A hierarchical approach to solve a production planning and scheduling problem in bulk cargo terminal

Abstract In the paper, we present a coordinated production planning and scheduling problem for three major shops in a typical alloy casting foundry, i.e. a melting shop, molding shop with automatic line and a core shop. The castings, prepared from different metal, have different weight and different number of cores. Although core preparation does not required as strict coordination with molding plan as metal preparation in furnaces, some cores may have limited shelf life, depending on the material used, or at least it is usually not the best organizational practice to prepare them long in advance. Core shop have limited capacity, so the cores for castings that require multiple cores should be prepared earlier. We present a mixed integer programming model for the coordinated production planning and scheduling problem of the shops. Then we propose a simple Lagrangian relaxation heuristic and evolutionary based heuristic to solve the coordinated problem. The applicability of the proposed solution in industrial practice is verified on large instances of the problem with the data simulating actual production parameters in one of the medium size foundry.

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Production planning and scheduling problem of continuous parallel lines with demand uncertainty and different production capacities

Journal of Computational Design and Engineering ◽

10.1093/jcde/qwaa055 ◽

2020 ◽

Vol 7 (6) ◽

pp. 761-774

Author(s):

Kailash Changdeorao Bhosale ◽

Padmakar Jagannath Pawar

Keyword(s):

Production Planning ◽

Demand Uncertainty ◽

Clustering Algorithm ◽

Real Life ◽

Initial Population ◽

Planning Problem ◽

Scheduling Problem ◽

Scheduling Problems ◽

Planning And Scheduling ◽

Production Planning And Scheduling

Abstract Production planning and scheduling problems are highly interdependent as scheduling provides optimum allocation of resources and planning is an optimum utilization of these allocated resources to serve multiple customers. Researchers have solved production planning and scheduling problems by the sequential method. But, in this case, the solution obtained by the production planning problem may not be feasible for scheduling method. Hence, production planning and scheduling problems must be solved simultaneously. Therefore, in this work, a mathematical model is developed to integrate production planning and scheduling problems. The solution to this integrated planning and scheduling problem is attempted by using a discrete artificial bee colony (DABC) algorithm. To speed up the DABC algorithm, a k-means clustering algorithm is used in the initial population generation phase. This k-means clustering algorithm will help to converge the algorithm in lesser time. A real-life case study of a soap manufacturing industry is presented to demonstrate the effectiveness of the proposed approach. An objective function to minimize overall cost, which comprises the processing cost, material cost, utility cost, and changeover cost, is considered. The results obtained by using DABC algorithm are compared with those obtained by CPLEX software. There is a saving of ₹2 23 324 for weeks 1–4 in overall cost compared with the results obtained by using CPLEX software.

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