci 40:1690–1704CrossRefGoogle Scholar
  8. Bowersox DJ (1978) Logistical management. Collier Macmillan Ltd, LondonGoogle Scholar
  9. Brandimarte P (2006) Multi-item capacitated lot-sizing with demand uncertainty. Int J Prod Res 44:2997–3022CrossRefGoogle Scholar
  10. Briskorn D, Zeise P, Packowski J (2016) Quasi-fixed cyclic production schemes for multiple products with stochastic demand. Eur J Oper Res 252:156–169CrossRefGoogle Scholar
  11. Erdirik-Dogan M, Grossmann IE (2008) Slot-based formulation for the short-term scheduling of multistage, multiproduct batch plants with sequence-dependent changeovers. Ind Eng Chem Res 47:1159–1183CrossRefGoogle Scholar
  12. Federgruen A, Katalan Z (1996) The stochastic economic lot scheduling problem: cyclical base-stock policies with idle times. Manag Sci 36:1579–1592Google Scholar
  13. Ferreira D, Morabito R, Rangel S (2009) Solution approaches for the soft drink integrated production lot sizing and scheduling problem. Eur J Oper Res 196:697–706CrossRefGoogle Scholar
  14. Gallego G (1990) Scheduling the production of several items with random demands in a single facility. Manag Sci 36:1579–1592CrossRefGoogle Scholar
  15. Gelders LF, van Wassenhove LN (1981) Production planning: a review. Eur J Oper Res 7:101–110CrossRefGoogle Scholar
  16. Günther HO, Grunow M, Neuhaus U (2006) Realizing block planning concepts in make-and-pack production using MILP modelling and SAP APO®. Int J Prod Res 44:3711–3726CrossRefGoogle Scholar
  17. Kallrath J (2005) Solving planning and design problems in the process industry using mixed integer and global optimization. Ann Oper Res 140:339–373CrossRefGoogle Scholar
  18. Kopanos GM, Méndez CA, Puigjaner L (2010) Mip-based decomposition strategies for large-scale scheduling problems in multiproduct multistage batch plants: a benchmark scheduling problem of the pharmaceutical industry. Eur J Oper Res 207:644–655CrossRefGoogle Scholar
  19. Kopanos GM, Puigjaner L, Georgiadis MC (2011) Production scheduling in multiproduct multistage semicontinuous food processes. Ind Eng Chem Res 50:6316–6324CrossRefGoogle Scholar
  20. Laporte G (1992) The traveling salesman problem: an overview of exact and approximate algorithms. Eur J Oper Res 59:231–247CrossRefGoogle Scholar
  21. Mehrotra M, Dawande M, Gavirneni S, Demirci M, Tayur S (2011) Production planning with patterns: a problem from processed food manufacturing. Oper Res 59:267–282CrossRefGoogle Scholar
  22. Méndez CA, Cerdá J (2002) An MILP-based approach to the short-term scheduling of make-and-pack continuous production plants. OR Spectr 24:403–429CrossRefGoogle Scholar
  23. Méndez CA, Cerdá J, Grossmann IE, Harjunkoski I, Fahl M (2006) State-of-the-art review of optimization methods for short-term scheduling of batch processes. Comput Chem Eng 30:913–946CrossRefGoogle Scholar
  24. Raaymakers W, Hoogeveen J (2000) Scheduling multipurpose batch process industries with no-wait restrictions by simulating annealing. Eur J Oper Res 126:131–151CrossRefGoogle Scholar
  25. Rappold JA, Yoho KD (2014) Setting safety stocks for stable rotation cycle schedules. Int J Prod Econ 156:146–158CrossRefGoogle Scholar
  26. Ruiz R, Maroto C (2006) A genetic algorithm for hybrid flowshops with sequence dependent setup times and machine eligibility. Eur J Oper Res 169:781–800CrossRefGoogle Scholar
  27. Sammarra M, Cordeau J-F, Laporte G, Monaco MF (2007) A tabu search heuristic for the quay crane scheduling problem. J Sched 10:327–336CrossRefGoogle Scholar
  28. Sharda B, Akiya N (2012) Selecting make-to-stock and postponement policies for different products in a chemical plant: a case study using discrete event simulation. Int J Prod Econ 136:161–171CrossRefGoogle Scholar
  29. Silver E, Pyke D, Peterson R (1998) Inventory management and production planning and scheduling. Wiley, LondonGoogle Scholar
  30. Soman CA, van Donk DP, Gaalman GJC (2007) Capacitated planning and scheduling for combined make-to-order and make-to-stock production in the food industry: an illustrative case study. Int J Prod Econ 108:191–199CrossRefGoogle Scholar
  31. Toledo CFM, França PM, Morabito R, Kimms A (2009) Multi-population genetic algorithm to solve the synchronized and integrated two-level lot sizing and scheduling problem. Int J Prod Res 47:3097–3119CrossRefGoogle Scholar
  32. Toledo CFM, da Silva Arantes M, França PM (2011) Tabu search to solve the synchronized and integrated two-level lot sizing and scheduling problem. In: Proceedings of the 13th annual conference on genetic and evolutionary computation. ACM, pp 443–448Google Scholar
  33. van Dam P, Gaalman GJC, Sierksma G (1998) Designing scheduling systems for packing in process industries: a tobacco company case. Int J Prod Econ 56–57:649–659Google Scholar
  34. van Donk DP (2001) Make to stock or make to order: the decoupling point in the food processing industries. Int J Prod Econ 69:297–306CrossRefGoogle Scholar
  35. Vaughan TS (2007) Cyclical schedules vs. dynamic sequencing:replenishment dynamics and inventory efficiency. Int J Prod Econ 107:518–527CrossRefGoogle Scholar
  36. Vaughan TS (2009) Alternative control mechanisms for cyclical scheduling systems. Int J Prod Res 47:6321–6332CrossRefGoogle Scholar
  37. Venditti L, Pacciarelli D, Meloni C (2010) A tabu search algorithm for scheduling pharmaceutical packaging operations. Eur J Oper Res 202:538–546CrossRefGoogle Scholar
  38. Wirtz BW (2007) Handbuch multi-channel-marketing. GablerGoogle Scholar

Copyright information

© Springer-Verlag GmbH Germany, part of Springer Nature 2019

Authors and Affiliations

  1. 1.Lehrstuhl für BWL, insbesondere Produktion und LogistikBergische Universität WuppertalWuppertalGermany
  2. 2.Camelot Management ConsultantsMannheimGermany

Personalised recommendations