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A decomposition heuristic to solve the two-stage lot sizing and scheduling problem with temporal cleaning

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Abstract

This paper presents a study on the fruit-based beverage lot sizing and scheduling problem. This is a two-stage lot-scheduling problem with some features, such as the presence of buffers between the production stages, mandatory temporal cleanings for the preparation tanks (stage I) and production lines (stage II), and production synchronization between the production stages. To solve this problem, we propose two variations of a two-phase heuristic algorithm by devising a production stage decomposition scheme coupled with a constructive procedure. In the first phase, a one-stage lot sizing is solved by a mixed integer programming model, and in the second phase, scheduling and the synchrony between the stages are carried out using a constructive algorithm. The two variations of the heuristic are: Stage I Heuristics (S1H) and Stage II Heuristics (S2H). In S1H, production stage I is solved by a mathematical model and in S2H, production stage II is solved by another mathematical model. Data from a typical beverage company of a large worldwide brand was used in the computational tests. The results showed that the heuristics are able to find competitive solutions very quickly and that the S2H heuristic performs better than S1H.

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Acknowledgements

The authors would like to thank the reviewers 1, 2, 3 and 4 for their helpful comments and suggestions, the fruit-based beverage company for its collaboration with this research and FAPESP (Grant 2010/10133-0) and CNPq (Grant No. 312569/2013-0) for their financial support.

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Authors and Affiliations

  1. Production Engineering Department, Federal University of Triângulo Mineiro, Uberaba, MG, Brazil

    Alyne Toscano

  2. Department of Physics, Chemistry and Mathematics, Federal University of São Carlos, Sorocaba, SP, Brazil

    Deisemara Ferreira

  3. Production Engineering Department, Federal University of São Carlos, São Carlos, SP, Brazil

    Reinaldo Morabito

Authors
  1. Alyne Toscano
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  2. Deisemara Ferreira
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  3. Reinaldo Morabito
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Correspondence to Reinaldo Morabito.

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Toscano, A., Ferreira, D. & Morabito, R. A decomposition heuristic to solve the two-stage lot sizing and scheduling problem with temporal cleaning. Flex Serv Manuf J 31, 142–173 (2019). https://doi.org/10.1007/s10696-017-9303-9

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