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An Order Scheduling Heuristic to Minimize the Total Collation Delays and the Makespan in High-Throughput Make-to-Order Manufacturing Systems

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Abstract

This paper presents an order scheduling heuristic to minimize the total collation delays and the makespan in high-throughput make-to-order manufacturing systems. Order collation delay is the completion time difference between the first and the last processed items within the same order. Large order collation delays contribute to a reduced throughput, non-recoverable productivity loss, or even system deadlocks. In manufacturing systems with high throughput, this scheduling problem becomes computationally expensive to solve because the number of orders is very large; thus, efficient constructive algorithms are needed. To minimize both objectives efficiently, this paper proposes a novel workload balance with single-item orders (WBSO) heuristic while considering machine flexibility. Through a comparison with (1) the non-dominated sorting genetic algorithm II (NSGA-II), (2) priority-based longest processing rule (LPT-P), (3) priority-based least total workload rule (LTW-P), and (4) multi-item orders first rule (MIOF), the effectiveness of the proposed method is evaluated. Experimental results for different scenarios indicate that the proposed WBSO heuristic provides 33% fewer collation delays and 6% more makespan on average when compared to the NSGA-II. The proposed method can work on both small and large problem sizes, and the results also show that for large size problems, the WBSO generates 74%, 89%, and 62% fewer collation delays on average than LPT-P, LTW-P, and MIOF rules respectively.

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Data Availability

The datasets analyzed during the current study are not publicly available due to the requirement of funder. Data are however available from the authors upon reasonable request and with permission of the funder.

Code Availability

The codes developed during the current study are not publicly available due to the requirement of funder. The codes are however available from the authors upon reasonable request and with permission of the funder.

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Acknowledgements

This study was supported by the Watson Institute of Systems Excellence (WISE) at Binghamton University and was partially supported by “Research Base Construction Fund Support Program” funded by Jeonbuk National University in 2022.

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Authors and Affiliations

  1. Department of Systems Science and Industrial Engineering, State University of New York at Binghamton, 4400 Vestal Parkway East, Binghamton, 13902, NY, USA

    Husam Dauod, Nieqing Cao, Sang Won Yoon & Daehan Won

  2. Department of Management Science and Engineering, Fuzhou University, Fuzhou, Fujian, China

    Debiao Li

  3. Department of Business Administration, Jeonbuk National University, Jeonju, Jeonbuk, South Korea

    Jaehee Kim

Authors
  1. Husam Dauod
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  2. Nieqing Cao
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  3. Debiao Li
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  4. Jaehee Kim
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  5. Sang Won Yoon
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  6. Daehan Won
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Contributions

HD did the conceptualization, data curation, formal analysis, investigation, methodology development, coding, result validation, and visualization and was a major contributor in writing the original manuscript. NC did the result validation and manuscript review and editing. DL did the data curation, result validation, and manuscript review and editing. JK did the data curation, resources providing, supervision, result validation, and manuscript review and editing. SY did the methodology development, project administration, supervision, and manuscript review and editing. DW did the conceptualization, methodology development, project administration, supervision, and manuscript review and editing. All authors read and approved the final manuscript.

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Correspondence to Daehan Won.

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Dauod, H., Cao, N., Li, D. et al. An Order Scheduling Heuristic to Minimize the Total Collation Delays and the Makespan in High-Throughput Make-to-Order Manufacturing Systems. Oper. Res. Forum 4, 49 (2023). https://doi.org/10.1007/s43069-023-00227-2

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